U.S. patent application number 16/945503 was filed with the patent office on 2021-02-04 for textiles and articles and processes for making the same.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Devon Frazier, Walter M. Hancock, Dave Klinger, Robert Mervar, Brian G. Prevo, Hilary Walker.
Application Number | 20210030115 16/945503 |
Document ID | / |
Family ID | 1000005046596 |
Filed Date | 2021-02-04 |
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United States Patent
Application |
20210030115 |
Kind Code |
A1 |
Frazier; Devon ; et
al. |
February 4, 2021 |
TEXTILES AND ARTICLES AND PROCESSES FOR MAKING THE SAME
Abstract
Films, fibers, filaments, yarns and textiles including
thermoplastic elastomeric compositions are described, as are
methods of making the films, fibers, filaments, yarns and textiles.
These films, fibers, filaments, yarns and textiles can be used to
make articles of apparel, footwear, and sporting equipment. When
thermoformed, the thermoplastic elastomeric compositions can impart
abrasion resistance, traction, and other advantageous properties to
the articles. This abstract is intended as a scanning tool for
purposes of searching in the particular art and is not intended to
be limiting of the present disclosure.
Inventors: |
Frazier; Devon; (Beaverton,
OR) ; Hancock; Walter M.; (Taichung, TW) ;
Klinger; Dave; (Beaverton, OR) ; Mervar; Robert;
(Beaverton, OR) ; Prevo; Brian G.; (Portland,
OR) ; Walker; Hilary; (Hillsboro, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
1000005046596 |
Appl. No.: |
16/945503 |
Filed: |
July 31, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62882008 |
Aug 2, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 5/14 20130101; D10B
2501/043 20130101; D04B 1/16 20130101; A43B 23/0215 20130101; A43B
5/02 20130101; A43B 5/001 20130101; D10B 2331/04 20130101; A43B
5/06 20130101; D02G 3/36 20130101; A43B 23/025 20130101; D10B
2401/041 20130101; D10B 2331/02 20130101; A43B 1/14 20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02; D04B 1/16 20060101 D04B001/16; A43B 5/06 20060101
A43B005/06; A43B 1/14 20060101 A43B001/14; A43B 5/02 20060101
A43B005/02; A43B 5/00 20060101 A43B005/00; A43B 5/14 20060101
A43B005/14; D02G 3/36 20060101 D02G003/36 |
Claims
1. An upper for an article of footwear, comprising: a knit textile
comprising a thermoformed network of interlooped yarns comprising a
first core yarn and a first polymeric composition, wherein the
first polymeric composition consolidates the thermoformed network
of interlooped yarns by surrounding at least a portion of the first
core yarn and occupying at least a portion of spaces between yarns
in the thermoformed network of yarns, wherein the first polymeric
composition comprises a thermoplastic elastomeric polyurethane, and
wherein the first polymeric composition has a Durometer Hardness
using a Shore A scale of from about 70 to about 80, as determined
using the Durometer Hardness Test; wherein the thermoformed network
of yarns is the thermoformed product of a first textile comprising
a first network of yarns including a first coated yarn comprising
the first core yarn and a first coating, the first coating
comprising the first polymeric composition, the first core yarn
comprising a second polymeric composition, wherein the first
coating is axially centered surrounding the core yarn, a nominal
average outer diameter of the coated yarn is up to about 1.0
millimeter, the first coating has an average radial coating
thickness of about 50 micrometers to about 200 micrometers, and
wherein, in the thermoformed network, the first polymeric
composition consolidating the thermoformed network of yarns is the
re-flowed and re-solidified product of the first polymeric
composition of the first coating of the first coated yarn; wherein,
in the first coated yarn, the first thermoplastic composition has a
first melting temperature greater than about 110 degrees centigrade
and less than about 190 degrees centigrade, the second polymeric
composition of the core yarn has a second deformation temperature,
and the second deformation temperature is at least 50 degrees
centigrade greater than the first melting temperature of the first
polymeric composition; wherein the thermoformed network of the
textile defines at least a portion of a surface of the upper
configured to be externally-facing when the upper is part of a
finished article of footwear; wherein the at least a portion of the
surface of the upper defined by the thermoformed network has a
total surface area of at least 1 square centimeter, and within the
total surface area, at least 15 to 100 percent of the total surface
area comprises the first polymeric composition.
2. The upper of claim 1, wherein the thermoplastic elastomeric
polyurethane is a thermoplastic elastomeric polyester polyurethane,
a thermoplastic polyether polyurethane, or any combination
thereof.
3. The upper of claim 1, wherein the thermoplastic elastomeric
polyurethane comprises an aromatic polyester thermoplastic
elastomeric polyurethane, an aliphatic polyester thermoplastic
elastomeric polyurethane, or a combination thereof.
4. The upper of claim 1, wherein the first polymeric composition
has a glass transition temperature of less than 20 degrees C.
5. The upper of claim 1, wherein the first polymeric composition
has a specific gravity of from about 0.80 to about 1.30 as
determined using the Specific Gravity Test.
6. The upper of claim 1, wherein the first polymeric composition
has a melt flow index of about 2 grams/10 minutes to about 50
grams/10 minutes at 160 degrees centigrade using a test weight of
2.16 kilograms as determined using the Melt Flow Index Test.
7. The upper of claim 1, wherein the first core yarn comprises a
polyester or a polyamide having a linear density from about 100
denier to about 300 denier.
8. The upper of claim 1, wherein the dynamic coefficient of
friction on a dry sample of soccer ball material of the knit
textile is from about 0.90 to about 1.50 as determined using the
Textile-Ball Coefficient of Friction Test.
9. The upper of claim 1, wherein the dynamic coefficient of
friction on a wet sample of soccer ball material of the knit
textile is from about 0.50 to about 0.80 as determined using the
Textile-Ball Coefficient of Friction Test.
10. The upper of claim 1, wherein the difference between the
dynamic coefficient of friction of the dry sample of soccer ball
material and the wet sample of soccer ball material of the knit
textile is less than 40 percent as determined using the
Textile-Ball Coefficient of Friction Test.
11. The upper of claim 1, wherein the static coefficient of
friction on a dry sample of soccer ball material of the knit
textile is from about 1.20 to about 1.60 as determined using the
Textile-Ball Coefficient of Friction Test.
12. The upper of claim 1, wherein the static coefficient of
friction on a wet sample of soccer ball material of the knit
textile is from about 0.80 to about 1.20 as determined using the
Textile-Ball Coefficient of Friction Test.
13. The upper of claim 1, wherein the difference between the static
coefficient of friction of the dry sample of soccer ball material
and the wet sample of soccer ball material of the knit textile is
less than 40 percent as determined using the Textile-Ball
Coefficient of Friction Test.
14. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile has an abrasion resistance of at least 1,200 cycles as
determined using the Stoll Abrasion Test.
15. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile has a dry dynamic COF of from about 0.7 to about 1.4 as
determined against smooth concrete under dry conditions using the
Coefficient of Friction Test.
16. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile has a dry dynamic COF of from about 0.4 to about 1.0 as
determined against rough concrete under dry conditions using the
Coefficient of Friction Test.
17. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile has a wet dynamic COF of from about 0.4 to about 0.6 as
determined against smooth concrete under wet conditions using the
Coefficient of Friction.
18. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile has a wet dynamic COF of from about 0.3 to about 0.6 as
determined against rough concrete under wet conditions using the
Coefficient of Friction Test.
19. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile produces a ball spin rate of at least 220 revolutions per
minute as determined using the Textile-Ball Impact Test.
20. The upper of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile produces a ball spin rate of at least 210 revolutions per
minute as determined using the Boot-Ball Impact Test.
21. The textile of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile has an abrasion loss of less than 0.50 cubic centimeters as
determined using the Akron Abrasion Test, or has an abrasion loss
of less than 0.30 cubic centimeters as determined using the DIN
Abrasion Test.
22. The textile of claim 1, wherein the at least a portion of the
surface of the upper defined by the thermoformed network of the
textile includes a molded texture.
23. The textile of claim 1, wherein the first coated yarn has at
least one property chosen from a stress at break greater than 7
megapascals as determined using the Modulus, Tenacity, and
Elongation Test at 25 degrees C.; a tensile stress at 300 percent
modulus greater than 2 megapascals as determined using the Modulus,
Tenacity, and Elongation Test at 25 degrees C.; an elongation at
break greater than 450 percent as determined using the Modulus,
Tenacity, and Elongation Test at 25 degrees C.; or a tenacity of
about 1 gram per denier to about 10 grams per denier.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and the benefit of,
co-pending U.S. provisional application entitled "TEXTILES AND
ARTICLES AND PROCESSES FOR MAKING THE SAME" having Ser. No.
62/882,008, filed Aug. 2, 2019, the contents of which are
incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure is directed to textiles, components
of articles, and articles, such as articles of apparel, articles of
footwear, and articles of sporting equipment. More specifically,
the present disclosure is directed to textiles which include a
coated yarn, and components of articles, and articles which
comprise the textiles. The present disclosure is also directed to
methods of making the textiles, components and articles described
herein.
BACKGROUND
[0003] Traditionally, vulcanized rubber has been used to provide
traction and abrasion resistance to articles such as apparel,
footwear and sporting equipment. The need to vulcanize the rubber
at high temperatures and/or pressures typically makes it necessary
to form a separate vulcanized rubber component which is then
affixed to the article using adhesives or stitching or both, as
other components of the article may not be able to withstand the
temperatures and/or pressures required by the vulcanization
process. Alternatively, in footwear uppers, crosslinked
polyurethanes can be used as durable covering layers, synthetic
leather textiles, or laminate film layers. A need remains for new
materials that can provide the same types of protection as
vulcanized rubber or crosslinked polyurethane in addition to
traction or abrasion resistance or both, and for new ways of
incorporating these materials into articles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Further aspects of the present disclosure will be readily
appreciated upon review of the detailed description, described
below, when taken in conjunction with the accompanying
drawings.
[0005] FIG. 1A is a top and side perspective view of an article of
footwear in accordance with aspects of the present invention.
[0006] FIG. 1B is a bottom and side perspective view of the article
of footwear of FIG. 1A, in accordance with aspects of the present
invention.
[0007] FIG. 1C is a top and side perspective view of an alternative
aspect of the article of footwear of FIG. 1A in accordance with
aspects of the present invention.
[0008] FIG. 2A is a side view of an article of apparel, primarily
illustrating an elbow patch, in accordance with aspects of the
present invention.
[0009] FIG. 2B is a close-up view of the elbow patch of the article
of apparel of FIG. 2A in accordance with aspects of the present
invention.
[0010] FIG. 3 is a plan view of a schematic depiction of a textile
having three types of textile zones, in accordance with aspects of
the present invention.
[0011] FIGS. 4A-5J depict exemplary knit structures in accordance
with aspects of the present invention.
[0012] FIG. 5A is a schematic representation of three
interconnected courses of loops with the middle course of loops
being formed of a different yarn than the outer courses of loops,
in accordance with aspects of the present invention.
[0013] FIG. 5B is a schematic representation of the interconnected
courses of loops of FIG. 5A after being exposed to a thermoforming
process, and showing the middle course of loops being transformed
into a component including re-flowed polymeric composition which no
longer has the configuration of a yarn upon thermoforming, where
the two outer courses of loops remain in the configuration of
yarns, in accordance with aspects of the present invention.
[0014] FIG. 6 is a schematic representation of a cross-section of
the component including re-flowed polymeric composition of FIG. 5B,
and showing a portion of a yarn from one of the outer courses of
loops being encapsulated within the re-flowed polymeric
composition, in accordance with aspects of the present
invention.
[0015] FIG. 7A shows a textile comprising coated yarns according to
the present disclosure prior to thermoforming, while FIG. 7B shows
the same textile after thermoforming. FIG. 7C shows a textile
comprising coated yarns and an additional yarn according to the
present disclosure prior to thermoforming, while FIG. 7D shows the
same textile after thermoforming.
[0016] FIG. 7E shows a textile comprising coated yarns on both a
top and bottom face of the textile and incorporating coated yarns
in the core of the textile prior to thermoforming, while FIG. 7F
shows the same textile after thermoforming.
[0017] FIGS. 8A-8M show various articles of footwear, apparel,
athletic equipment, container, electronic equipment, and vision
wear in accordance with the present disclosure.
[0018] FIGS. 8N(a)-8Q(e) illustrate additional details regarding
different types of footwear.
DETAILED DESCRIPTION
[0019] Thermoplastic elastomers have been identified which can be
incorporated into polymeric compositions that provide levels of
abrasion resistance, traction, or both, making them suitable for
use in articles where abrasion resistance or traction are
desirable, such as articles of apparel, footwear and sporting
equipment. In many cases, the level of abrasion resistance,
traction, or both provided by these polymeric compositions are
equivalent to or better than standard vulcanized rubber
compositions used in the manufacture of footwear, apparel and
sporting equipment. Unlike vulcanized rubber, due to the
thermoplastic nature of these polymeric compositions, and their
properties in the solid and molten state, it is possible to readily
form them into coated yarns which have suitable properties for use
in industrial scale knitting or weaving equipment. These properties
result in yarns that can readily be incorporated into various
articles including textiles using conventional manufacturing
processes such as knitting and weaving, as well as industrial scale
processes for making non-woven textiles. Also unlike vulcanized
rubber, these textiles and articles into which these textiles are
incorporated can then, in turn, be thermoformed in a manner which
reflows the polymeric composition of the coated yarns and creates
an abrasion resistant or high traction surface on the textile or
article under conditions which do not damage other components of
the textile or article, such as, for example, other yarns, other
textiles, foams, molded resin components, etc. The polymeric
compositions disclosed herein retain their favorable properties
after repeated cycles of melting and re-solidifying, making it
possible to first use them to coat yarns, and then thermoform the
yarns to create re-flowed structures which retain their abrasion
resistance, traction properties, or both. Additionally, due to the
compatibility of these polymeric compositions with other materials
commonly used to make articles of footwear, apparel as sporting
equipment such as polyurethanes, polyesters and polyamides, the
thermoforming process may securely bond the polymeric composition
to the other components, making it unnecessary to use adhesives or
stitching to attach the textiles to the other component, thereby
reducing the number of manufacturing steps and avoiding the use of
toxic primers and adhesives.
[0020] Additionally, polymeric compositions have been found which
are capable of being extruded as coatings onto core yarns in
amounts and at rates needed for commercial yarn production, and
which produce yarns having the balance of elongation, strength, and
shrinkage necessary for use in commercial high-speed knitting
equipment, either as a knitting yarn or an inlay yarn.
[0021] The coated yarns disclosed herein include a core yarn and a
first coating. The core yarn can comprise a conventional
monofilament or multifilament yarn such as a commercially available
polyester or polyamide yarn having properties (such as denier and
tenacity) sufficient for it to be manipulated by industrial-scale
knitting equipment. The first coating of the coated yarn comprises
a polymeric composition which is a thermoplastic elastomeric
composition. While it is possible to extrude a polymeric
composition which is a thermoplastic elastomeric composition and
form fibers, filaments, yarns or films directly from the polymeric
composition, due to its elastomeric properties, these forms of the
polymeric composition will have high levels of stretch and heat
shrinkage. This means the fibers, filaments, yarns or films may
tend to stretch around machine guides rather than slide past them,
and may tend to shrink at the temperatures commonly encountered in
industrial-scale knitting and weaving equipment. However, by
applying the polymeric composition as a coating onto a core yarn
which is suitable to be mechanically manipulated, the resulting
coated yarn retains the tenacity and stretch resistance of the core
yarn, while also providing an outer surface having superior
traction and abrasion resistance provided by the polymeric
composition due to its elastomeric properties. For example, it has
been found that a 150 denier core yarn having a tensile strength of
at least 1 kilogramforce at break and less than 20 percent strain
to break, and heat shrink of less than 20 percent can be coated
with the polymeric composition to a nominal average outer diameter
of up to about 1.0 millimeter, and retain its ability to be knit or
inlaid using commercial flat-knitting equipment. Due to the ability
to use this yarn on industrial-scale equipment, this coated yarn
also opens up possibilities for new methods of manufacturing which
allow placement of the polymeric composition within textiles and
articles comprising the textiles at greater levels of specificity
in terms of both location and amount as compared to conventional
manufacturing processes.
[0022] Additionally, the thermoplastic nature of the polymeric
composition makes it possible to melt the composition and use it to
coat the core yarn when the melting temperature of the polymeric
composition is sufficiently lower than the deformation temperature
of the core yarn, as well as to subsequently thermoform the textile
to create a thermoformed network comprising both the core yarn and
the re-flowed and re-solidified polymeric composition consolidating
the core yarn. When the textile includes one or more second yarn in
addition of the coated yarn, the thermoformed network of yarns
(i.e., the core yarn and the one or more second yarn) are
consolidated by the re-flowed and re-solidified polymeric
composition. The presence of the re-flowed and re-solidified
polymeric composition can serve one or more functions within the
thermoformed textile, such as controlling the level of stretch
within the entire textile or just within a region of the textile,
forming a skin having high abrasion-resistance and/or traction
across an entire surface of the textile or just within a region of
the textile, improving water resistance of an entire surface of the
textile or just within a region of the textile, or bonding all of
the textile or just a region of the textile to a substrate. Use of
the coated yarn in these textiles can also reduce the number of
different materials required to form an article. The coating of the
coating yarn, when thermoformed, can form a skin on a surface of
the textile. Alternatively or additionally, the coating of the
coating yarn, when thermoformed, can act as a bonding agent, either
to bond yarns together within the textile, or to bond other
elements to a surface of the textile. Conventionally, a separate
film layer is required to form a skin on a textile, or a separate
adhesive layer is required to bond yarns within a textile or to
bond other elements to the surface of a textile. For example, in a
conventional article of footwear, the upper may incorporate
elements such as multiple layers of textiles, films and/or cables
to limit stretch of regions of the upper, separate elements or
layers of textiles, films or rubber to increase abrasion resistance
of the upper, separate elements or layers of rubber to form areas
of high traction on an outsole, and separate layers of adhesives or
cements to bond the various elements or layer to each other. The
use of the thermoformed textiles described herein can replace one
or more of the separate elements, reducing waste and simplifying
manufacturing processes while improving recyclability of the
articles.
[0023] As will be discussed below, in one aspect, the thermoformed
textiles comprising coated yarns as described herein can be used to
form uppers for articles of footwear. In a particular aspect, the
thermoformed network of the thermoformed textile can form an
externally-facing surface of an upper, such as an upper for a
global football boot. Unexpectedly, the thermoformed network formed
by thermoforming the textiles has superior properties for ball
contact, in that the properties of the thermoformed network can be
equal to or superior to those of kangaroo skin leather in terms of
the spin rate imparted to the ball by the upper when kicking the
ball. For example, it has been found that using polymeric
compositions having a Durometer hardness of about 65 to about 85
results in uppers with improved ball spin rates. Uppers comprising
the textiles described herein have also been found to be equivalent
to or superior to those of synthetic leather or knit uppers coated
with a DURAGON skin in terms of traction under wet and dry
conditions. Additionally, as uppers formed from the thermoformed
textiles use fewer components in the manufacturing process and do
not rely on animal-based materials, their manufacture produces less
waste while using more sustainable materials which can be
recycled.
[0024] In another aspect, the thermoformed textiles comprising
coated yarns as described herein can be used to form outsoles for
articles of footwear. In a particular aspect, the thermoformed
network of the thermoformed textile can form an externally-facing
surface of an outsole, including a ground-facing surface or a
ground-contacting surface of an outsole. Conventionally,
cross-linked polymeric compositions such as vulcanized rubber or
cross-linked polyurethanes have been used for outsoles due to their
high levels of abrasion resistance and traction. Unexpectedly, it
has been found that the use of the textiles including coated yarns
comprising polymeric coatings disclosed herein can be used to
replace cross-linked polymeric compositions as outsole materials,
while retaining the high levels of traction and abrasion resistance
required for outsoles. Specifically, by using the coated yarns
described herein which can be used in commercial knitting machines,
it is possible to create thermoformed networks which provide levels
of abrasion resistance and traction equivalent to, and in come
cases superior to, conventional outsole materials. As these
thermoformed networks can be formed at lower temperatures and
pressures as compared to conventional vulcanization processes, it
is possible to thermoform the textiles while they are in contact
with other components such as other textiles or molded resin
components, thereby reducing energy consumption and reducing
manufacturing steps.
[0025] The present disclosure is directed to a textile comprising a
first network of yarns including a first coated yarn, wherein the
first coated yarn comprises a core yarn and a first coating,
wherein the first coating comprises a first polymeric composition.
The first polymeric composition is a thermoplastic elastomeric
composition, and comprises at least one thermoplastic elastomer. In
some aspects, the first network of yarns further comprises one or
more second yarns. The one or more second yarns can be coated
yarns, or can be uncoated yarns. The textile can be a knit textile,
and the first network of yarns can include interconnected loops of
the first coated yarn, or can include the first coated yarn inlaid
in a knit structure formed of interconnecting loops of one or more
second yarns.
[0026] The present disclosure is directed to a textile, comprising:
a first network of yarns including a first coated yarn, the first
coated yarn comprising a first core yarn and a first coating
including a first polymeric composition disposed on at least a
portion of an outer surface of the first core yarn, wherein the
first polymeric composition is a thermoplastic elastomeric
composition.
[0027] The present disclosure is directed to a textile, comprising:
a thermoformed network of yarns, the thermoformed network
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition.
[0028] The present disclosure is directed to an upper for an
article of footwear, comprising: a textile, wherein the textile
comprises a first network of yarns including a first coated yarn,
the first coated yarn comprising a first core yarn and a first
coating including a first polymeric composition disposed on at
least a portion of an outer surface of the first core yarn, wherein
the first polymeric composition is a thermoplastic elastomeric
composition.
[0029] The present disclosure is directed to an upper for an
article of footwear, comprising: a first textile comprising a
thermoformed network of yarns comprising a first core yarn and a
first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, and wherein the first polymeric composition is a
thermoplastic elastomeric composition.
[0030] The present disclosure is directed to an outsole for an
article of footwear, comprising: a textile comprising a
thermoformed network of yarns comprising a first core yarn and a
first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, and wherein the first polymeric composition is a
thermoplastic elastomeric composition.
[0031] The present disclosure is directed to a method of making a
textile, the method comprising: forming a first network of yarns
including a first coated yarn, the first coated yarn comprising a
first core yarn and a first coating including a first polymeric
composition disposed on at least a portion of an outer surface of
the first core yarn, wherein the first polymeric composition is a
thermoplastic elastomeric composition.
[0032] The present disclosure is directed to a method of making a
textile, the method comprising: thermoforming a first textile
comprising a first network of yarns including a first coated yarn,
the first coated yarn comprising a first core yarn and a first
coating including a first polymeric composition disposed on at
least a portion of an outer surface of the first core yarn, wherein
the first polymeric composition is a thermoplastic elastomeric
composition; thereby forming a thermoformed network of yarns
comprising the first core yarn and the first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns.
[0033] The present disclosure is directed to a method of making an
upper for an article of footwear, the method comprising: affixing a
first textile to a second component, wherein the first textile
comprises a first network of yarns including a first coated yarn,
the first coated yarn comprising a first core yarn and a first
coating including a first polymeric composition disposed on at
least a portion of an outer surface of the first core yarn, wherein
the first polymeric composition is a thermoplastic elastomeric
composition.
[0034] The present disclosure is directed to a method of making an
upper for an article of footwear, the method comprising:
thermoforming an upper comprising a first textile, wherein the
first textile comprises a first network of yarns including a first
coated yarn, the first coated yarn comprising a first core yarn and
a first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition; and wherein the thermoforming comprises
melting, reflowing, and re-solidifying the first polymeric
composition within the first textile, forming a thermoformed
textile comprising a thermoformed network of yarns comprising the
first core yarn and the first polymeric composition, wherein the
first polymeric composition consolidates the thermoformed network
of yarns by surrounding at least a portion of the first core yarn
and occupying at least a portion of spaces between yarns in the
thermoformed network of yarns.
[0035] The present disclosure is directed to a method of making an
upper for an article of footwear, the method comprising: affixing a
first textile to a second component, wherein the first textile
comprises a thermoformed network of yarns comprising a first core
yarn and a first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, and wherein the first polymeric composition is a
thermoplastic elastomeric composition.
[0036] The present disclosure is directed to a method for making an
outsole for an article of footwear, the method comprising
thermoforming a first textile; wherein the thermoforming comprises
thermoforming the textile on a sole component, or on a molding
surface, optionally wherein the molding surface is a molding
surface having the dimensions of the outsole; wherein the first
textile comprises a first network of yarns including a first coated
yarn, the first coated yarn comprising a first core yarn and a
first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition; and wherein the thermoforming comprises
melting, reflowing, and re-solidifying the first polymeric
composition within the first textile, forming a thermoformed
textile comprising a thermoformed network of yarns comprising the
first core yarn and the first polymeric composition, wherein the
first polymeric composition consolidates the thermoformed network
of yarns by surrounding at least a portion of the first core yarn
and occupying at least a portion of spaces between yarns in the
thermoformed network of yarns.
[0037] The present disclosure is directed to a method of making an
article, comprising: affixing a first textile to a second
component, wherein the first textile comprises a first network of
yarns including a first coated yarn, the first coated yarn
comprising a first core yarn and a first coating including a first
polymeric composition disposed on at least a portion of an outer
surface of the first core yarn, wherein the first polymeric
composition is a thermoplastic elastomeric composition.
[0038] The present disclosure is directed to a method of making an
article, the method comprising: thermoforming a first textile,
wherein the first textile comprises a first network of yarns
including a first coated yarn, the first coated yarn comprising a
first core yarn and a first coating including a first polymeric
composition disposed on at least a portion of an outer surface of
the first core yarn, wherein the first polymeric composition is a
thermoplastic elastomeric composition; and wherein the
thermoforming comprises melting, reflowing, and re-solidifying the
first polymeric composition within the first textile, forming a
thermoformed textile comprising a thermoformed network of yarns
comprising the first core yarn and the first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns.
[0039] The present disclosure is directed to a method of making an
article, the method comprising: affixing a first textile to a
second component, wherein the first textile comprises a
thermoformed network of yarns comprising a first core yarn and a
first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, and wherein the first polymeric composition is a
thermoplastic elastomeric composition; optionally wherein the
article is a component of an article of footwear, apparel or
sporting equipment, or is an article of footwear, apparel or
sporting equipment.
[0040] The present disclosure is directed to an outsole for an
article of footwear, comprising:
[0041] a textile comprising a thermoformed network of yarns
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition comprises a thermoplastic elastomeric
polyurethane, wherein the first polymeric composition has a
Durometer Hardness of from about 70 to about 80 Shore A, as
determined using the Durometer Hardness Test;
[0042] wherein the thermoformed network of yarns is the
thermoformed product of a first textile comprising a first network
of yarns including a first coated yarn comprising the first core
yarn and a first coating, the first coating comprising the first
polymeric composition, the first core yarn comprising a second
polymeric composition, wherein the first coating is axially
centered surrounding the core yarn, a nominal average outer
diameter of the coated yarn is up to about 1.0 millimeter, the
first coating has an average radial coating thickness of about 50
micrometers to about 200 micrometers, and wherein, in the
thermoformed network, the first polymeric composition consolidating
the thermoformed network of yarns is the re-flowed and
re-solidified product of the first polymeric composition of the
first coating of the first coated yarn;
[0043] wherein, in the first coated yarn, the first thermoplastic
composition has a first melting temperature greater than about 110
degrees Celsius and less than about 190 degrees Celsius, the second
polymeric composition of the core yarn has a second deformation
temperature, and the second deformation temperature is at least 50
degrees Celsius greater than the first melting temperature of the
first polymeric composition;
[0044] wherein a first side of the thermoformed network defines at
least a portion of a surface of the outsole configured to be
externally-facing or ground-facing or ground-contacting when the
outsole is part of a finished article of footwear.
[0045] The present disclosure is directed to an upper for an
article of footwear, comprising:
[0046] a knit textile comprising a thermoformed network of
interlooped yarns comprising a first core yarn and a first
polymeric composition, wherein the first polymeric composition
consolidates the thermoformed network of interlooped yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, wherein the first polymeric composition comprises
a thermoplastic elastomeric polyurethane, and wherein the first
polymeric composition has a Durometer Hardness using a Shore A
scale of from about 70 to about 80, as determined using the
Durometer Hardness Test;
[0047] wherein the thermoformed network of yarns is the
thermoformed product of a first textile comprising a first network
of yarns including a first coated yarn comprising the first core
yarn and a first coating, the first coating comprising the first
polymeric composition, the first core yarn comprising a second
polymeric composition, wherein the first coating is axially
centered surrounding the core yarn, a nominal average outer
diameter of the coated yarn is up to about 1.0 millimeter, the
first coating has an average radial coating thickness of about 50
micrometers to about 200 micrometers, and wherein, in the
thermoformed network, the first polymeric composition consolidating
the thermoformed network of yarns is the re-flowed and
re-solidified product of the first polymeric composition of the
first coating of the first coated yarn;
[0048] wherein, in the first coated yarn, the first thermoplastic
composition has a first melting temperature greater than about 110
degrees centigrade and less than about 190 degrees centigrade, the
second polymeric composition of the core yarn has a second
deformation temperature, and the second deformation temperature is
at least 50 degrees centigrade greater than the first melting
temperature of the first polymeric composition;
[0049] wherein the thermoformed network of the textile defines at
least a portion of a surface of the upper configured to be
externally-facing when the upper is part of a finished article of
footwear;
[0050] wherein the at least a portion of the surface of the upper
defined by the thermoformed network has a total surface area of at
least 1 square centimeter, and within the total surface area, at
least 15 to 100 percent of the total surface area comprises the
first polymeric composition.
[0051] The present disclosure is directed to an outsole for an
article of footwear, comprising:
[0052] a textile comprising a thermoformed network of yarns
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition comprises a thermoplastic elastomeric
styrenic copolymer, wherein the first polymeric composition has a
Durometer Hardness of from about 70 to about 80 Shore A, as
determined using the Durometer Hardness Test;
[0053] wherein the thermoformed network of yarns is the
thermoformed product of a first textile comprising a first network
of yarns including a first coated yarn comprising the first core
yarn and a first coating, the first coating comprising the first
polymeric composition, the first core yarn comprising a second
polymeric composition, wherein the first coating is axially
centered surrounding the core yarn, a nominal average outer
diameter of the coated yarn is up to about 1.0 millimeter, the
first coating has an average radial coating thickness of about 50
micrometers to about 200 micrometers, and wherein, in the
thermoformed network, the first polymeric composition consolidating
the thermoformed network of yarns is the re-flowed and
re-solidified product of the first polymeric composition of the
first coating of the first coated yarn;
[0054] wherein, in the first coated yarn, the first thermoplastic
composition has a first melting temperature greater than about 110
degrees Celsius and less than about 190 degrees Celsius, the second
polymeric composition of the core yarn has a second deformation
temperature, and the second deformation temperature is at least 50
degrees Celsius greater than the first melting temperature of the
first polymeric composition;
[0055] wherein a first side of the thermoformed network defines at
least a portion of a surface of the outsole configured to be
externally-facing or ground-facing or ground-contacting when the
outsole is part of a finished article of footwear.
[0056] The present disclosure is directed to an upper for an
article of footwear, comprising:
[0057] a knit textile comprising a thermoformed network of
interlooped yarns comprising a first core yarn and a first
polymeric composition, wherein the first polymeric composition
consolidates the thermoformed network of interlooped yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, wherein the first polymeric composition comprises
a thermoplastic elastomeric styrenic copolymer, and wherein the
first polymeric composition has a Durometer Hardness using a Shore
A scale of from about 70 to about 80, as determined using the
Durometer Hardness Test;
[0058] wherein the thermoformed network of yarns is the
thermoformed product of a first textile comprising a first network
of yarns including a first coated yarn comprising the first core
yarn and a first coating, the first coating comprising the first
polymeric composition, the first core yarn comprising a second
polymeric composition, wherein the first coating is axially
centered surrounding the core yarn, a nominal average outer
diameter of the coated yarn is up to about 1.0 millimeter, the
first coating has an average radial coating thickness of about 50
micrometers to about 200 micrometers, and wherein, in the
thermoformed network, the first polymeric composition consolidating
the thermoformed network of yarns is the re-flowed and
re-solidified product of the first polymeric composition of the
first coating of the first coated yarn;
[0059] wherein, in the first coated yarn, the first thermoplastic
composition has a first melting temperature greater than about 110
degrees centigrade and less than about 190 degrees centigrade, the
second polymeric composition of the core yarn has a second
deformation temperature, and the second deformation temperature is
at least 50 degrees centigrade greater than the first melting
temperature of the first polymeric composition;
[0060] wherein the thermoformed network of the textile defines at
least a portion of a surface of the upper configured to be
externally-facing when the upper is part of a finished article of
footwear;
[0061] wherein the at least a portion of the surface of the upper
defined by the thermoformed network has a total surface area of at
least 1 square centimeter, and within the total surface area, at
least 15 to 100 percent of the total surface area comprises the
first polymeric composition.
[0062] In one aspect, the deformation temperature of the polymeric
composition of the core yarn is at least 20 degrees Celsius higher
than the melting temperature of the polymeric composition of the
coating. This allows the core yarn to be coated by the coating when
the coating is in a molten state. In another aspect, the
thermoplastic elastomer(s) of the polymeric composition of the
coating have glass transition temperature(s) below minus 20 degrees
Celsius. This allows the thermoplastic elastomer(s) present in the
polymeric composition to be in their "rubbery" state, even when the
article comprising the textile is used in cold environments. In
another aspect, the melting temperature of polymeric composition of
the coating is at least 100 degrees Celsius. This ensures the
polymeric composition will not melt when the article comprising the
textile is shipped or stored under hot conditions. In another
aspect, the melting temperature of polymeric composition of the
coating is at least 130 degrees Celsius. This ensures the polymeric
composition will not melt when the article comprising the textile
is subjected to conditions often encountered by textiles during the
manufacturing processes for articles of footwear, apparel or
sporting equipment, such as steaming processes. In another aspect,
the melting temperature of polymeric composition of the coating is
at less than 170 degrees Celsius. This ensures the textile can be
thermoformed at temperatures which do not negatively impact other
textiles or components which may form part of the textile or
article comprising the textile. For example, dye may migrate out of
package-dyed polyester yarns when they are exposed to temperatures
greater than 150 degrees Celsius for extended periods of time. In
another aspect, the enthalpy of melting of the thermoplastic
elastomer(s) of the polymeric composition of the coating can be
less than about 30 Joules per gram or 25 Joules per gram. A lower
melting enthalpy means that, during the thermoforming process, less
heat and a shorter heating time is required to fully melt the
polymeric composition and achieve good flow of the molten polymeric
composition to better consolidate the network of yarns in the
textile. In another aspect, the recrystallization temperature of
thermoplastic elastomer(s) of the polymeric composition of the
coating can be above 60 degrees Celsius, or above 95 degrees
Celsius. A higher recrystallization temperature promotes rapid
re-solidification of the polymeric composition after thermoforming,
which can reduce the amount of time required to cool the textile
after thermoforming, and may avoid the need to provide active
cooling of the textile, thereby reducing cycle time and reducing
energy consumption.
[0063] The present disclosure is directed to a film, fiber,
filament or yarn comprising a first polymeric composition
comprising at least one thermoplastic elastomer.
[0064] The present disclosure is also directed to a textile
comprising a film, fiber, filament or yarn comprising a first
polymeric composition comprising at least one thermoplastic
elastomer.
[0065] The present disclosure is also directed to process for
manufacturing a film, fiber, filament or yarn, comprising using a
first polymeric composition comprising at least one thermoplastic
elastomer to form the film, fiber, filament or yarn.
[0066] The present disclosure is also directed to a textile
comprising a first network of yarns including a first coated yarn,
the first coated yarn comprising a first core yarn and a first
coating including a first polymeric composition disposed on at
least a portion of an outer surface of the first core yarn, wherein
the first polymeric composition is a thermoplastic elastomeric
composition.
[0067] The present disclosure is also directed to process for
manufacturing a textile comprising using a film, fiber, filament or
yarn as described herein.
[0068] The present disclosure is also directed to an article
comprising: a first polymeric composition, wherein the first
polymeric composition is a reflowed and re-solidified product of a
film, fiber, filament or yarn as described herein; and a second
element selected from a second shaped component, a second film, a
second fiber, a second filament, a second yarn, or a second
textile.
[0069] The present disclosure is also directed to a process for
manufacturing an article, the process comprising: placing a first
film, fiber, filament, yarn, or textile comprising a first
polymeric composition comprising a thermoplastic elastomer as
described herein, or a textile comprising the first polymeric
composition comprising the thermoplastic elastomer as described
herein on a surface; while the first film, fiber, filament, yarn or
textile is on the surface, increasing a temperature of the first
film, fiber, filament, yarn or textile to a temperature that is
above the melting temperature of the first polymeric composition;
and subsequent to the increasing the temperature, while the first
film, fiber, filament, yarn or textile remains on the surface,
decreasing the temperature to a temperature below the melting
temperature of the first polymeric composition, thereby forming a
article.
[0070] Described herein are films comprising a first polymeric
composition comprising at least one thermoplastic elastomer. In
some aspects, the first polymeric composition of the film can be a
low processing temperature polymeric composition. In various
aspects, the film can be a multi-layered film comprising a first
layer comprising the first thermoplastic elastomer. For example,
the multi-layered film can be a bilayer film comprising a first
layer comprising the first thermoplastic elastomer and a second
layer comprising a second polymeric material. The second polymeric
material can be a second thermoplastic composition comprising a
second thermoplastic elastomer. The multi-layered film can be
formed by co-extrusion or lamination.
[0071] Described herein are fibers comprising the first polymeric
composition comprising at least one thermoplastic elastomer. As
used herein, the "fiber" is understood to be a fiber suitable for
use in a yarn or a textile. A fiber has a small diameter relative
to its length, where its length is discrete, e.g., a cut or staple
fiber include filaments. In various aspects, the fiber can be a
single-component fiber composed of one thermoplastic composition.
In other aspects, the fiber can be a bi-component fiber composed of
two thermoplastic compositions. In a further aspect, the fiber can
be a multi-component fiber composed of three or more thermoplastic
compositions.
[0072] Described herein are filaments comprising the first
polymeric composition comprising at least one thermoplastic
elastomer. As used herein, the "filament" is understood to be
filament suitable for use in a yarn or a textile. A filament has a
small diameter relative to its length, where its length is many
orders of magnitude greater than its diameter, such as a silk
filament or extruded filament, or can be substantially continuous,
such as an extruded filament. In various aspects, the filament can
be a single-component filament composed of one thermoplastic
composition. In other aspects, the filament can be a bi-component
filament composed of two thermoplastic compositions. In a further
aspect, the filament can be a multi-component fiber composed of
three or more thermoplastic compositions. The filament can be a
single filament, e.g., a monofilament. Alternatively, the filament
can be a plurality of filaments. The plurality of filaments can
include filaments formed of a single thermoplastic composition, or
a plurality of filaments formed from two or more different
thermoplastic compositions. The plurality of filaments can be a
plurality of loose (i.e., not entangled) filaments, or can be a
plurality of entangled filaments.
[0073] Described herein are yarns useful in making textiles. In one
aspect, the yarn comprises a coating of a first polymeric
composition comprising at least one thermoplastic elastomer. The
yarns can be formed using staple fibers or continuous filaments
comprising of the thermoplastic composition. In one aspect, the
fibers or filaments used to produce the yarn comprise a single
polymeric composition. The first polymeric composition can be a low
processing temperature polymeric composition. In one example, the
yarn can be a coated yarn having a core, wherein the core comprises
a high processing temperature polymeric composition, and the
coating comprises the low processing temperature polymeric
composition. Alternatively, the yarn can comprise fibers,
filaments, cores and/or coatings formed from two or more different
polymeric compositions.
[0074] In one aspect, using a coated yarn allows the incorporation
of desirable rubbery polymeric properties into textiles. In one
aspect, tensile strength of a 150 denier, high tenacity core
polyester eliminates excess stretch and heat shrink risks. In one
aspect, the tensile strength of the yarn is about 1 kilogramforce
at break, and less than 20 percent strain to break, or less than 15
percent strain to break, or from about 10 to about 12 percent
strain to break. In another aspect, heat shrink for the coated
yarns is less than 20 percent or less than 10 percent upon
heating.
[0075] In some aspects, use of lubricating oil such as mineral oil
or silicone oil enables knitting of elastomer-coated yarns to be
comparable to knitting of common polyester yarns. In one aspect,
from about 0.1 weight percent to about 3 weight percent of the
textile, or about 0.5 weight percent to about 2 weight percent of
the textile. In one aspect, the lubricating composition can be
applied to the coated yarn after the coating process. In another
aspect, the lubricating compositions can be admixed with the first
polymeric composition prior to coating the core yarn.
[0076] In another aspect, the yarn can be coated by any method
known in the art. In one aspect, the polymeric coating compositions
disclosed herein are suitable for manufacturing by pultrusion
and/or pulling the yarns through baths of liquid polymeric
materials. In still another aspect, regardless of coating process,
sufficient coating material is provided on the yarn such that, when
knit or woven alone or with one or more other yarns in various
configurations and subsequently thermoformed and allowed to re-flow
and re-solidify, the polymeric material forms a structure with an
adequate concentration of the polymeric material on one or more
surfaces, and/or within the core, depending upon the placement of
the coated yarn within the knit or woven structure.
[0077] The foregoing films, fibers, filaments, yarns, or any
combination thereof, can be used to prepare a textile. The textile
can comprise one or more of the disclosed films, fibers, filaments
or yarns. In various aspects, the textile can be a woven textile
comprising one or more of the disclosed films, fibers, filaments,
or yarns. In a further aspect, the textile can be a knit textile
comprising one or more disclosed films, fibers, filaments, or
yarns. In a still further aspect, the textile can be a non-woven
textile comprising one or more of the disclosed films, fibers,
filaments or yarns. In other aspects, the textile can be a
crocheted textile or braided textile comprising one or more of the
disclosed films, fibers, filaments or yarns.
[0078] In an aspect, a textile is provided comprising a first film,
fiber, filament or yarn described herein. In one aspect, the
textile further includes a second yarn, where the second yarn is
different from the first yarn (e.g., comprises at least one
thermoplastic elastomer that differs from a thermoplastic elastomer
of the first polymeric composition based on molecular weight,
polymeric structure, melting temperature, melt flow index,
hardness, or modulus). In another aspect, the second yarn is
substantially free of a thermoplastic elastomer.
[0079] In one aspect, the textile comprises a first network of
yarns including a first coated yarn, where the first coated yarn
includes a first core yarn and a first coating including a first
polymeric composition disposed on at least a portion of an outer
surface of the first core yarn, wherein the first polymeric
composition is a thermoplastic elastomeric composition.
[0080] The first yarn and second yarn can be used so as to form
separate zones of the textile. For example, the first yarn can form
a majority of a first surface of the textile, and the second yarn
can form a majority of a second surface opposing the first surface
of the textile. The first yarn and the second yarn can be laid down
in a first zone and an adjacent second zone, wherein the first zone
comprises an increased concentration of the second yarn compared to
the second zone. The first yarn and the second yarn can be laid
down in a first zone, a second zone, and a third zone, the second
zone positioned between the first and third zones, wherein the
first zone comprises an increased concentration of the second yarn
compared to the second zone, and wherein the third zone comprises
an increased concentration of the first yarn compared to the second
zone. percent
[0081] In an aspect, a woven textile is provided comprising a first
film, fiber, filament, or yarn as described herein. Optionally, the
woven textile further includes a second film, fiber, filament or
yarn, where the second yarn has a higher melting or deformation
temperature from the first yarn. In another aspect, the second
film, fiber, filament or yarn is substantially free of a
thermoplastic elastomer. The first film, fiber, filament or yarn
and the second film, fiber, filament or yarn can be used to form
separate zones of the woven thermoformed textile. For example, a
first yarn can form substantially all or a portion of a warp of the
weave of the woven thermoformed textile, and a second yarn can form
substantially all or a portion of a weft of the weave of the woven
thermoformed textile, or vice versa.
[0082] In an aspect, a knit or crochet textile is provided
comprising a first film, fiber, filament or yarn as described
herein. The knit or crochet textile can optionally further include
a second film, fiber, filament or yarn, where the second film,
fiber, filament or yarn has a higher melting temperature or
deformation temperature from the first film, fiber, filament or
yarn In another aspect, the second film, fiber, filament or yarn is
substantially free of a thermoplastic elastomer. A first yarn and a
second yarn can at least partly form a plurality of interconnected
courses in at least one knit layer of a knit textile.
Alternatively, the knit or crochet textile can include
interconnected loops comprising a second yarn and inlaid portions
comprising the first film, fiber, filament or yarn, wherein the
second yarn has a melting temperature or deformation temperature
greater than the melting temperature of the first polymeric
composition.
[0083] The knit textile can be formed through one or more of a
variety of a knitting process, such as flat knitting or circular
knitting. For example, a flat knitting process can be utilized to
manufacture the knit textile. Although flat knitting can provide a
suitable process for forming the knit textile, other knitting
processes can also be utilized such as wide tube circular knitting,
narrow tube circular knit jacquard, single knit circular knit
jacquard, double knit circular knit jacquard, warp knit tricot,
warp knit raschel, and double needle bar raschel. In aspects, the
knit textile can be subject to post-processing steps, e.g., to
remove a portion of the knit textile, to add components to the knit
textile, to create a fleece texture, etc. In other aspects, the
knit textile can comprise various knitted structures and/or
comprise different knitted sublayers.
[0084] In certain aspects, the knit textile can be a knit article
having a substantially seamless configuration. In certain aspects,
the entire knit article can be seamless. The seamless knit article
may, for example, be provided by circular knitting. A circular knit
article can allow a three-dimensionally preshaped article to be
provided without having to be sewn up at a designated place(s).
Thus, unwanted seams in the knit article can be avoided and the
three-dimensionally preshaped knit article can have a particularly
good fit and the additional aforementioned benefits of a seamless
structure.
[0085] In a further aspect, the knit textile can be a knit article
formed of unitary knit construction. As utilized herein, a knit
article is defined as being formed of "unitary knit construction"
when formed as a one-piece element through a knitting process. That
is, the knitting process substantially forms the various features
and structures of the knit article without the need for significant
additional manufacturing steps or processes. Although portions of
the knit article can be joined to each other (e.g., edges of the
knit article being joined together, as at seam) following the
knitting process, the knit article remains formed of unitary knit
construction because it is formed as a one-piece knit element. In
various aspects, the knit article can further comprise other
elements (e.g., a tongue, a strobel, a lace, a heel counter, logos,
trademarks, placards) that can be added following the knitting
process.
[0086] The knit textile can incorporate various types and
combinations of stitches and yarns. With regard to stitches, the
knit textile can have one type of stitch in one area of the knit
textile and another type of stitch in another area of the knit
textile. Depending upon the types and combinations of stitches
utilized, areas of the knit textile can have, for example, a plain
knit structure, a mesh knit structure, or a rib knit structure. The
different types of stitches may affect the physical properties of
the knit textile, including aesthetics, stretch, thickness, air
permeability, and abrasion-resistance. That is, the different types
of stitches may impart different properties to different areas of
knit textile. With regard to yarns, the knit textile may have one
type of yarn in one area of the knit textile and another type of
yarn in another area of the knit textile, e.g., a yarn comprising a
first polymeric composition in one area of the knit textile and a
yarn comprising a second polymeric composition, such as a
thermoplastic composition, in another area of the knit textile.
Depending upon various design criteria, the knit textile can
incorporate yarns with different deniers, materials (e.g., cotton,
elastane, polyester, rayon, wool, and nylon), and degrees of twist,
for example. The different types of yarns may affect the physical
properties of the knit textile, including aesthetics, stretch,
thickness, air permeability, and abrasion-resistance. That is, the
different types of yarns may impart different properties to
different areas of the knit textile. By combining various types and
combinations of stitches and yarns, each area knit article can have
specific properties that enhance the comfort, durability, and
performance of the knit textile as required by its use in an
article of footwear, article of apparel, or article of sporting
equipment.
[0087] It should be noted, however, that the textiles and
thermoformed textiles of the present disclosure, including knit
articles, can be utilized in manufacture of composite elements. In
some aspects, a composite element can comprise a first textile
prepared as disclosed herein, along with a second textile or a film
or a shaped component. That is, the composite element comprises a
first textile region and a second region selected from a region
comprising a second textile, a region comprising a film, a region
comprising a shaped component, or combinations thereof.
[0088] In certain aspects, a thermoformed textile is provided
according to the present disclosure. As used herein, a thermoformed
textile is understood to be a textile comprising the first
polymeric composition that has been thermoformed to have a
different shape or texture or both. The thermoforming can be
conducted on a substantially flat surface such as a plate, or in a
shaped mold, or on a shaped article such as a last. For example,
the thermoformed textile is a textile in which at least a portion
of the first polymeric composition present in the textile has been
thermoformed (i.e., softened, molded and re-solidified, or melted,
molded and re-solidified, such that at least a portion of the first
network of yarns of the textile becomes a thermoformed network of
yarns in which the first polymeric composition of the coated yarn
consolidates the thermoformed network of yarns by surrounding at
least a portion of the first core yarn and occupying at least a
portion of spaces between yarns). Once thermoformed, the first
polymeric composition of a thermoformed textile has a different
physical shape than before it was thermoformed and retains this
second shape until the first polymeric composition is thermoformed
again. In one example, the thermoforming process re-flows the first
polymeric composition from a first state as a first film to a
second state in which the first polymeric composition penetrates
into or between portions of the textile which had surrounded the
first film. For example, during the thermoforming process, the
molten first polymeric composition may penetrate between or into
second fibers, filaments or yarns of the textile, and may, when
re-solidified, act as a consolidating resin for the second fibers,
filaments or yarns. In another example, the thermoforming process
re-flows the plurality of fibers, filament, plurality of filaments,
yarn, plurality of yarns, or any combination thereof, into a second
state, in which the first polymeric composition no longer has a
fibrous, filamentous, or yarn-like configuration.
[0089] The thermoformed textile comprising the first polymeric
composition can be a thermoformed textile wherein at least a
portion of the film, plurality of fibers, filament, plurality of
filaments, yarn, yarns, or any combination thereof have been at
least partially melted and re-solidified into a new conformation
which is different than their original (i.e., pre-thermoforming)
conformation. The thermoformed textile can comprise a partially
re-flowed structure in which only a portion of the first polymeric
composition present in the textile has been re-flowed, or an
essentially completely re-flowed structure in which substantially
all of the first polymeric composition present in the textile has
been re-flowed. The thermoformed textile can also include a second
plurality of fibers including a second polymeric composition, such
as a second polymeric composition comprising a second thermoplastic
elastomer. In an aspect, zones or regions of the textile can be
thermoformed into continuous, film-like layers, or thermoformed and
molded to adopt desired surface topographies.
[0090] The textile or thermoformed textile as described herein can
be a component of an article of footwear. The textile or
thermoformed textile can be used to provide or enhance properties
of the article such as, for example, abrasion resistance, traction,
grip, or a combination of these properties to at least a portion of
the article of footwear. The textiles described herein can define
an externally-facing surface of the article of footwear. In one
aspect, the textile or thermoformed textile is a component of an
upper for an article of footwear. In one aspect, disclosed herein
is an upper for an article of footwear comprising a textile,
wherein the textile comprises a first network of yarns including a
first coated yarn, where the first coated yarn comprises a first
core yarn and a first coating including a first polymeric
composition disposed on at least a portion of an outer surface of
the first core yarn, wherein the first polymeric composition is a
thermoplastic elastomeric composition. In an aspect, the textile
defines at least a portion of a surface of the upper configured to
be externally facing when the upper is part of a finished article
of footwear.
[0091] In another aspect, the textile or thermoformed textile is an
outsole for an article of footwear or is a component of an article
of footwear. In another aspect, the textile or thermoformed textile
is a rand or zone bridging a region between a footwear upper and
the sole structure. In yet another aspect, the textile or
thermoformed textile is a combination upper and outsole for an
article of footwear, wherein the upper includes an integrated
outsole area. Optionally, the upper and the integrated outsole area
are at least partially formed from a textile. The outsole, or the
outsole area of the combination upper and outsole can be configured
to include a ground-facing surface, or a ground-contacting surface,
or both, and at least a portion of the textile described herein
defines at least a portion of the ground-facing surface, or the
ground-contacting surface, or both. For example, the outsole or
outsole area can be configured to include a ground-facing surface
but not a ground-contacting surface, and at least a portion of the
textile defines at least a portion of the ground-facing surface. In
another example, the outsole or outsole area can be configured to
include a ground-facing surface but not a ground-contacting
surface, and at least a portion of the textile defines at least a
portion of the ground-facing surface, and wherein the at least a
portion of the textile defines the at least a portion of the
ground-facing surface is textured, or includes at least one
traction element, or both. Optionally, the at least one traction
element can a thermoformed traction element formed from the
textile.
[0092] The textile or thermoformed textile as described herein can
be a component of an article of apparel. The textile can define an
externally-facing surface of the article of apparel. The textile or
thermoformed textile can be used to provide abrasion resistance or
traction or both to at least a portion of the article of apparel,
such as, for example on an elbow area, a knee area, or both. The
textile or thermoformed textile can be used to provide protection
to electronic components embedded in or attached to the article of
apparel. The textile or thermoformed textile can be used to provide
protection to a wearer from hard or sharp components embedded in or
attached to the article of apparel.
[0093] The textile or thermoformed textile as described herein can
be a component of an article of sporting equipment. The textile can
define an externally-facing surface of the article of sporting
equipment. The textile or thermoformed textile can be used to
provide abrasion resistance or traction or both to at least a
portion of the article of sporting equipment, such as a portion of
the article of sporting equipment which contacts the ground or had
surfaces during use. The textile or thermoformed textile can be
used to provide protection to electronic components embedded in or
attached to the article of sporting equipment.
[0094] In certain aspects, the present disclosure is also directed
to articles comprising a thermoformed film component that has been
thermoformed from a first state as a film into a second state as a
softened or melted and re-solidified film (i.e., a film comprising
a first polymeric composition, wherein at least a portion of the
film has been softened or melted and re-solidified into a new
conformation which is different than its original film conformation
prior to thermoforming). The thermoforming can be conducted on a
substantially flat surface such as a plate, or in a shaped mold, or
on a shaped article such as a last.
[0095] The thermoformed film component as described herein can be a
component of an article of footwear. The thermoformed film
component can be used to provide abrasion resistance or traction or
both to at least a portion of the article of footwear. The first
polymeric composition can define an externally-facing surface of
the article of footwear. In one aspect, the thermoformed film
component is a component of an upper for an article of footwear. In
another aspect, disclosed herein is an upper for an article of
footwear comprising a textile comprising a thermoformed network of
yarns comprising a first core yarn and a first polymeric
composition, wherein the first polymeric composition consolidates
the thermoformed network of yarns by surrounding at least a portion
of the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition. In an aspect the textile can define at least a portion
of a surface on the upper configure to be externally-facing when
the upper is part of a finished article of footwear. In another
aspect, the first polymeric composition can define at least a
portion of the surface of the upper configured to be
externally-facing when the upper is part of a finished article of
footwear, or defines at least a portion of a surface of the upper
configured to be internally-facing when the upper is part of a
finished article of footwear, or forms at least a portion of an
interior layer of the upper when the upper is part of a finished
article of footwear, or any combination thereof.
[0096] In another aspect, the thermoformed film component is an
outsole for an article of footwear or is a component of an article
of footwear. In yet another aspect, the thermoformed film component
is a combination upper and outsole for an article of footwear,
wherein the upper includes an outsole area. The outsole, or the
outsole area of the combination upper and outsole can be configured
to include a ground-facing surface, or a ground-contacting surface,
or both, and at least a portion of the first polymeric composition
defines at least a portion of the ground-facing surface, or the
ground-contacting surface, or both. For example, the outsole or
outsole area can be configured to include a ground-facing surface
but not a ground-contacting surface, and at least a portion of the
first polymeric composition defines at least a portion of the
ground-facing surface. In another example, the outsole or outsole
area can be configured to include a ground-facing surface but not a
ground-contacting surface, and at least a portion of the first
polymeric composition defines at least a portion of the
ground-facing surface, and wherein the at least a portion of the
first polymeric composition defines the at least a portion of the
ground-facing surface is textured, or includes at least one
traction element, or both. Optionally, the at least one traction
element can a thermoformed traction element formed from the
textile.
[0097] The thermoformed film component as described herein can be a
component of an article of apparel. The first polymeric composition
can define an externally-facing surface of the article of apparel.
The thermoformed film component can be used to provide abrasion
resistance or traction or both to at least a portion of the article
of apparel, such as, for example on an elbow area, a knee area, or
both. The thermoformed film component can be used to provide
protection to electronic components embedded in or attached to the
article of apparel. The thermoformed film component can be used to
provide protection to a wearer from hard or sharp components
embedded in or attached to the article of apparel.
[0098] The thermoformed film component as described herein can be a
component of an article of sporting equipment. The first polymeric
composition can define an externally-facing surface of the article
of sporting equipment. The thermoformed film component can be used
to provide abrasion resistance or traction or both to at least a
portion of the article of sporting equipment, such as a portion of
the article of sporting equipment which contacts the ground or had
surfaces during use. The thermoformed film component can be used to
provide protection to electronic components embedded in or attached
to the article of sporting equipment.
[0099] The present disclosure is also directed to articles
comprising: a textile comprising a thermoformed network of yarns
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition; and a second element selected from a second shaped
component, a second film, a second fiber, a second filament, a
second yarn, or a second textile. The article can be a textile or
thermoformed textile as described herein, wherein the article
includes the re-flowed and re-solidified product of the first
polymeric composition, and the second element selected from the
second shaped component, second film, second fiber, second
filament, second yarn, or second textile. The article can be a
thermoformed film component as described herein, wherein the
article includes the re-flowed and re-solidified product of the
first polymeric composition, and the second element selected from
the second shaped component, second film, second fiber, second
filament, second yarn, or second textile.
[0100] In some aspects, the article is an article of footwear,
which includes, but is not limited to, such articles as shoes.
"Article of footwear" is used to refer to an article intended for
wear on a human foot, e.g., in some aspects, an article of footwear
can be a shoe, such as an athletic shoe. Articles of footwear
generally include an upper and a sole structure. The upper provides
a covering for the foot that comfortably receives and securely
positions the foot with respect to the sole structure. Moreover,
the upper generally provides protection for the foot and may
provide other attributes such as weather resistance, water
resistance, contact or interaction with athletic equipment, or the
like. The sole structure can provide various kinds of support,
cushioning and shock absorption. The sole structure is secured to a
lower portion of the upper and is generally positioned between the
foot and the ground. In addition to attenuating ground reaction
forces (that is, providing cushioning) during walking, running, and
other ambulatory activities, the sole structure can influence foot
motions (for example, by resisting pronation), impart stability,
and provide traction, for example. Accordingly, the upper and the
sole structure operate cooperatively to provide a comfortable
structure that is suited for a wide variety of activities.
[0101] An exemplary article of footwear is athletic or sports
footwear, including, but not limited to, running shoes, basketball
shoes, soccer shoes, baseball shoes, football shoes, tennis shoes,
rugby shoes, cross-training shoes, walking shoes, hiking boots,
golf shoes, sneakers, and the like. Alternatively, the article of
footwear can be non-athletic footwear, including, but not limited
to, dress shoes, loafers, casual wear shoes, sandals, and boots,
including work boots. A shoe can or cannot enclose the entire foot
of a wearer. For example, a shoe could be a sandal or other article
that exposes large portions of a wearing foot. The person of
ordinary skill in the art can appreciate, therefore, that the
materials and processes disclosed herein apply to a wide variety of
footwear types or styles, in addition to the specific type or style
discussed in the following material and depicted in the
accompanying figures.
[0102] An upper forms a structure that that provides a covering for
some or all of a wearer's foot and positions that foot relative to
a sole structure of that shoe. The upper forms a void on the
interior of the footwear for receiving the foot. The void has the
general shape of the foot, and access to the void can be provided
at an ankle opening. In certain aspects, the upper extends over the
instep and toe areas of the foot, along medial and lateral sides of
the foot, and around the heel area of the foot. The upper can have
any design, shape, size and/or color. For example, in certain
aspects, e.g., if an article is a basketball shoe, then the upper
can be a high top upper that is shaped to provide high support on
an ankle. Alternatively, in certain aspects, e.g., if an article is
a running shoe, then the upper can be a low top upper. In
accordance with the present disclosure, the upper or upper
component can comprise a film, fiber, filament, yarn, textile,
thermoformed textile, or thermoformed film component as described
herein.
[0103] The upper can also incorporate a closure system such as a
lacing system to permit entry and removal of the foot from the void
within the upper. Additionally or alternatively, the upper can also
incorporate an adjustment system to adjust fit of the footwear
and/or provide lock-down between the upper and the sole structure.
A closure and/or adjustment system such as a lacing system often is
incorporated into the upper to selectively change the size of the
ankle opening and to permit the wearer to modify certain dimensions
of the upper, particularly girth, to accommodate feet with varying
proportions. In addition, the upper can include a tongue that
extends under the lacing system to enhance the comfort of the
footwear (e.g., to modulate pressure applied to the foot by the
laces). The tongue can be attached at the base of the lacing
structure; can be attached at the base of the lacing structure and
on the medial side of the lacing structure, or on the lateral side
of the lacing structure, or on both sides; or can be integrally
formed with the upper. The upper can include a heel counter to
limit or control movement of the heel. The upper can include a toe
cap to provide abrasion resistance or protection or both to the toe
box portion of the upper. Abrasion resistance, traction, or both
can be provided in specific regions of the upper including on
portions of the medial side, the lateral side, the instep region,
or any combination thereof. For example, use of materials which
provide increased levels of traction are useful on athletic
footwear which may come into contact with a ball during use.
Optionally, the upper can include a heel counter; a toe cap; an
abrasion resistant region on the medial side, the lateral side, or
the instep; a region of increased traction on the medial side, the
lateral side, or the instep; or any combination thereof.
[0104] In one aspect, a textile, including a thermoformed textile,
as described herein defines at least a portion of an outer surface
of the upper. In another aspect, the textile as described herein
defines at least a portion of the surface of the upper configured
to be externally-facing when the upper is part of a finished
article of footwear, or defines at least a portion of a surface of
the upper configured to be internally-facing when the upper is part
of a finished article of footwear, or forms at least a portion of
an interior layer of the upper when the upper is part of a finished
article of footwear, or any combination thereof.
[0105] In one aspect, the textiles, including the thermoformed
textiles described herein can cover from about 15 percent to about
100 percent of the outward-facing surface area of an upper. In one
aspect, the textile covers from about 15 percent to about 35
percent of the surface area of the external face of the upper. In
another aspect, the textile covers from about 40 percent to about
70 percent of the surface area of the external face of the upper.
In another aspect, the textile covers from about 75 percent to
about 100 percent of the surface area of the external face of the
upper.
[0106] In another aspect, the textiles, including the thermoformed
textiles, can be present on a lateral side of the upper, a medial
side of the upper, a heel region of the upper, a toe region of the
upper, or any combination thereof. In some aspects, when the
textiles form part or all of an upper for an article of footwear,
the textiles can be present in a first layer and a second layer. In
one aspect, the first layer can be an outward facing layer and the
second layer can be a base layer or internal layer that is not seen
when the article of footwear is being worn. In another aspect, the
first layer and second layer can independently comprise a knitted
textile, a crocheted textile, a braided textile, a woven textile, a
non-woven textile, or some combination thereof. In one aspect, when
two layers of the textiles are present, the top layer can be useful
for boot-to-ball control, abrasion resistance, and stretch
resistance and the bottom layer can be useful for providing water
resistance, stretch resistance, and durability to the article of
footwear. In some aspects, a core layer can be present between the
top layer and the base layer. In an alternative aspect, the textile
can be present as a single layer comprising an outward-facing side,
an inward-facing side, and a core, wherein the outward-facing side
comprises the coated yarns which can be useful for boot-to-ball
control, abrasion resistance, and stretch resistance, and the
inward-facing side comprises the coated yarns which can be useful
for water resistance, stretch resistance, and durability, among
other properties.
[0107] In some aspects, a sole structure can include one or more
components or layers, which can individually or collectively
provide an article of footwear with a number of attributes, such as
support, rigidity, flexibility, stability, cushioning, comfort,
reduced weight, or other attributes. In some aspects, a sole
structure can comprise layers referred to as an insole, a midsole,
and an outsole. In some aspects, however, one or more of these
components can be omitted. In certain aspects, a sole structure can
optionally comprise a sole plate. In some aspects, the sole
structure comprises at an outsole component that includes an
exterior major surface, which can be exposed and ground-contacting,
and an interior major surface. In a further aspect, the sole
structure can further comprise a midsole component that can be
attached to the upper along the entire length of the upper. When
present, the midsole forms the middle layer of the sole structure
and serves a variety of purposes that include controlling foot
motions and attenuating impact forces.
[0108] The outsole includes the ground-contacting portions of the
article of footwear. Conventionally, durable, wear-resistant
materials are used for outsoles. In accordance with the present
disclosure, the outsole or outsole component can comprise a film,
fiber, filament, yarn, textile, thermoformed textile, or
thermoformed film component as described herein. Outsoles commonly
include texturing or other features such as traction elements to
improve traction. The outsole can optionally further comprise one
or more integrally formed or removable cleats.
[0109] In one aspect, the textile defines at least a portion of an
externally-facing surface of the outsole, optionally wherein the
externally-facing surface is configured to be ground-facing or
ground-contacting when the outsole is part of a finished article of
footwear. In another aspect, the textile defines at least a portion
of the medial side or lateral side of the outsole.
[0110] A combination upper and outsole for an article of footwear
is an integrated component which serves both as the upper of the
article of footwear and as the outsole of the article of footwear.
In contrast to conventional footwear formed by first forming a
separate upper and a separate outsole, and then attaching the upper
and the outsole to each other. In contrast, in a combination upper
and outsole, at least a portion of the upper area and the outsole
area of the unit are formed at the same time, for example, by
thermoforming one or more components on a last. Thus, the
combination upper and outsole unit comprises a single textile,
thermoformed textile, or thermoformed film component which forms
both at least a portion of the externally-facing surface of the
upper and at least a portion of the ground-facing or
ground-contacting surface of the outsole.
Exemplary Aspects of Articles of Sporting Equipment, Articles of
Wear and Textiles
[0111] As discussed above, certain aspects are directed to one or
more textiles, thermoformed textiles, or thermoformed film
components that include the films, fibers, filaments or yarns as
described herein. In certain aspects, such textiles, thermoformed
textiles, or thermoformed film components can form at least a
portion of an article of sporting equipment or article of wear,
including articles of apparel and articles of footwear. In certain
aspects, the disclosed textiles, thermoformed textiles, or
thermoformed film components can form at least a portion of a
component of an article of footwear. In certain aspects, the
disclosed textiles, thermoformed textiles, or thermoformed film
components can form at least a portion of a component of an article
of sporting equipment.
[0112] Turning now to the figures, in particular, FIGS. 1A and 1B,
an article of footwear 100 is depicted as one exemplary article of
wear. While FIGS. 1A and 1B depict an article of footwear 100, it
should be understood that other articles of wear are also
contemplated by the present disclosure. The article of footwear 100
of FIGS. 1A and 1B generally can include a ground-facing outsole
area 110, an ankle collar area 112, a lateral midfoot area 114a,
and a medial midfoot area 114b, a toe box area 116, and a heel area
118. Further, the article of footwear 100 can include a plurality
of eyestays 120, a vamp area 122, a tongue area 124, and a throat
area 126. As shown in FIGS. 1A and 1B, article of footwear 100, is
intended to be used with a right foot; however, it should be
understood that the following discussion can equally apply to a
mirror image of article of footwear 100 that is intended for use
with a left foot.
[0113] The article of footwear 100 depicted in FIGS. 1A and 1B can
include at least one textile 102 that at least partly forms a
portion of the article of footwear 100. Optionally, the textile 102
of the article of footwear 100 can include at least two, or
optionally at least three separate textile zones, e.g., zones 104,
106, and 108, identifying specific functional areas of the article
of footwear 100. In certain aspects, these specific functional
areas are at least partly associated with the targeted
incorporation of specific textile media in varying amounts,
techniques, and combinations into these textile zones (illustrated
as zones 104, 106, and 108 in FIGS. 1A and 1B). It should be
understood that, while the textile 102 includes three specific
functional areas, more than three functional areas are also
contemplated.
[0114] In certain aspects, the textile zone 104 can exhibit a rigid
or semi-rigid functionality suitable for use as a ground-facing
outsole 110 for the article of footwear 100. Accordingly, in
certain aspects, the textile zone 104 can be positioned to include
at least a portion of a ground-facing outsole 110 of the article of
footwear 100. In certain aspects, the targeted incorporation of the
films, fibers, filaments or yarns described herein into the textile
zone 104 of the textile 102, upon thermoforming, can at least
partly provide the abrasion-resistant and/or traction functionality
for use as a ground-facing outsole 110.
[0115] Further, in aspects, another textile zone, such as, for
example, textile zone 108, can exhibit flexibility and/or
pliability to accommodate movements from a wearer. In certain
aspects, the textile zone 108 can include the ankle collar area
112, the tongue area 124, and/or the throat area 126 of the article
of footwear 100.
[0116] In certain aspects, another textile, such as, for example,
zone 106, can be positioned between the textile zones 104 and 108.
In certain aspects, the textile zone 106 can include at least a
portion of the lateral midfoot region 114a and/or the medial
midfoot region 114b on the article of footwear 100. In certain
aspects, the textile zone 106 can include a combination of a first
film, fiber, filament or yarn described herein from the textile
zone 104 with a second film, fiber, filament or yarn, such as, for
example, the second film, fiber, filament or yarn from the textile
zone 108, where the second film, fiber, filament or yarn has
different properties (e.g., melting temperature, deformation
temperature, etc.) compared to the first film, fiber, filament or
yarn. In such aspects, this combination of textile media present in
the textile zone 106 allows the textile zone 106 to function as a
flexible, pliable portion of the upper and as an abrasion-resistant
or high traction zone, and optionally as a transition between the
outsole functionality of the textile zone 104 and the flexible
pliable functionality of the textile zone 108, allowing for a more
gradual transition from the outsole portion to flexibility of the
textile 102. In one example, only textile zone 104 comprises the
first polymeric composition of the disclosure. In another example,
only textile zone 106 comprises the first polymeric composition of
the present disclosure. In another example, both textile zones 104
and 106 comprise the first polymeric composition, wherein a
concentration of the first polymeric composition in textile zone
104 is greater (e.g., at least 10 weight percent greater, at least
20 weight percent greater, or at least 30 weight percent greater)
than in textile zone 106. In yet another example, textile zone 108
is substantially free of the first polymeric composition of the
disclosure.
[0117] Further, in such aspects, the textile zone 106 can exhibit
rigidity or semi-rigidity to a lesser extent than the textile zone
104, but to a greater extent than the textile zone 108. Also, in
the same or alternative aspects, the textile zone 106 can exhibit
flexibility to a lesser extent than the textile zone 108, but to a
greater extent than the textile zone 104.
[0118] Alternatively or additionally, the three textile zones 104,
106 and 108 can be at least partly located within a midfoot region,
such as lateral midfoot region 114a and/or medial midfoot region
114b.
[0119] While any or all of textile zones 104, 106 and 108 can be
formed of separate textiles operably connected to each other, a
single textile having two or more integrally formed textile zones
can be used. In one particular example, a single upper and outsole
unit comprises two or more separately formed or integral textile
zones.
[0120] In certain aspects in the textile zone 106, the combination
of the first film, fiber, filament or yarn described herein is
present in the textile zone 104 and a second film, fiber, filament
or yarn described herein is present in the textile zone 108. When
this textile is exposed to the thermoforming process, the process
can impart one or more structural properties to these zones making
them appropriate for use in the article of footwear 100, such as
abrasion resistance, improved traction, semi-rigid support, or any
combination thereof, in the lateral and/or medial midfoot regions
114a and 114b, and/or three-dimensional shape or structure suitable
for one or more portions of the article of footwear 100.
[0121] In certain aspects, as can be seen in FIG. 1A, the textile
zone 106 extends away from the textile zone 104 towards the
eyestays 120. In such aspects, the combination of textile media
comprising the first film, fiber, filament or yarn described herein
and textile media comprising the second film, fiber, filament or
yarn can allow for the transferring of a force transmitted from the
eyestays 120 or other lacing mechanisms into this combination of
textile media present in the lateral and/or medial midfoot regions
114a and 114b. In certain aspects, for the successful transfer of
the forces transmitted from the eyestays 120, the textile zone 104,
and/or the first film, fiber, filament or yarn described herein
present in the textile zone 104, can terminate to an area 128 that
is a distance of at least about 0.5 cm, about 1.0 cm, or about 2.0
cm from the eyestays 120, and/or at least about 3, at least about
4, or at least about 5 needle lengths below the eyestays 120, when
the textile 102 is a knit textile formed on a commercial knitting
machine. In such aspects, the flexible and pliable characteristics
of the second film, fiber, filament or yarn that are present in the
zone 108 that is adjacent the eyestays 120 can facilitate in
transferring forces transmitted from the eyestays 120 to the
textile zone 106 and/or the first films, fibers, filaments or yarns
described herein present in the lateral and/or medial midfoot
regions 114a and 114b.
[0122] In the aspect depicted in FIGS. 1A and 1B, the textile zone
106 is positioned in the toe box area 116 and the heel area 118. In
such aspects, the combination of the first film, fiber, filament or
yarn described herein and the second film, fiber, filament or yarn
can provide structure and/or support due to the rigidity provided
by the thermoformed material. Further, the thermoformed material
can provide abrasion resistance or increased traction in the toe
box area 116 and/or the heel area 118. In alternative aspects, the
textile zone 104 can form at least a portion of the toe box area
116 and/or the heel area 118 for increased rigidity or increased
abrasion resistance or traction, since the textile zone 104
includes a greater amount, or alternative positioning (e.g., outer
knit surface), of the first film, fiber, filament or yarn described
herein than the textile zone 106.
[0123] FIG. 1C depicts an alternative aspect of an article of
footwear 100a. In such aspects, the article of footwear 100a can
generally include at least three types of textile zones: the
textile zone 104a, the textile zone 106a, and the textile zone
108a. In certain aspects, the textile zones 104a, 106a, and 108a
can have the same properties and parameters as the textile zones
104, 106, and 108, respectively, of the article of footwear 100
discussed above with reference to FIG. 1A.
[0124] In the aspect depicted in FIG. 1C, portions, e.g., portions
104b and 104c, of the textile zone 104a can extend from an outsole
area up through a midfoot area 115A and toward a plurality of
eyestays 120a. In such aspects, a rigid or semi-rigid functionality
provided by the portions 104b and 104c extending from an outsole
area through the midfoot area 115A to a plurality of eyestays 120a
can provide increased wearer stability in the midfoot area 115A.
Further, in aspects, a force applied through one or more of the
plurality of eyestays 120a can at least partly be transferred onto
the rigid or semi-rigid portions 104b and 104c extending through
the midfoot area 115A, and into the rigid or semi-rigid textile
zone 104a present in an outsole area, providing increased support
and comfort for a wearer.
[0125] In certain aspects, in addition to the thermoformed material
providing abrasion resistance or traction or both to one or more
areas of the article, the thermoformed material can provide
structure, rigidity, strength, support, a water-proof or
water-resistant surface, or any combination thereof.
[0126] FIGS. 2A and 2B depict a shirt 200 as an exemplary article
of apparel. The shirt 200 depicted in FIGS. 2A and 2B includes at
least one textile, thermoformed textile, or thermoformed film
component 202 that at least partly forms a portion of the shirt
200. As best seen in FIG. 2B, the textile, thermoformed textile, or
thermoformed film component 202 can be a textile or thermoformed
textile which includes three separate textile zones 204, 206a-d,
and 208, which can identify specific functional areas of the 200.
In certain aspects, these specific functional areas are at least
partly associated with the targeted incorporation of specific
textile media in varying amounts and combinations into these
textile zones 204, 206a-d, and 208.
[0127] In certain aspects, the textile zone 204 can include a
reinforced area such as an exterior-facing film or patch 210, which
can, for example, provide abrasion resistance to an elbow region
212 of the shirt 200. In such aspects, the targeted integral
incorporation of the films, fibers, filaments or yarns described
herein into the textile zone 204 can at least partly form the patch
210, when the textile 202 is thermoformed, by melting or deforming
the films, fibers, filaments or yarns as described herein and
subsequent cooling and solidifying of the melted first polymeric
composition to form a patch 210.
[0128] In various aspects, the textile zone 208 can exhibit
flexibility and/or pliability similar to a conventional shirt
material. Further, in certain aspects, the textile zone 206 can at
least partly provide a transition within the textile 202 from the
more rigid or semi-rigid patch 210 present in textile zone 204 to
the more flexible pliable portion present in the textile zone 208.
In such aspects, the textile zones 206a-d can include a combination
of the first film, fiber, filament or yarn described herein present
in the textile zone 204 and the second film, fiber, filament or
yarn present in the textile zone 208. While not shown in FIGS. 2A
and 2B, the textile zones 206b-d also provide a transition to a
flexible pliable material, such as that present in the textile zone
208.
[0129] In certain aspects, like with the textile zone 106 of the
textile 102 discussed above with reference to FIGS. 1A and 1B, this
combination of the first film, fiber, filament or yarn described
herein from textile zone 204 and the second film, fiber, filament
or yarn present from textile zone 208 can provide a seamless or
integrated transition from the patch 210 to the flexible pliable
portion found in textile zone 208 of the shirt 200.
[0130] While this exemplary description in FIGS. 2A and 2B of the
textile zones 204, 206a-d, and 208 relates to an elbow region of
the article of apparel 200, it should be understood that the
textile zones 204, 206a-d, and 208 and associated properties can be
applied to other areas of a shirt or other articles of apparel,
such as a knee, thigh, hip, chest, and/or lower back region of an
article of apparel, or to areas requiring reinforcement such as
areas adjacent to a fastener, for example, a zipper, a button, a
snap, a pull cord, and the like.
[0131] Turning now to FIG. 3, a plan view of a schematic textile
300 is provided. It should be understood that the textile 300 can
be any type of textile known to one skilled in the art. A
non-limiting list of textiles that are suitable for use in the
articles of wear and methods disclosed herein includes knit
textiles, woven textiles, non-woven textiles, crocheted textiles,
and braided textiles.
[0132] Similar to the textile 102 of FIGS. 1A and 1B, and the
textile 202 of FIGS. 2A and 2B, the textile 300 of FIG. 3 includes
three types of textile zones. For example, the textile 300 includes
a textile zone 302 that can include the first film, fiber, filament
or yarn described herein, textile zones 306a and 306b that can
include the second film, fiber, filament or yarn, and textile zones
304a and 304b that can include a combination of films, fibers, or
yarns compose of different thermoplastic elastomers. In textile 300
of FIG. 3, the textile zones 304a and 304b can be positioned on
either side of textile zone 302, while textile zones 306a and 306b
can be positioned on the opposite sides of the textile zones 304
and 304b, respectively.
[0133] In certain aspects, the films, fibers, filaments, yarns, and
textiles described herein, when exposed to a thermoforming process,
can impart a structural or functional property to an article of
wear or sporting equipment. Further, the combination of first
films, fibers, filaments, yarns described herein and second films,
fibers, filaments, or yarns can provide structural support and
three-dimensional structure for a particular article of wear or
sporting equipment. Further, in certain aspects, this combination
of films, fibers, filaments, yarns, and textiles can provide an
integrated transition between a rigid thermoformed material and
flexible pliable fibers.
[0134] In certain aspects, based on the relative positioning of the
first films, fibers, filaments, yarns, and textiles described
herein and the second films, fibers, filaments, or yarns in the in
different zones of the textiles, thermoformed textiles and
thermoformed film component, the zones can have varying
concentration of the first and second films, fibers, filaments or
yarns, and thus can have varying concentrations of the first
polymeric composition and the second polymeric composition in these
zones.
[0135] As used herein, the term "concentration" refers to a
clustering or congregation in a specific volume. Thus, the term
concentration includes measuring the amount (e.g., the weight in
grams) of a material in a specified volume (e.g., cubic
centimeter). For example, in a knit textile, a first portion of a
single knit layer of a textile can have an increased concentration
of a first yarn compared to a second portion of the textile by
having more stitches (e.g., knit stitches, tuck stitches, and/or
float stitches) of that first yarn than the second portion of equal
size. In another example, a first portion of a textile can include
a greater concentration of an inlaid film, fiber, filament or yarn
than a second portion. In another example, in a non-woven textile,
a first portion of the textile can have an increased concentration
of a first fiber if that textile was formed with more of the first
fiber (e.g., a weight in grams) than a second portion of equal
size.
[0136] In aspects, a textile, thermoformed textile, or thermoformed
film component can include a first zone and a second zone, wherein
the first zone comprises at least 5 weight percent, or at least 10
weight percent, or at least 20 weight percent, or at least 30
weight percent more of the first polymeric composition than the
second zone.
[0137] FIGS. 4A-4J depict exemplary potential knitting structures
that can be present in a knit textile or knit thermoformed textile
as disclosed herein. FIG. 4A depicts a knit stitch (or sometimes
referred to as a Jersey stitch) structure 502 formed from a back
needle bed 504. It should be understood that the row of small
circles associated with the back needle bed 504, represents needles
(e.g., a needle 505) of the back needle bed 504, in accordance with
traditional stitch schematics. Further, the same is true for a
front needle bed, e.g., the front needle bed 508 depicted in FIG.
4B; that is, that the row of small circles associated with the
front needle bed 508 represent needles (e.g., a needle 507) in the
front needle bed 508.
[0138] FIG. 4B depicts a knit stitch structure 506 formed from a
front needle bed 508. FIG. 4C depicts a float and tuck stitch
structure 510, with tuck stitches that are formed by a front needle
bed 512 and a back needle bed 514. FIG. 4D depicts another float
and tuck stitch structure 516, with tuck stitches formed by a front
needle bed 518 and a back needle bed 520. FIG. 4E depicts a float
stitch structure 522. FIG. 4F depicts a knit and tuck stitch
structure 524 having knit stitches 524a formed by a back needle bed
528 and tuck stitches 524b formed by a front needle bed 526. FIG.
4G depicts a knit and float stitch structure 530, with the knit
stitches formed on a front needle bed 532. FIG. 4H depicts a knit
and float stitch structure 534, with the knit stitches formed a
back needle bed 536. FIG. 4I depicts a tuck and float knit
structure 538, with the tuck stitches formed by a front needle bed
540. FIG. 4J depicts a tuck and float knit structure 542, with the
tuck stitches formed by a back needle bed 544.
[0139] In certain aspects, it can be desirable to bulk up the film,
fiber, filament or yarn described herein in a particular region or
zone, in order to provide a desired thickness and rigidity to the
article when thermoformed, e.g., to form a ground-facing outsole of
an article of footwear. In such aspects, when using a knit textile,
the region or zone can include repeat stitches or inlaid films,
fibers, filaments or yarns to increase the concentration of the
first polymeric composition described herein relative to other
zones.
[0140] In certain aspects, in regions of the textile 300 that
include a substantial amount of the first polymeric composition
described herein, e.g., the textile zone 302, an anchor yarn can be
provided in the textile 300 to help restrict the flow of the melted
first polymeric composition described herein and/or to provide some
flexibility to the zone once thermoformed. For example, the anchor
yarn can be present in the textile 300 as many different types of
knit structure, such as one or more of structures depicted in FIGS.
4E and 4G-J. In certain aspects, the stitch selection for the
anchor yarn can depend upon the desired resistance to elongation of
the material through which the anchor yarn extends. For example, an
anchor yarn stitch which floats five needles between tuck or knit
stitches would provide a greater resistance to stretch to the
material through which the anchor yarn extends compared to an
anchor yarn stitch which only floats 2 or 3 needles between tuck or
knit stitches. In such an example, the differing resistance to
elongation between the length of the float is a result of
non-linear portions (e.g., stitch loops) that are more prone to
elongation than linear segments, which results in different amounts
of resistance to elongation.
[0141] In such aspects, the anchor yarn can exhibit an elongation
that is less than the elongation of the low processing temperature
polymeric composition, such as a yarn comprising the low processing
temperature polymeric composition or a melted yarn component
produced by thermoforming such a yarn. For example, in aspects, the
anchor yarn can exhibit an elongation that is at least about 10%
less than the elongation of a yarn comprising the low processing
temperature polymeric composition or a melted yarn component
produced by thermoforming a yarn comprising the low processing
temperature polymeric composition. In one aspect, the anchor yarn
can exhibit an elongation that at least about 25% less than the
elongation of a yarn comprising the low processing temperature
polymeric composition or a melted yarn component produced by
thermoforming a yarn comprising the low processing temperature
polymeric composition. In another aspect, the anchor yarn can
exhibit an elongation that at least about 50% less than the
elongation of a yarn comprising the low processing temperature
polymeric composition or a melted yarn component produced by
thermoforming a yarn comprising the low processing temperature
polymeric composition. In yet another aspect, the anchor yarn can
exhibit an elongation that at least about 75% less than the
elongation of a yarn comprising the low processing temperature
polymeric composition or a melted yarn component produced by
thermoforming a yarn comprising the low processing temperature
polymeric composition. Exemplary anchor yarns include polyamide
yarns, polyolefin yarns, and polyester yarns, including yarns
having tenacities of from about 5 grams per denier to about 10
grams per denier.
[0142] As discussed above, the textiles described herein, which can
include fibers and/or yarns comprising the film, fiber, filament or
yarn described herein, can be thermoformed to impart some structure
of properties to the article of wear. Further, as discussed above,
the thermoforming process can cause at least a portion of the film,
fiber, filament or yarn described herein present in the textile to
melt or deform and subsequently solidify.
[0143] FIG. 5A schematically depicts a portion 700 of the textile
zone 304a of the upper knit layer of the textile 300 of FIG. 3
prior to a thermoforming process. The portion 700 includes a first
course 702 and a second course 704 having a first yarn 708. The
portion also includes a third course 706 of a second yarn 710 that
comprises the film, fiber, filament or yarn described herein. In
such an aspect, the third course 706 of loops of the second yarn
710 can be interconnected, e.g., interlooped, to the first course
702 and the second course 707 having the first yarn 708. As used
herein, "interlooped" refers to the how a loop from one course can
wrap around a loop of another course such as in a knit stitch, and
also refers to how one loop can have another segment of yarn pulled
through the loop (or through the loop and around the yarn forming
the loop) in order to form a second loop, as in a crochet
process.
[0144] FIG. 5B depicts the portion 700 after being exposed to a
thermoforming process. As can be seen by comparing FIGS. 5A and 5B,
the second yarn 710 that comprises the film, fiber, filament or
yarn described herein was thermoformed from a yarn material into a
melted yarn component 712. In certain aspects, the heating step of
the thermoforming process at least partly caused the film, fiber,
filament or yarn described herein in the second yarn 710 to melt
and flow and then subsequently solidify by the completion of the
thermoforming process into the melted yarn component 712.
[0145] In aspects, as can be seen in FIGS. 5A and 5B, the
thermoforming process has also transformed at least a portion of
the knit structure of the portion 700 of the upper knit layer of
the textile 300 of FIG. 3. For example, the courses 702, 704, and
706 depicted in FIG. 7A have been transformed such that the portion
700 no longer includes interconnected courses of loops of a yarn
comprising the film, fiber, filament or yarn described herein and a
second yarn, at least partly due to the transformation of the yarn
710 in the second course 706 to the melted yarn component 712. As
can be seen in FIG. 5B, although the thermoforming process can
eliminate the interconnected loops in the portion 700 of the upper
knit layer of the textile 300 of FIG. 3, the remaining course 702
and 704 can be connected by the melted yarn component 712. In such
aspects, this portion 700 of upper knit layer of the textile 300 of
FIG. 3 can fix the position of the courses 702 and 704 to one
another, as opposed to when the courses 702 and 704 were
interconnected via the course 706 prior thermoforming. Further, in
such aspects, a top portion 714 of the loops of the first course
702 can still be free to interconnect with other courses of yarn
allowing one to modulate the level of rigidity and/or
three-dimensional forming provided by the textile zone 304a.
[0146] FIG. 6 depicts a cross-section of the portion 700 of the
upper knit layer of the textile 300 of FIG. 3 along the cut line 8
illustrated in FIG. 5B. As can be seen in FIG. 6, at least portion
of the first yarn 708 can be encapsulated within the melted yarn
component 712. Depending on the conditions used during the
thermoforming process, the melted yarn component 712 can solidify
into a film-like structure surrounding at least a portion of the
loops of the first course 702 and the second course 704 of the
first yarn 708.
[0147] As can be seen in the aspect depicted in FIGS. 5B and 6, the
first yarn 708 did not melt or deform after being exposed to the
thermoforming process. Further, in certain aspects, the first yarn
708 can contain a dye 716 (depicted as the speckling within the
first yarn 708) that does not leach out after being exposed to the
thermoforming process. For example, as can be seen in FIGS. 5B and
6, there is no visible leaching of the dye 716 from the first yarn
708 into adjacent regions of the melted yarn component 712, e.g.,
the adjacent region 718. In certain aspects, at least about 80
weight percent, at least about 90 weight percent, at least about 95
weight percent, or at least 99 weight percent of the dye 716
remains within the first yarn 708 or within the thermoformed
portion 700 of the upper knit layer of the textile 300 of FIG. 3.
In the same or alternative aspects, upon thermoforming, there is no
visible leaching of the dye into any additional materials
associated with the final article of wear, which the portion 700 of
upper knit layer of the textile 300 of FIG. 3 textile 300 is
incorporated into.
[0148] FIG. 7A shows a cross-sectional view of a textile as
disclosed herein, prior to thermoforming, the textile having a
first side 800, a second side 802, and a core comprising coated
yarns as disclosed herein, the coated yarns further having a core
yarn 804 and a coating comprising a polymeric composition 806. FIG.
7B shows the same textile following thermoforming, where the core
yarn 804 is disposed within the re-flowed and re-solidified
polymeric composition 808 of the coated yarn.
[0149] FIG. 7C shows a cross-sectional view of a textile as
disclosed herein, prior to thermoforming, the textile having a
first side 800, a second side 802, and a core comprising coated
yarns as disclosed herein and an additional second yarn 810
disposed on at least one side of the textile, the coated yarns
further having a core yarn 804 and a coating comprising a polymeric
composition 806. FIG. 7D shows the same textile following
thermoforming, where the core yarn 804 is disposed within the
re-flowed and re-solidified polymeric composition 808 of the coated
yarn and the second yarn is disposed at the surface of the
re-flowed and re-solidified polymeric composition.
[0150] FIG. 7A shows a cross-sectional view of a textile as
disclosed herein, prior to thermoforming, the textile having a
first side 800, a second side 802, and a core comprising coated
yarns as disclosed herein an additional second yarn disposed on the
first side and the second side of the textile 810, the coated yarns
further having a core yarn 804 and a coating comprising a polymeric
composition 806. FIG. 7B shows the same textile following
thermoforming, where the core yarn 804 is disposed within the
re-flowed and re-solidified polymeric composition 808 of the coated
yarn and the second yarn is disposed at both surfaces of the
re-flowed and re-solidified polymeric corn position.
[0151] The article can be an article of manufacture or a component
of the article. The article of manufacture can include footwear,
apparel (e.g., shirts, jerseys, pants, shorts, gloves, glasses,
socks, hats, caps, jackets, undergarments), containers (e.g.,
backpacks, bags), and upholstery for furniture (e.g., chairs,
couches, car seats), bed coverings (e.g., sheets, blankets), table
coverings, towels, flags, tents, sails, and parachutes, or
components of any one of these. In addition, the textile or
articles including the textile can be used with or disposed items
such as striking devices (e.g., bats, rackets, sticks, mallets,
golf clubs, paddles, etc.), athletic equipment (e.g., golf bags,
baseball and football gloves, soccer ball restriction structures),
protective equipment (e.g., pads, helmets, guards, visors, masks,
goggles, etc.), locomotive equipment (e.g., bicycles, motorcycles,
skateboards, cars, trucks, boats, surfboards, skis, snowboards,
etc.), balls or pucks for use in various sports, fishing or hunting
equipment, furniture, electronic equipment, construction materials,
eyewear, timepieces, jewelry, and the like.
[0152] The article can be an article of footwear. The article of
footwear can be designed for a variety of uses, such as sporting,
athletic, military, work-related, recreational, or casual use.
Primarily, the article of footwear is intended for outdoor use on
unpaved surfaces (in part or in whole), such as on a ground surface
including one or more of grass, turf, gravel, sand, dirt, clay,
mud, pavement, and the like, whether as an athletic performance
surface or as a general outdoor surface. However, the article of
footwear may also be desirable for indoor applications, such as
indoor sports including dirt playing surfaces for example (e.g.,
indoor baseball fields with dirt infields).
[0153] In particular, the article of footwear can be designed for
use in indoor or outdoor sporting activities, such as global
football/soccer, golf, American football, rugby, baseball, running,
track and field, cycling (e.g., road cycling and mountain biking),
and the like. The article of footwear can optionally include
traction elements (e.g., lugs, cleats, studs, and spikes as well as
tread patterns) to provide traction on soft and slippery surfaces,
where components of the present disclosure can be used or applied
between or among the traction elements and optionally on the sides
of the traction elements but on the surface of the traction element
that contacts the ground or surface. Cleats, studs and spikes are
commonly included in footwear designed for use in sports such as
global football/soccer, golf, American football, rugby, baseball,
and the like, which are frequently played on unpaved surfaces. Lugs
and/or exaggerated tread patterns are commonly included in footwear
including boots design for use under rugged outdoor conditions,
such as trail running, hiking, and military use.
[0154] In particular, the article can be an article of apparel
(i.e., a garment). The article of apparel can be an article of
apparel designed for athletic or leisure activities. The article of
apparel can be an article of apparel designed to provide protection
from the elements (e.g., wind and/or rain), or from impacts.
[0155] In particular, the article can be an article of sporting
equipment. The article of sporting equipment can be designed for
use in indoor or outdoor sporting activities, such as global
football/soccer, golf, American football, rugby, baseball, running,
track and field, cycling (e.g., road cycling and mountain biking),
and the like.
[0156] FIGS. 8A-8Q illustrate various articles which can comprise a
textile of the present disclosure, including a thermoformed textile
of the present disclosure. As illustrated in FIGS. 8A-8Q, hashed
areas are positioned on various regions and structures of the
articles. These hashed areas are intended to illustrate general
regions and structures which can comprise a textile of the present
disclosure, and are not necessarily intended to be representative
of the size of the surface area of the region or surface defined by
a surface of the textile. In some aspects, the hashed areas
indicate a surface of a region or a surface of a structure which
can be defined by the thermoplastic network of a thermoformed
textile in accordance with the present disclosure. In one aspect,
the surface defined by the thermoplastic network can have a total
surface area of at least one square centimeter. In another aspect,
the surface defined by the thermoplastic network comprises a
polymeric composition of a coated yarn in re-flowed and
re-solidified form.
[0157] FIGS. 8A-8M illustrates footwear, apparel, athletic
equipment, container, electronic equipment, and vision wear that
include the textile of the present disclosure, including a
thermoformed textile of the present disclosure. The structure
including the textile is represented by hashed areas
12A'/12M'-12A''/12M'. The location of the structure is provided
only to indicate one possible area that the structure can be
located. Also, two locations are illustrated in some of the figures
and one location is illustrated in other figures, but this is done
only for illustration purposes as the items can include one or a
plurality of structure, where the size and location can be
determined based on the item.
[0158] FIGS. 8N(a)-8N(b) illustrate a perspective view and a side
view of an article of footwear 100 that include a sole structure
1004 and an upper 1002. The structure including the textile is
represented by 1022a and 1022b. The sole structure 1004 is secured
to the upper 1002 and extends between the foot and the ground when
the article of footwear 1000 is worn. The primary elements of the
sole structure 1004 are a midsole 1014 and an outsole 1012. The
midsole 1014 is secured to a lower area of the upper 1002 such as a
strobel (not shown) and may include a cushioning element comprising
a resilient material such as a polymer foam or another appropriate
material. In other configurations, the cushioning element of the
midsole 1014 can incorporate fluid-filled chambers, plates,
moderators, and/or other elements that further attenuate forces,
enhance stability, or influence motions of the foot. The outsole
1012 is secured to a lower surface of the midsole 1014 and may
comprise a wear-resistant elastomeric material such as a natural or
synthetic rubber material. The outsole can be textured to impart
traction, or can include one or more traction elements. The
traction elements can be separate elements affixed to the outsole,
or can be integrally formed with the outsole The upper 1002 can be
formed from various elements (e.g., lace stays, tongue, collar,
medial side, lateral side, vamp, toe box, heel counter) that
combine to provide a structure for securely and comfortably
receiving a foot. Although the configuration of the upper 1002 may
vary significantly, the various elements generally define a void
within the upper 1002 for receiving and securing the foot relative
to sole structure 1004. Surfaces of the void within upper 1002 are
shaped to accommodate the foot and can extend over the instep and
toe areas of the foot, along the medial and lateral sides of the
foot, under the foot, and around the heel area of the foot. The
upper 1002 can be made of one or more materials such as films,
textiles, cables, yarns, fibers, foams, natural leathers, synthetic
leathers, and the like that are knitted, stitched, bonded or
otherwise connected together. Although this configuration for the
sole structure 1004 and the upper 1002 provides an example of a
sole structure that may be used in connection with an upper, a
variety of other conventional or nonconventional configurations for
the sole structure 1004 and/or the upper 1002 can also be utilized.
Accordingly, the configuration and features of the sole structure
1004 and/or the upper 1002 can vary considerably.
[0159] FIGS. 8O(a) and 8O(b) illustrate a perspective view and a
side view of an article of footwear 1030 that include a sole
structure 1034 and an upper 1032. The structure including the
textile is represented by 1036a and 1036b/1036b'. The sole
structure 1034 is secured to the upper 1032 and extends between the
foot and the ground when the article of footwear 1030 is worn. The
upper 1032 can be formed from various elements (e.g., lace, tongue,
collar) that combine to provide a structure for securely and
comfortably receiving a foot. Although the configuration of the
upper 1032 may vary significantly, the various elements generally
define a void within the upper 1032 for receiving and securing the
foot relative to the sole structure 1034. Surfaces of the void
within the upper 1032 are shaped to accommodate the foot and can
extend over the instep and toe areas of the foot, along the medial
and lateral sides of the foot, under the foot, and around the heel
area of the foot. The upper 1032 can be made of one or more
materials such as textiles including natural and synthetic
leathers; molded polymeric components, polymer foam and the like
that are stitched or bonded together.
[0160] The primary sole components of the sole structure 1034 can
include a forefoot component 1042, a heel component 1044, and an
outsole 1046. Each of the forefoot component 1042 and the heel
component 1044 can be directly or indirectly secured to a lower
area of the upper 1032. In some aspects, the outsole 1046 may
include one or both of an integrally-formed heel component and
forefoot component (not shown). The sole component can comprise a
polymeric material that encloses a fluid, which may be a gas,
liquid, or gel. During walking and running, for example, the
forefoot component 1042 and the heel component 1044 may compress
between the foot and the ground, thereby attenuating ground
reaction forces. That is, the forefoot component 1042 and the heel
component 1044 may be inflated and/or may be pressurized with the
fluid to cushion the foot. In aspects where the outsole 1046 is a
separate sole component, the outsole 1046 can be secured to lower
areas of the forefoot component 1042 and the heel component 1044
and may be formed from a wear-resistant material that is textured
to impart traction. The sole component, such as a forefoot
component 1042 or a heel component 1044 or a combination forefoot
and heel component (not shown), can comprise, one or more polymeric
materials (e.g., a film comprising layers of one or more polymeric
materials) that form one or more chambers that includes a fluid
such as a gas. When the sole component comprises a plurality of
chambers, the plurality of chambers can be independent or
fluidically interconnected. In some configurations, the sole
structure 1034 may include a foam material forming at least one
layer or region of the sole structure, for example, a layer or
region that extends between the upper 1032 and one or both of the
forefoot component 1042 and the heel component 1044, or a foam
region may be located within indentations in the lower areas of the
forefoot component 1042 and the heel component 1044, In other
configurations, the sole structure 1032 may incorporate plates,
moderators, lasting elements, or motion control members that
further attenuate forces, enhance stability, or influence the
motions of the foot, for example. In some configurations, the sole
structure or sole component can consist essentially of one or more
plates comprising one or more traction elements, such as a single
plate extending from the toe to the heel of the upper, or two or
more plates, where a single plate is directly or indirectly affixed
to a tip of the region of the upper, a forefoot region of the
upper, a midfoot region of the upper, a heel region of the upper,
or any combination thereof. Although the depicted configuration for
the sole structure 1034 and the upper 1032 provides an example of a
sole structure that may be used in connection with an upper, a
variety of other conventional or nonconventional configurations for
the sole structure 1034 and/or the upper 1032 can also be utilized.
Accordingly, the configuration and features of the sole structure
1034 and/or the upper 1032 can vary considerably.
[0161] FIG. 80(c) is a cross-sectional view of A-A that depicts the
upper 1032 and the heel component 1044. The textile 103613 can be
disposed on the externally-facing surface of the heel component
1044 or alternatively or optionally the textile 1036b' can be
disposed on the internally-facing side of the heel component
1044.
[0162] FIGS. 8P(a) and 8P(b) illustrate a perspective view and a
side view of an article of footwear 160 that includes traction
elements 1068. The structure including the textile is represented
by 1072a and 1072b. The article of footwear 1060 includes an upper
1062 and a sole structure 1064, where the upper 1062 is secured to
the sole structure 1064. The sole structure 1064 can include one or
more of a toe plate 1066a, a mid-foot plate 1066b, and a heel plate
1066c. The plate can include one or more traction elements 1068, or
the traction elements can be applied directly to a ground-facing
surface of the article of footwear. As shown in FIGS. 8P(a) and
(b), the traction elements 1068 are cleats, but the traction
elements can include lugs, cleats, studs, and spikes as well as
tread patterns to provide traction on soft and slippery surfaces.
In general, the cleats, studs and spikes are commonly included in
footwear designed for use in sports such as global football/soccer,
golf, American football, rugby, baseball, and the like, while lugs
and/or exaggerated tread patterns are commonly included in footwear
(not shown) including boots design for use under rugged outdoor
conditions, such as trail running, hiking, and military use.
Footwear designed for running on paved surfaces commonly include
tread patterns. The sole structure 1064 is secured to the upper
1062 and extends between the foot and the ground when the article
of footwear 1060 is worn.
[0163] FIGS. 8Q(a)-8Q(j) illustrate additional views of exemplary
articles of athletic footwear including various configurations of
upper 1076. FIG. 8Q(a) is an exploded perspective view of an
exemplary article of athletic footwear showing insole 1074, upper
1076, optional midsole or optional lasting board 1077, and outsole
1078, which can take the form of a plate. Structures including the
disclosed textiles are represented by 1075a-1075d. FIG. 8Q(b) is a
top view of an exemplary article of athletic footwear indicating an
opening 183 configured to receive a wearer's foot as well as an
ankle collar 1081 which may include textile 1082. The ankle collar
is configured to be positioned around a wearers ankle during wear,
and optionally can include a cushioning element. Also illustrated
are the lateral side 1080 and medial side 1079 of the exemplary
article of athletic footwear. FIG. 8Q(c) is a back view of the
article of footwear depicted in FIG. 8Q(b), showing an optional
heel dip 1084 that can include textile 1085. FIG. 8Q(d) shows a
side view of an exemplary article of athletic footwear, which may
optionally also include a tongue 1086, laces 1088, a toe cap 1089,
a heel counter 1090, a decorative element such as a logo 1091,
and/or eyestays for the laces 1092 as well as a toe area 1093a, a
heel area 1093b, and a vamp 1093c. In some aspects, the heel
counter 1090 can be covered by a layer of knitted, woven, or
nonwoven fabric, natural or synthetic leather, film, or other shoe
upper material. In some aspects, the eyestays 1092 are formed as
one continuous piece; however, they can also comprise several
separate pieces or cables individually surrounding a single eyelet
or a plurality of eyelets. Structures including the disclosed
textiles are represented by 1087a-1087e. While not depicted, the
disclosed textiles can be present on the eyestays 1092 and/or the
laces 1088. In some configurations, the sole structure can include
a sole structure, such as a midsole having a cushioning element in
part or substantially all of the midsole, and the textile can be
disposed on an externally-facing side of the sole structure,
including on an externally-facing side of the midsole. FIG. 8Q(e)
is a side view of another exemplary article of athletic footwear.
In certain aspects, the upper can comprise one or more containment
elements 1094 such as wires, cables or molded polymeric component
extending from the lace structure over portions of the medial and
lateral sides of the exemplary article of athletic footwear to the
top of the sole structure to provide lockdown of the foot to the
sole structure, where the containment element(s) can have a textile
(not shown) disposed on an externally-facing side thereon. In some
configurations, a rand (not shown) can be present across part or
all of the biteline 1095.
Processes for Manufacturing
[0164] Certain conventional thermoforming processes include the
selective thermoforming of only a portion of an article, e.g., by
masking portions of the article not desired to be exposed to the
thermoforming process, or using tooling which contacts or covers
only a portion of an article. However, such conventional methods
result in time and energy intensive manufacturing processes, as
multiple steps are required to mask and unmask portions of the
article before and after the thermoforming process, or multiple
sets of tooling are required. Other conventional thermoforming
processes include the thermoforming of article components prior to
assembly into an article. This conventional process is also a time
and resource intensive process, as multiple steps and machinery are
required to individually form the article components prior to
assembling the article. Moreover, an article formed from several
individual components results in multiple seams where the
individual components interface, thereby providing weaknesses in
the article, less natural feel for a wearer, and/or actual
discomfort or injury for a wearer.
[0165] The manufacturing processes disclosed herein solve one or
more of the foregoing problems. The manufacturing processes
disclosed herein utilize one or more of the films, textiles, yarns
and fibers disclosed herein. For example, in certain aspects, as
discussed further below, the specific and selective incorporation
of the film, fiber, filament, yarn, or textile as described herein
into an article provides a way to program structural features into
an article that can be formed upon thermoforming. In some aspects,
the article can comprise a textile comprising the film, fiber,
filament or yarn as described herein, e.g., a textile comprising at
least one plurality of fibers or yarn comprising a film, fiber,
filament or yarn as described herein in at least a portion of the
textile. In another aspect, the article can comprise a first shaped
article comprising a film, fibers, filaments, textile, yarn as
described herein, and a second shaped component, film, textile,
yarn or plurality of fibers, e.g., a knit upper for an article of
footwear and a film as described herein. In further aspects, the
article can comprise an aggregation of components at least a
portion of which comprise a film, fiber, filament or yarn as
described herein and a second fiber, upon which the disclosed
thermoforming process has been applied.
[0166] Since, in aspects, such structural features are built into
the article depending upon the location in the article of the film,
fiber, filament or yarn as described herein, upon thermoforming
these structural features become integrated with each other,
allowing for a more natural feel for the wearer or user. For
example, a knit program for electronic knitting equipment can used
to determine the location of structural features. However, as
already noted, the manufacturing processes (and advantages
associated with these processes) is not limited to the use of the
textiles disclosed herein. For example, a process to form
structural features in a disclosed article can utilize a film as
described herein with a textile is also contemplated as a process
to program structural features into a disclosed article.
Alternatively, a process to effectively program structural features
into a disclosed article can utilize a shaped component comprising
a film, fiber, filament or yarn as described herein with a
textile.
[0167] Additionally, this selective incorporation of the film,
fiber, filament or yarn as described herein into an article
provides for a streamlined manufacturing process. For example, in
certain aspects, an entire article can be formed by arranging
components and exposing the arranged components to a thermoforming
process, where the components that include the film, fiber,
filament or yarn as described herein melt, flow, and re-solidify
into a more rigid structural feature, while the components that
include a film, fiber, filament or yarn as not provided herein do
not deform during the thermoforming process. In such aspects, this
allows for the entire article to be exposed to the thermoforming
process without the need to mask or protect areas that the
manufacturer does not wish to melt, flow, and re-solidify, thereby
resulting in a more time and energy efficient manufacturing
process. Further, in some cases, use of the articles described
herein in the manufacturing processes described herein also allows
for several different structural or other advantageous features to
be provided in the article without the need to combine individual
components into the final article, since such features can be built
into the article at the textile level using the film, fiber,
filament or yarn as described herein.
[0168] In various aspects, the thermoforming process occurs at a
temperature above the melting temperature of the thermoplastic
elastomer present in the films, fibers, yarns and textiles
described herein. In an aspect, thermoforming generates a
"consolidated" textile. In one aspect, a consolidated textile
comprises a thermoformed network of yarns comprising a first core
yarn and a first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, and wherein the first polymeric composition is a
thermoplastic elastomeric composition. In another aspect, the
thermoformed network of yarns is the thermoformed product of a
first textile comprising a first network of yarns including a first
coated yarn comprising the first core yarn and a first coating,
where the first coating includes the first polymeric composition
and wherein, in the thermoformed network, the first polymeric
composition consolidating the thermoformed network of yarns is the
re-flowed and re-solidified product of the first polymeric
composition of the first coating of the first coated yarn. In some
aspects, the thermoformed network of yarns is the thermoformed
product of a first textile as described herein.
[0169] Also disclosed is a method of making a textile, the method
comprising forming a first network of yarns including a first
coated yarn, the first coated yarn comprising a first core yarn and
a first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition, thereby forming a thermoformed network of
yarns comprising the first core yarn and the first polymeric
composition, wherein the first polymeric composition consolidates
the thermoformed network of yarns by surrounding at least a portion
of the first core yarn and occupying at least a portion of the
spaces between yarns in the thermoformed network of yarns.
[0170] In a further aspect, in a consolidated textile, the first
polymeric composition surrounds external surfaces of at least a
portion of the yarn or yarns forming the textile, the first
polymeric composition occupies spaces between the yarns, and the
first polymeric composition forms attachments between the yarns,
such that the stretch of the textile is reduced. In one aspect, the
reduction in stretch can be along just one axis of the consolidated
textile (e.g., an x axis, a y axis, or a bias axis at a 45 degree
angle to the x and y axes) or along more than one axis of the
consolidated textile.
[0171] In certain aspects, the core yarn can be a monofilament or
multifilament yarn. The yarns can be based on natural or manmade
fibers including polyester, high tenacity polyester, polyamide
yarns, metal yarns, stretch yarns, carbon yarns, glass yarns,
polyethylene or polyolefin yarns, bi-component yarns, PTFE yarns,
ultra-high-molecular-weight polyethylene (UHMWPE) yarns, liquid
crystal polymer yarns, specialty decorative yarns or reflective
yarns or a multi-component yarn comprising one or more of the
yarns.
[0172] In various aspects, the polymeric composition can further
comprise an additive, such as, but not limited to, be one or more
of a thickener, processing aid, a dye or colorant. In a further
aspect, the additive is not optional and comprises at least one
thickener. In a still further aspect, the additive is not optional
and comprises at least one processing aid. In yet a further aspect,
the additive is not optional and comprises at least one thickener
and at least one processing aid. In certain aspects, the thickener
can comprise an inorganic material such as silica, talc, or calcium
carbonate (CaCO.sub.3).
[0173] In certain aspects, as described herein, a thickener can be
used during the preparation of the first polymeric composition
(i.e., coating composition) in order to improve productivity and
matting properties. In a further aspect, the thickener is silica
powder, talc, or CaCO.sub.3. The thickener acts, at least in part,
to increase the viscosity of the first polymeric composition.
[0174] In certain aspects, the first polymeric composition can
comprise a processing agent in order to improve productivity. In a
further aspect, the processing agent can be montane wax or a fatty
acid ester (C5-C9) with pentaerythritol.
[0175] In certain aspects, the coated yarn having a desired color
can be produced by adding a master batch corresponding to the
desired color during production of the first polymeric composition
for coating yarn. In a further aspect, a TPU compound for coating
yarn, which has a desired hardness, can be prepared by controlling
the content of raw material. In a still further aspect, the
thickness of coated yarn can be reduced depending on the thickness
of yarn made of polyester, nylon, spandex or the like.
[0176] In various aspects, the first polymeric composition for
coating yarn has a cold Ross flex test result of about 120,000 to
about 180,000, or of about 140,000 to about 160,000, or of about
130,000 to about 170,000 when tested on a thermoformed plaque of
the first polymeric composition for coating yarn in accordance with
the cold Ross flex test as described herein below.
[0177] In certain aspects, the coated yarn can be prepared by
compounding in a conventional extruder the first polymeric
composition, and optionally also including one or more additives,
and then coating the compounded first polymeric composition on the
surface of the core yarn. In a further aspect, the process for
preparing the coated yarn comprises the steps of: 1) preparing
formed thermoplastic pellets; and 2) producing coated yarn. The
formed thermoplastic pellets can be prepared by the method
disclosed herein, prepared by similar methods as known to the
skilled artisan, or obtained from a commercially available
source.
[0178] The step of preparing formed thermoplastic pellets can
comprise the following steps: 1) mixing a thermoplastic elastomer
with various additives, e.g., a thickener and/or a processing aid,
and feeding the mixture into the hopper of a conventional
compounding extruder; 2) melting, kneading and compounding the
mixture in the cylinder of the compounding extruder at a suitable
temperature and pressure; 3) cutting the compounded thermoplastic
elastomer, discharged through the dice of the compounding extruder,
in cooling water to form pellets; and 4) drying the formed
thermoplastic elastomer pellets at a suitable temperature for about
period of time and aging the dried pellets at a suitable
temperature for a suitable period of time.
[0179] In a particular example, the step of preparing formed
thermoplastic pellets comprises the steps of: 1) mixing
thermoplastic elastomer with various additives, e.g., a thickener
and/or a processing aid, and feeding the mixture into the hopper of
a conventional compounding extruder; 2) melting, kneading and
compounding the mixture in the cylinder of the compounding extruder
at a temperature of about 150-250 degrees Celsius and a pressure of
about 50-150 kgf; 3) cutting the compounded thermoplastic
elastomer, discharged through the dice of the compounding extruder,
in cooling water to form pellets; and 4) drying the formed
thermoplastic elastomer pellets at a temperature of 60-80 degrees
Celsius for about 4-6 hours and aging the dried pellets at a
temperature of 30-50 degrees Celsius for about 7 days or more.
[0180] In certain aspects, the step of producing the coated yarn
can comprise the following steps: 1) mixing the formed
thermoplastic elastomer pellets, prepared as described above, with
a master batch corresponding to a desired color and feeding the
mixture into the hopper of a yarn coating extruder; 2) melting the
mixture of the formed thermoplastic elastomer pellets and the
master batch in the cylinder of the yarn coating extruder at a
suitable temperature and a suitable pressure; 3) coating the
compounded thermoplastic elastomer and master batch on the surface
of yarn passing through a nipple and a dice to produce coated yarn;
and 4) winding the coated yarn around a bobbin using a winding
machine.
[0181] In one aspect, the coated yarn can have a thermal shrinkage
of from 0 to 20 percent, optionally of from 0 to 15 percent, or of
from 0 to 10 percent, measured as described in the Property
Analysis and Characterization Procedures. In another aspect, the
coated yarn can have a tenacity of from about 1 gram per denier to
about 10 grams per denier, optionally of about 2 grams per denier
to about 8 grams per denier, or of about 2.5 grams per denier to
about 5 grams per denier, measured as described in the Property
Analysis and Characterization Procedures. In still another aspect,
the coated yarn can have a strain at break of from 0 to 20 percent,
optionally of from 0 to 15 percent, or of 0 to 10 percent, measured
as described in the Property Analysis and Characterization
Procedures. In any of these aspects, thermal shrinkage, tenacity,
and strain at break relate to the suitability of yarns for
commercial knitting machines. In a further aspect, coated yarns
having the disclosed properties are suitable for commercial
knitting.
[0182] In particular, the step of producing the coated yarn can
comprise the following steps: 1) mixing the formed thermoplastic
elastomer pellets with a master batch corresponding to a desired
color and feeding the mixture into the hopper of a yarn coating
extruder; 2) melting the mixture of the formed thermoplastic
elastomer pellets and the master batch in the cylinder of the yarn
coating extruder at a temperature of about 150-250 degrees Celsius.
and a pressure of about 50-150 kgf; 3) coating the compounded
thermoplastic elastomer and master batch on the surface of yarn
passing through a nipple and a dice to produce coated yarn; and 4)
winding the coated yarn around a bobbin using a winding
machine.
[0183] In one aspect, the yarn is a coated yarn comprising a core
yarn comprising a second polymeric composition and a coating layer
disposed on the core yarn, the coating layer comprising the first
polymeric composition, wherein the first polymeric composition has
a first melting temperature, wherein the second polymeric
composition is a second thermoplastic composition having a second
deformation temperature, and the second deformation temperature is
at least 20 degrees Celsius greater, optionally at least 50 degrees
Celsius greater, optionally at least 75 degrees Celsius greater, or
optionally at least 100 degrees Celsius greater than the first
melting temperature of the first polymeric composition.
[0184] In one aspect, the yarn is a coated yarn comprising a core
yarn comprising a second polymeric composition and a coating layer
disposed on the core yarn, the coating layer comprising the first
polymeric composition, wherein the first polymeric composition has
a first melting temperature, wherein the second polymeric
composition is a second thermoplastic composition having a second
deformation temperature, and the second deformation temperature is
at least 20 degrees Celsius greater than the first melting
temperature of the first polymeric composition, wherein the second
polymeric composition is a first thermoset composition.
[0185] In one aspect, the yarn is a coated yarn comprising a core
yarn comprising a second polymeric composition and a coating layer
disposed on the core yarn, the coating layer comprising the first
polymeric composition, wherein the first polymeric composition has
a first melting temperature, wherein the second polymeric
composition is a second thermoplastic composition having a second
deformation temperature, and the second deformation temperature is
at least 20 degrees Celsius greater than the first melting
temperature of the first polymeric composition, wherein the second
polymeric composition is a first thermoset composition, and wherein
the difference between the second deformation temperature and the
first melting temperature is at least 20 degrees Celsius, at least
50 degrees Celsius, at least 75 degrees Celsius, or at least 100
degrees Celsius.
[0186] In various aspects, the thermoforming process occurs at a
temperature above the first melting temperature of the first
polymeric composition but below the deformation temperature of the
second polymeric composition. In this aspect, the core yarn (i.e.,
the second polymeric composition) does not deform or soften during
the coating process.
[0187] In various aspects, the thermoforming process occurs at a
temperature below the deformation temperature of the second
polymeric composition that has been dyed so that such dye does not
leach out of the yarn or fiber and into the surround during the
thermoforming process. Thus, in order to form various textiles and
articles described herein, the deformation temperature of the
second polymeric composition is below a temperature used to dye the
core fiber.
[0188] In particular examples, the films, fibers, filaments, and
yarns described herein have melting characteristics and acceptable
levels of shrinkage when present in a yarn and used in commercial
knitting equipment.
[0189] Accordingly, in one aspect, a process for manufacturing an
article is provided. The article can be a component of an article
of footwear, a component of an article of apparel, or is a
component of an article of sporting equipment. For example, a
component of an article of sporting equipment can be a hat, a
component of a bag, a component of a ball, and a component of
protective equipment.
[0190] In one aspect, the process for manufacturing the article
includes placing a first film, fiber, filament or yarn as described
herein, or a textile as described herein on a surface; while the
first film, fiber, filament, yarn or textile is on the surface,
increasing a temperature of the first film, fiber, filament, yarn
or textile to a temperature that is above the melting temperature
of the first polymeric composition; and subsequent to the
increasing the temperature, while the first film, fiber, filament,
yarn or textile remains on the surface, decreasing the temperature
to a temperature below the melting temperature of the first
polymeric composition, thereby forming a article.
[0191] In one aspect, disclosed herein is a method for making an
article comprising affixing a first textile to a second component,
wherein the first textile comprises a first network of yarns
including a first coated yarn, the first coated yarn comprising a
first core yarn and a first coating including a first polymeric
composition disposed on at least a portion of an outer surface of
the first core yarn, wherein the first polymeric composition is a
thermoplastic elastomeric composition. In another aspect, disclosed
herein is a method of making an article, the method comprising
thermoforming a first textile, wherein the first textile comprises
a first network of yarns including a first coated yarn, the first
coated yarn comprising a first core yarn and a first coating
including a first polymeric composition disposed on at least a
portion of an outer surface of the first core yarn, wherein the
first polymeric composition is a thermoplastic elastomeric
composition and wherein the thermoforming comprises melting,
reflowing, and re-solidifying the first polymeric composition
within the first textile, forming a thermoformed textile comprising
a thermoformed network of yarns comprising the first core yarn and
the first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns. In still another aspect, disclosed herein is a
method for making an article, the method comprising affixing a
first textile to a second component, wherein the first textile
comprises a thermoformed network of yarns comprising a first core
yarn and a first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns, and wherein the first polymeric composition is a
thermoplastic elastomeric composition. In some aspects, the method
for making the article further includes the process of making a
textile as disclosed herein. Also disclosed are articles made by
the disclosed methods and processes.
[0192] In one aspect, a method for making an upper for an article
of footwear is provided, the method comprising affixing a first
textile to a second component, wherein the first textile comprises
a first network of yarns including a first coated yarn, the first
coated yarn comprising a first core yarn and a first coating
including a first polymeric composition disposed on at least a
portion of an outer surface of the first core yarn, wherein the
first polymeric composition is a thermoplastic elastomeric
composition. In another aspect, disclosed herein is a method for
making an upper for an article of footwear, the method comprising
thermoforming an upper comprising a first textile, wherein the
first textile comprises a first network of yarns including a first
coated yarn, the first coated yarn comprising a first core yarn and
a first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition and wherein the thermoforming comprises
melting, reflowing, and re-solidifying the first polymeric
composition with n the first textile, forming a thermoformed
textile comprising a thermoformed network of yarns comprising the
first core yarn and the first polymeric composition, wherein the
first polymeric composition consolidates the thermoformed network
of yarns by surrounding at least a portion of the first core yarn
and occupying at least a portion of spaces between yarns in the
thermoformed network of yarns. In still another aspect, disclosed
herein is a method for making an upper for an article of footwear,
the method comprising affixing a first textile to a second
component, wherein the first textile comprises a thermoformed
network of yarns comprising a first core yarn and a first polymeric
composition, wherein the first polymeric composition consolidates
the thermoformed network of yarns by surrounding at least a portion
of the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition. Also disclosed are uppers made by the disclosed
methods and processes.
[0193] In some aspects, more than one coating can be applied to the
yarns disclosed herein. In one aspect, disclosed herein are yarns
containing an optional second coating and/or an optional third
coating. In some aspects, the first coating is applied to the
entirety of the core yarn and the second and/or third coatings are
applied on top of the first coating. In other aspects, the first
coating is applied to only a portion of the core yarn and the
second and/or third coatings are applied to portions of the core
yarn uncoated by the first coating. In any of these aspects, when
the second coating and/or the third coating is polymeric, the
second coating and/or third coating displays melting
characteristics similar to those of the first coating. In some
aspects, the second coating and/or the third coating melts at a
lower temperature than the T.sub.m of the first coating.
[0194] In another aspect, a process for making a midsole-outsole
unit for an article of footwear is provided. The process includes
affixing a midsole cushioning element and an outsole component for
an article of footwear to each other, wherein the first polymeric
composition defines at least a portion of an outer surface of the
outsole configured to be ground-facing or ground-contacting.
[0195] In another aspect, a process for manufacturing an upper for
an article of footwear is provided. In one aspect, the method
involves affixing an upper and an outsole to each other to form the
article of footwear, wherein the first polymeric composition
defines at least a portion of an outer surface of the upper.
[0196] In another aspect, a process for manufacturing an outsole
for an article of footwear is provided. In one aspect, the method
involves affixing an upper and an outsole to each other to form the
article of footwear, wherein the first polymeric composition
defines at least a portion of an outer surface of the outsole
configured to be ground-facing or ground-contacting.
[0197] In another aspect, a process for manufacturing a
midsole-outsole unit for an article of footwear comprising a
midsole cushioning element and an outsole element is provided. In
one aspect, the method involves affixing an upper and an outsole to
each other to form the article of footwear, wherein the first
polymeric composition defines at least a portion of an outer
surface of the midsole-outsole unit configured to be ground-facing
or ground-contacting.
[0198] In another aspect, a process for making an upper for an
article of apparel is provided. The process includes weaving a
first course that includes interlacing a first yarn and a second
yarn. The first and/or second yarn includes a film, fiber, filament
or yarn as described herein. In some aspects, at least a portion of
the first yarn is a warp yarn; and wherein at least a portion of
the second yarn is a weft yarn. In alternative aspects, at least a
portion of the first yarn is a weft yarn; and wherein at least a
portion of the second yarn is a warp yarn. In one aspect, when the
textile is a woven textile, the first network of yarns includes
interlaced sets of yarns comprising the first coated yarn in a warp
direction, or in a weft direction, or in both the warp and weft
directions.
[0199] In a still further aspect, a process for manufacturing an
upper for a shoe is provided. The process includes receiving an
upper that includes a first yarn and a second yarn. The first
and/or second yarn includes a film, fiber, filament or yarn as
described herein. In a first portion of the upper, at least one of
the first yarn and the second yarn form a plurality of
interconnected loops. The process also includes placing the upper
on a last. Further, the process includes heating the entire upper,
while on the last, to a temperature that is above the melting
temperature of the thermoplastic elastomer present in the film,
fiber, filament or yarn described herein. Subsequent to the heating
the entire upper, cooling the entire upper, while on the last, to a
temperature below the melting temperature of the thermoplastic
elastomer, to thereby form a thermoformed upper.
[0200] In yet another aspect, a process for manufacturing an upper
for a shoe is provided. The process includes receiving an upper
including one or more first film, fiber, filament or yarns as
described herein and one or more second films, fibers, or yarns.
The upper includes a ground-facing outsole area, and wherein at
least a portion of the one or more first fibers is present on the
ground-facing outsole area. The process further includes placing
the upper on a last such that at least a portion of the
ground-facing outsole area covers at least a portion of a bottom of
the last. The process also includes heating the entire upper, while
on the last, to a temperature that is above the melting temperature
of the thermoplastic elastomer present in the film fibers, or yarn
described herein. Subsequent to the heating the entire upper,
cooling the entire upper, while on the last, to a temperature below
the melting temperature of the thermoplastic elastomer, to thereby
form a thermoformed upper.
[0201] In a yet further aspect, a process for making a knit upper
for an article of footwear is provided. The process includes
knitting a first course that includes loops of a first yarn and a
second yarn. The first yarn included a film, fibers, filaments, or
yarn as described herein. The process further includes knitting a
second course that comprises loops of the first yarn and the second
yarn. At least a portion of the first course and at least a portion
of the second course form a plurality of interconnected loops.
[0202] In one aspect, the first yarn and second yarn can be knitted
to form a textile. Following textile formation, it can, in some
aspects, be desirable to add additional polymeric components
directly to the knitted textile. In one aspect, additional
polymeric components can be used to form components of an article
of footwear such as soccer boot lug tips, an outsole, a rand, or
another component. In one aspect, the additional polymeric
components can have the same composition as the coating composition
disclosed herein but are not incorporated as yarn coatings. In a
further aspect, the additional polymeric components can be
processed by another method such as injection overmolding. In one
aspect, the molten injection component is miscible with and adheres
well to the knit textile without the need for primer or adhesive
bonding preparation since the molten injection component and the
yarn coating composition have the same chemical composition.
[0203] The method steps, processes, and operations described herein
are not to be construed as necessarily requiring their performance
in the particular order discussed or illustrated, unless
specifically identified as an order of performance. Additional or
alternative steps can be employed.
Exemplary Pre-Thermoforming and Thermoforming Processes
[0204] As discussed above, in certain aspects, the articles and
textiles described above, e.g., the textile 300 of FIG. 3, can form
at least a portion of an article of wear, such as an article of
footwear. In such aspects, the textile can form an upper for the
article of footwear, where the upper includes a ground-facing
outsole portion.
[0205] In certain aspects, the article or textile can be combined
with additional materials in forming the upper for the article of
footwear. For example, in one or more aspects, the textile can be
combined or layered with one or more of an ankle collar lining,
ankle collar foam, upper lining, or upper foam layer. In certain
aspects, one or more of these additional materials can be secured
to the textile, e.g., by knitting, stitching, or adhesion, prior to
thermoforming the textile.
[0206] In one aspect, the films, fibers, filaments, yarns and
textiles can be thermoformed using a molding surface such as a flat
plate or a conventional two-piece mold. The articles can be heated
before contacting the molding surface or can be heated while
contacting the molding surface. Optionally, pressure can be applied
during or following the heating. When the articles are thermoformed
in a flat form, the entire article does not need to be heated
(e.g., portions can be masked, or a shaped heated element can be
used).
[0207] In particular examples, the film, fiber, filament, yarn,
textile, or footwear component comprising the first polymeric
composition disclosed herein can be thermoformed on a molding
surface such as a last. In the example where the article is a
component footwear that includes an upper or a component of an
upper, (e.g., is a textile that will become part of an upper, is an
upper, or is an upper and outsole unit), in order to prepare the
article for the thermoforming process, the article is placed on a
last such that the article wraps over a portion of the last, or
last enters the inside of the upper. For example, the article can
wrap around the last to cover all of or a portion of: a bottom
portion of the last, a forefoot portion of the last, a heel portion
of the last, or any combination thereof. In certain aspects, the
last can be formed of a polymeric material such as a high
processing temperature polymer composition. In a particular aspect,
the last can be formed of a polymeric material having a melting
temperature T.sub.m or a degradation temperature greater than 250
degrees Celsius or greater than 300 degrees Celsius such as, for
example, a silicone polymer. The last can be made of other types of
material as long as such a material would not be deformed or melt
during the thermoforming process or otherwise adversely affect the
thermoforming of the upper.
[0208] In certain aspects, a first layer can be placed on a molding
surface, such as a last, before the article, such as an article of
footwear or component of an article of footwear. For example, a
first layer, such as a liner, can be optionally placed over a
molding surface, such as a last. Accordingly, a film, fiber,
filament, yarn or textile according to this disclosure is then
placed such it covers at least a portion of the liner. Thus, at
least a portion of the film, fiber, filament or yarn as described
herein is covering at least a portion of the liner.
[0209] In further aspects, an outer layer can be optionally
positioned on at least a portion of the article that is positioned
on a molding surface and covering at least a portion of the
article. The outer layer, which can comprise a film, fiber,
filament, yarn or textile comprising the first polymeric
composition, can be optionally placed over at least a portion of a
textile or an article, such as an upper, that is positioned on a
molding surface, such as a last. For example, a textile zone which
is associated with the ground-facing outsole portion of the upper
can cover all or at least a portion of the bottom portion of the
last, or at least a portion of a textile or article in contact with
the last. Accordingly, a textile zone associated with the upper can
cover all or at least a portion of the upper region of the last or
can cover all or at least a portion of a textile or upper in
contact with the last. Thus, at least a portion of the film, fiber,
filament, yarn, textile or component comprising the first polymeric
composition as described herein is in contact with at least a
portion of the outer layer, or forms at least a portion of the
outer layer.
[0210] In certain aspects, a shaped component, such as a heel
counter or a toe cap, can be optionally placed on an outer surface
of an upper or a combination upper and outsole unit. Alternatively,
a shaped component, such as a heel counter or a toe cap, can be
optionally placed on an inner surface of an upper and thermoformed
in contact therewith. It is understood that the placement of a
shaped component, whether an outer surface of an upper or an inner
surface of an upper, is completed before applying a mask,
protective sheath, a vacuum, or any combination thereof as
described herein below.
[0211] In certain aspects, during the thermoforming process, the
film, fiber, filament or yarn as described herein can melt and
flow. In various aspects, it can be desirable to mask regions of
the article or restrict or direct the flow of the melted film,
fiber, filament or yarn as described herein, or both. In such
aspects, a protective sheath can be applied over the article
positioned on a molding surface. For example, a protective sheath
can be positioned over an upper positioned on a last. In certain
aspects, the protective sheath can be formed of a polymeric
material having a melting temperature greater than that of the
second polymeric composition. In a particular aspect, the
protective sheath can be formed of an elastomeric polymeric
material having a melting temperature T.sub.m or a degradation
temperature greater than 250 degrees Celsius or greater than 300
degrees Celsius such as, for example, a silicone polymer. The
protective sheath can be made of other types of material as long as
such a material would not be deformed or melt during the
thermoforming process or otherwise adversely affect the
thermoforming of the upper. In aspects, the protective sheath can
apply a compressive force to the outer surface of the article being
thermoformed, which can aid in restricting and/or directing the
flow of the melted first polymeric composition as described herein.
Additionally or alternatively, a vacuum can be drawn on the
combination of the molding surface and the article positioned on
the molding surface, and optionally, when present the protective
sheath positioned on the article. For example, a bag under vacuum
can be compressed on the outside of the article or protective
sheath to apply a compressive force to the article or the article
and the protective sheath to ensure the article is in flush contact
with the molding surface, or is in flush contact with the molding
surface and the protective sheath. Additionally, a protective
sheath or a vacuum bag can be used to form a texture on the
reflowed first polymeric composition during the thermoforming
process.
[0212] As discussed above, the thermoforming process includes
increasing the temperature of the first polymeric composition,
e.g., the film, fiber, filament, yarn, textile, to a temperature
that can cause at least a portion of the first polymeric
composition as described herein present to melt and flow, or to
deform. Further, the thermoforming process includes the subsequent
decreasing of the temperature of the first polymeric composition to
solidify the re-flowed first polymeric composition as described
herein into the desired conformation and/or shape, such as an
article of footwear.
[0213] As discussed above, it is desirable that the thermoforming
process does not deform or alter the shaped components, textiles,
fibers and/or yarn comprising the second polymeric composition with
a deformation temperature greater than the melting temperature of
the first polymeric composition present in the film, fiber,
filament or yarn. In one or more aspects, the thermoforming can
increase the temperature of the un-masked materials, or only the
first polymeric composition, to a temperature of from about 90
degrees Celsius to about 240 degrees Celsius. In aspects, the
thermoforming can increase the temperature of the un-masked
materials, or only the first polymeric composition, to a
temperature of from about 90 degrees Celsius to about 200 degrees
Celsius. In one aspect, the thermoforming can increase the
temperature of the un-masked materials, or only the first polymeric
composition, to a temperature of from about 110 degrees Celsius to
about 180 degrees Celsius.
[0214] In certain aspects, the temperature of the un-masked
materials, or only the first polymeric composition, can be
increased for about 10 seconds to about 5 minutes. In aspects, the
temperature of the un-masked materials, or only the first polymeric
composition, can be increased for about 30 seconds to about 5
minutes. In one aspect, the temperature of the un-masked materials,
or only the first polymeric composition, can be increased for about
30 seconds to about 3 minutes.
[0215] In certain aspects, the thermoforming can expose the
materials on the mold surface to a pressure of about 50 kPa to
about 300 kPa. In aspects, the thermoforming can expose the
materials on the mold surface to a pressure of about 50 kPa to
about 250 kPa. In one aspect, the thermoforming can expose the
materials on the mold surface to a pressure of about from about 100
kPa to about 300 kPa.
[0216] In certain aspects, the un-masked materials, or only the
first polymeric composition, can be exposed the thermoforming under
the above conditions multiple times in a row prior to undergoing
the cooling step. For example, in some aspects, the un-masked
materials, or only the first polymeric composition, can be exposed
to the temperatures described above under the above conditions 2 to
10 times in a row prior to undergoing the cooling step. In an
alternative example, in some aspects, the un-masked materials, or
only the first polymeric composition, can be exposed the
temperatures described above under the above conditions twice in a
row prior to undergoing the cooling step.
[0217] In various aspects, subsequent to increasing the temperature
of un-masked materials or only the first polymeric composition, the
temperature of the un-masked materials, or only the first polymeric
composition is decreased to a temperature below the melting
temperature T.sub.m of the first polymeric composition present in
the film, fiber, filament or yarn as described herein for a
duration of time sufficient for the yarner-flowed first polymeric
composition to solidify. For example, the un-masked materials or
only the first polymeric composition can be heated using a thermal
energy source, including, but not limited to, conventional heaters,
such as convection heating, a conventional oven, air-circulating
oven or forced hot air oven, steam, targeted microwave heat,
ultraviolet radiation, infrared heating, and combinations of any of
the foregoing. In an aspect, heat can be applied using hotplates,
heat presses, or high tonnage presses with rigid clamshell molds.
The thermal energy source can further comprise a plurality of
thermal energy sources such as a plurality of similar sources,
e.g., a plurality of heating coils or infrared emitters.
Alternatively, a plurality of thermal energy sources can comprise a
plurality of one or more different thermal energy sources, e.g., a
plurality of heating coils and a plurality of infrared emitters
that can be used simultaneously or sequentially, or alternatively,
used in a mode where only one of the plurality of thermal energy
sources is used at any given time.
[0218] In some aspects, heating can be carried out such that heat
is transferred from another material or object to the un-masked
materials or only the first polymeric composition. For example, a
molding surface, such as plate, a multi-part closed mold, or a
last, can itself be heated directly, e.g., via configuration as a
resistive heating element. In an alternative aspect, a molding
surface, such as a last, can be preheated to the desired
temperature immediately prior to positioning an upper, a textile or
an article thereon. In the foregoing aspects, the molding surface
itself can act as a heating zone that transfers heat to an entire
upper.
[0219] In some aspects, heating can be carried out using
radio-frequency heating, e.g., microwave radiation, such that the
radio-frequency heats the compositions via interaction of a
radio-frequency field with a composition, such as the first
polymeric composition, that is part of film, fiber, filament, yarn,
textile or article.
[0220] In certain aspects, subsequent to heating the un-masked
materials, the un-masked materials are cooled to a temperature
below the melting temperature T.sub.m of the first polymeric
composition present in the, fiber, filament or yarn as described
herein. In such aspects, the un-masked materials can be exposed to
reduced temperatures in a cooling zone. The cooling zone can expose
the materials to a pressure of about 0 kilopascals. The materials,
when in the cooling zone, can be exposed to a temperature of about
-25 degrees Celsius to about 25 degrees Celsius. In aspects, the
materials, when in the cooling zone, can be exposed to a
temperature of about -10 degrees Celsius to about 25 degrees
Celsius. In one aspect, the materials, when in the cooling zone,
can be exposed to a temperature of about from about -10 degrees
Celsius to about 10 degrees Celsius. The materials can be exposed
to one or more of the cooling zone temperatures or ranges discussed
above for about 10 seconds to about 5 minutes. The materials can be
exposed to one or more of the cooling zone temperatures or ranges
discussed above for about 10 seconds to about 3 minutes. The
materials can be exposed to one or more of the cooling zone
temperatures or ranges discussed above for about 10 seconds to
about 2.5 minutes.
[0221] The textile can be prepared in a number of different ways.
In one aspect, the textile can be prepared as a large piece (e.g.,
as a rolled good) from which one or more pieces of are cut out. In
another aspect, the textile can be formed into a single piece
(e.g., knit into a single element having roughly the desired size
and shape).
[0222] In one aspect, the textile (e.g., a large piece or a single
element) can be thermoformed before cutting out smaller pieces from
a larger piece, or before trimming a single element. In another
aspect, the textile can be cut or trimmed (e.g., cutting a large
piece into a smaller piece, or trimming excess material from a
single element) and then thermoformed.
[0223] In one aspect, the textile (e.g., a cut piece or a single
element) can be attached to a second component (e.g., by stitching)
before it is thermoformed. In another aspect, the textile (e.g., a
cut piece or a single element) can be thermoformed after it has
been attached to a second component.
[0224] In one aspect, the textile (e.g., an unattached cut piece or
single element, or a cut piece or single element attached to a
second component) can be thermoformed flat. In another aspect, a
three-dimensional conformation can be imparted to the textile
(e.g., by stitching or welding it to itself or a second component
so that the textile takes on a curved shape, such as the shape of
an upper of an article of footwear) before the textile is
thermoformed.
[0225] In one aspect, the textile can be thermoformed in contact
with a molding surface (e.g., to impart a curved surface or a
surface texture). The molding surface can be flat, or can have a
three-dimensional shape, such as a last for an article of footwear.
In another aspect, the textile can be supported only at a few
points of contact (e.g., supported by a few pins on a jig) when
thermoformed.
[0226] In one aspect, the textile can be pressed against the
molding surface with a force greater than atmospheric pressure
during the thermoforming process. In another aspect, no additional
pressure beyond atmospheric pressure may be applied to the textile
during the thermoforming process.
[0227] In one aspect, the temperature of the entire textile can be
increased during the thermoforming process (e.g., the entire
textile can be heated). In another aspect, the temperature of only
particular regions of the textile may be increased during the
thermoforming process (e.g., by applying heat to only those regions
of the textile, or by masking other regions of the textile with an
insulating material such as silicone).
Films, Fibers, Filaments and Yarns
[0228] As discussed above, textiles and shaped components can
include the selective incorporation of films, fibers, filaments,
and yarns as described alone or in combination with other materials
(e.g., second films, fibers, filaments, or yarns that do not fall
under the films, fibers, filaments, and yarns described herein). In
one aspect, the films, fibers and filaments, described herein can
be used to form yarns which in turn can be used to form textiles,
including knit, woven, crocheted, or braided textiles, in
accordance with the present disclosure. The films, fibers,
filaments, and yarns described herein can also be used to form
non-woven textiles in accordance with the present disclosure. In
one aspect, when the textile is a non-woven textile, the first
network of yarns includes entangled or bonded yarns comprising the
first coated yarn. In another aspect, the entangled or bonded yarns
can be mechanically entangled yarns, thermally bonded yarns, yarns
bonded by a solvent treatment, chemically bonded yarns, or any
combination thereof.
[0229] In certain aspects, one or more of the yarns described
herein can be mono-filament yarns or multi-filament yarns. In
certain aspects, the yarns can be spun yarns. In various aspects,
one or more of the yarns can be formed using conventional
techniques including, but not limited to, melt-spinning, solution
spinning, or electrospinning.
[0230] In certain aspects, the fibers described herein can be
fibers of varying sizes, including fibers that are not suitable for
spinning into spinning into commercial yarns. The yarns described
herein include yarns that are suitable for use in a commercial
knitting machine as well as yarns that are not individually
suitable for use in a commercial knitting machine. In one aspect,
the core yarns described herein have a linear mass density of about
150 denier to about 1,500 denier, or of about 150 denier to about
1,000 denier, or about 250 denier to about 1,500 denier, or about
250 denier to about 1,000 denier, or about 500 to about 1,000
denier, or about 500 to about 750 denier, or about 750 to about
1,000 denier. In another aspect, the core yarn has a diameter of
from about 60 micrometers to about 200 micrometers, or about 80
micrometers to about 150 micrometers, or about 90 micrometers to
about 120 micrometers.
[0231] In certain aspects, the yarns and/or fibers described herein
can be used to provide a specific functionality. For example in
certain aspects, a yarn as described herein can be thermoformed to
form a film having water-proof or water-resistant properties.
[0232] In one aspect, coated yarns described herein can have a
break strength of from about 0.6 to about 0.9 kilograms of applied
force, or of from about 0.7 to about 0.9 kilograms of applied
force, or of about 0.8 to about 0.9 kilograms of applied force, or
greater than 0.9 kilograms of applied force.
[0233] As discussed above, in certain aspects, the films, fibers,
filaments and yarns described herein can be dyed, e.g., for
aesthetic purposes. In various aspects, the films, fibers,
filaments and yarns can be dyed using conventional dyeing
techniques, such as package dyeing or solution dyeing. Generally,
package dyeing is a process that is performed on already formed
films, fibers, filaments, and yarns, while solution dyeing adds
coloration the thermoplastic polymeric composition prior to forming
the films, fibers, filaments, or yarn. In certain aspects, the
films, fibers, filaments and yarns as described herein are not
pigmented or dyed, which can result in the region comprising the
first polymeric composition being clear or nearly transparent.
[0234] In an aspect, the yarns described herein can be produced
from films, fibers, or filaments composed of only a single
thermoplastic elastomer. In other aspects, the fibers can be
composed of a blend of two or more different thermoplastic
elastomers.
[0235] In one aspect, the yarn is a coated yarn, wherein a core
yarn comprises a second polymeric composition and a coating layer
disposed on the core yarn, the coating layer comprising the first
polymeric composition, wherein the first polymeric composition has
a first melting temperature. In one aspect, the second polymeric
composition is a second thermoplastic composition having a second
deformation temperature, and the second deformation temperature is
at least 20 degrees Celsius greater, at least 50 degrees Celsius
greater, at least 75 degrees Celsius greater, or at least 100
degrees Celsius greater than the first melting temperature of the
first polymeric composition. In another aspect, the second
polymeric composition is a second thermoplastic composition having
a second melting or deformation temperature, and the second
deformation temperature is at about 20 degrees Celsius greater,
about 50 degrees Celsius greater, about 75 degrees Celsius greater,
or about 100 degrees Celsius greater than the first melting
temperature of the first polymeric composition.
[0236] In one aspect, the first polymeric composition includes a
polymeric component. In one aspect, the first polymeric composition
can include a single polymeric component (e.g., a single
thermoplastic elastomer). In other aspects, the first polymeric
composition can include two or polymeric components (e.g., two or
more different thermoplastic elastomers).
[0237] In one aspect, the second polymeric composition is a first
thermoset composition. In one aspect, the second polymeric
composition comprises a second thermoset composition. The core yarn
can be any material which retains its strength at the temperature
at which the first polymeric material is extruded during the
coating process. The core yarn can be natural fibers or regenerated
fibers or filaments, or synthetic fibers or filaments. In one
aspect, the core yarn can be composed of a cotton, silk, wool,
rayon, nylon, elastane, polyester, polyamide, polyurethane, or
polyolefin. In one aspect, the core yarn is composed of
polyethylene terephthalate (PET). In one aspect, the second
polymeric composition has a deformation temperature greater than
200 degrees Celsius, greater than 220 degrees Celsius, greater than
240 degrees Celsius, or between about 200 degrees Celsius to about
300 degrees Celsius.
[0238] In one aspect, the core yarn is a staple yarn, a
multi-filament yarn or a mono-filament yarn. In one aspect the core
yarn is polytwisted. In one aspect, the core yarn has a linear
density of about 100 denier to about 300 denier, or of about 100 to
about 250 denier, or about 100 to about 200 denier, or about 100 to
150 denier, or about 150 to 300 denier, or about 200 to 300 denier,
or about 250 to 300 denier. In one aspect, the core yarn has a
thickness of about 60 microns to 200 microns, about 60 to 160
microns, about 60 to 120 microns, about 60 to 100 microns, about
100 to 200 microns, or about 140 to 200 microns.
[0239] In one aspect, the core yarn is polyethylene terephthalate
having a thickness of about 100 denier to about 200 denier, about
125 denier to about 175 denier, or about 150 denier to 160 denier.
In one aspect, the core yarn is polyethylene terephthalate having a
percent elongation of about 20 percent to about 30 percent, about
22 percent to about 30 percent, about 24 percent to about 30
percent, about 20 percent to about 28 percent, or about 20 percent
to about 26 percent. In one aspect, the core yarn is polyethylene
terephthalate having a tenacity of about 1 gram per denier to about
10 grams per denier, about 3 grams to about 10 grams per denier,
about 5 grams to about 10 grams per denier, about 1 gram to about 7
grams per denier, or about 1 gram to about 5 grams per denier.
[0240] In one aspect, the coated yarn can be produced by extruding
the coating (i.e., the first polymeric composition) onto the core
yarn through an annular die or orifice such that the coating layer
is axially centered surrounding the core yarn. The thickness of the
coating applied to the core yarn can vary depending upon the
application of the yarn. In one aspect, the coated yarn is used to
produce a knitted textile. In one aspect, the coated yarn has a
nominal average outer diameter of up to 1.00 millimeter, or of up
to about 0.75 millimeters, or of up to about 0.5 millimeters, or of
up to about 0.25 millimeters, or of up to about 0.2 millimeters, or
of up to about 0.1 millimeters. In another aspect, the coating has
a nominal average outer diameter of about 0.1 millimeters to about
1.00 millimeter, or about 0.1 millimeters to about 0.80
millimeters, or about 0.1 millimeters to about 0.60 millimeters. In
another aspect, the coating on the yarn has an average radial
coating thickness of about 50 micrometers to about 200 micrometers,
or about 50 micrometers to about 150 micrometers, or about 50
micrometers to about 125 micrometers.
[0241] In one aspect, the core yarn has a thickness of about 100
denier to about 200 denier, about 125 denier to about 175 denier,
or about 150 denier to 160 denier, and the coating has a nominal
average outer diameter of about 0.10 millimeters to about 0.50
millimeters, or of about 0.10 millimeters to about 0.25
millimeters, or of about 0.10 millimeters to about 0.20
millimeters. In one aspect, the core yarn is polyethylene
terephthalate having a thickness of about 100 denier to about 200
denier, about 125 denier to about 175 denier, or about 150 denier
to about 160 denier, and the coating has a nominal average outer
diameter of about 0.10 millimeters to about 0.50 millimeters, or of
about 0.10 millimeters to about 0.25 millimeters, or of about 0.10
millimeters to about 0.20 millimeters.
[0242] In a further aspect, the coated yarn has a net total
diameter of from about 0.2 to about 0.6 millimeters, or about 0.3
to about 0.5 millimeters, or about 0.4 to about 0.6 millimeters In
some aspects, a lubricating oil including, but not limited to,
mineral oil or silicone oil can be present on the yarn at from
about 0.5 percent to about 2 percent by weight, or from about 0.5
percent to about 1.5 percent by weight, or from about 0.5 percent
to about 1 percent by weight. In some aspects, lubricating
compositions can be applied to the surface of the coated yarn
before or during the process of forming the textile. In some
aspects, the thermoplastic composition and the lubricating
composition are miscible when the thermoplastic composition is
reflowed and resolidified in the presence of the lubricating
composition. Following reflowing and resolidification, the reflowed
and resolidified composition can comprise the lubricating
composition.
[0243] In one aspect, the core yarn has a percent elongation of
about 8 percent to about 30 percent, about 10 percent to about 30
percent, about 15 percent to about 30 percent, about 20 percent to
about 30 percent, about 10 percent to about 25 percent, or about 10
percent to about 20 percent. In one aspect, the core yarn has a
tenacity of about 1 gram per denier to about 10 grams per denier,
about 2 grams per denier to about 8 grams per denier, about 4 grams
per denier to about 8 grams per denier, or about 2 grams per denier
to about 6 grams per denier.
[0244] In another aspect, the yarn can be used as an inlaid that is
incorporated into a textile (e.g., knit, woven etc.). In one
aspect, the core yarn has a thickness of about 200 denier to about
300 denier, about 225 denier to about 275 denier, or about 250
denier to 260 denier. In one aspect, the core yarn is polyethylene
terephthalate having a thickness of about 200 denier to about 300
denier, about 225 denier to about 275 denier, or about 250 denier
to 260 denier. In one aspect, the coating has a nominal average
outer diameter of up to about 3.0 millimeters, of up to about 2.5
millimeters, of up to about 2 millimeters, of up to about 1.5
millimeters, of up to about 1.0 millimeter, or of up to about 0.5
millimeters. In one aspect, the core yarn has a thickness of about
200 denier to about 300 denier, about 225 denier to about 275
denier, or about 250 denier to about 260 denier, and the coating
has a nominal average outer diameter of about 0.5 millimeters to
about 3.0 millimeters, or of about 1.0 millimeter to about 2.5
millimeters, or of about 1.5 millimeters to about 2.0 millimeters.
In one aspect, the core yarn is polyethylene terephthalate having a
thickness of about 200 denier to about 300 denier, about 225 denier
to about 275 denier, or about 250 denier to about 260 denier, and
the coating has a nominal average outer diameter of about 0.5
millimeters to about 3.0 millimeters, or of about 1.0 millimeter to
about 2.5 millimeters, or of about 1.5 millimeters to about 2.0
millimeters.
[0245] The films, fibers, filaments, and yarns described herein
have several unique properties that make them suitable for the
production of articles such as textiles and the like. In one
aspect, the films, fibers, filaments, and yards have improved
resistance to abrasion. In other aspects, textiles and articles
produced from or incorporating the films, fibers, filaments, and
yarns described herein have improved resistance to abrasion. For
example, when the films, fibers, filaments, and yarns are used to
produce the outer sole of an article of footwear, the outer sole
will have improved durability as the outer sole is less likely to
lose mass over time.
[0246] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has
an Akron abrasion of less than 0.50 cubic centimeters, optionally
less than 0.40 cubic centimeters, less than 0.30 cubic centimeters,
less than 0.20 cubic centimeters, or less than 0.10 cubic
centimeters as determined using the Akron Abrasion Test. In another
aspect, when thermoformed, the first polymeric composition of the
film, fibers, filaments, yarn, and textile has an Akron abrasion of
about 0.05 cubic centimeters to about 0.5 cubic centimeters, about
0.10 cubic centimeters to about 0.45 cubic centimeters, or about
0.05 to about 0.20 cubic centimeters as determined using the Akron
Abrasion Test.
[0247] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has
an Akron abrasion of less than 500 milligrams, optionally less than
400 milligrams, less than 300 milligrams, less than 200 milligrams,
or less than 100 milligrams as determined using the Akron Abrasion
Test. In another aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has
an Akron abrasion of about 50 milligrams to about 500 milligrams,
about 100 milligrams to about 400 milligrams, or about 100
milligrams to about 150 milligrams as determined using the Akron
Abrasion Test.
[0248] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has a
DIN abrasion of less than 0.30 cubic centimeters, optionally less
than 0.20 cubic centimeters, less than 0.10 cubic centimeters, less
than 0.05 cubic centimeters, or less than 0.07 cubic centimeters as
determined using the DIN Abrasion Test. In another aspect, when
thermoformed, the first polymeric composition of the film, fibers,
filaments, yarn, and textile has a DIN abrasion of about 0.01 cubic
centimeters to about 0.30 cubic centimeters, about 0.05 cubic
centimeters to about 0.20 cubic centimeters, or about 0.05 cubic
centimeters to about 0.10 cubic centimeters as determined using the
DIN Abrasion Test.
[0249] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, and yarn has a DIN
abrasion of less than 300 milligrams, optionally less than 200
milligrams, less than 100 milligrams, less than 50 milligrams, or
less than 30 milligrams as determined using the DIN Abrasion Test.
In another aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has a
DIN abrasion of about 10 milligrams to about 300 milligrams, about
50 milligrams to about 250 milligrams, or about 50 milligrams to
about 100 milligrams as determined using the DIN Abrasion Test.
[0250] In certain aspects, the films, fibers, and yarns described
herein when incorporated into a textile or article the product has
improved traction properties. In one aspect, the coefficient of
friction of the films, fibers or yarns can be used to measure
traction properties on various surfaces.
[0251] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has a
dry dynamic coefficient of friction (COF) on a dry surface (e.g., a
smooth, flat, or textured surface such as, for example, wooden
parquet court, concrete, asphalt, laminate, brick, or ceramic tile)
of greater than 0.6, optionally of greater than 0.7, greater than
0.8, greater than 0.9, greater than 1.0, as determined using the
Coefficient of Friction Test. In another aspect, when thermoformed,
the first polymeric composition of the film, fibers, filaments,
yarn, and textile has a dry dynamic COF of greater than 0.15,
optionally of greater than 0.2, greater than 0.25, or greater than
0.3, using the Coefficient of Friction Test.
[0252] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and polymeric has
a wet dynamic COF of greater than 0.25, optionally of greater than
0.30, greater than 0.35, greater than 0.40, or greater than 0.50,
as determined using the Coefficient of Friction Test. In another
aspect, when thermoformed, the first polymeric composition of the
film, fibers, filaments, yarn, and textile has a wet dynamic COF of
greater than 0.15, optionally of greater than 0.2, greater than
0.25, or greater than 0.3, using the Coefficient of Friction
Test.
[0253] In certain aspect, it is desirable for the dynamic
coefficient of friction for the same dry and wet surface (e.g.,
smooth concrete or court) to be as close as possible. In one
aspect, the difference between the dynamic coefficient of friction
of the dry surface and the wet surface is less than 15 percent. In
another aspect, the difference between the dynamic coefficient of
friction of the dry surface and the wet surface is from about 0
percent to about 15 percent, about 1 percent to about 10 percent,
about 1 percent to about 5 percent, or about 2 percent to about 5
percent.
[0254] In one aspect, when thermoformed, the first polymeric
composition of the film, fibers, filaments, yarn, and textile has a
melting temperature from about 100 degrees Celsius to about 210
degrees Celsius, optionally from about 110 degrees Celsius to about
195 degrees Celsius, from about 120 degrees Celsius to about 180
degrees Celsius, or from about 120 degrees Celsius to about 170
degrees Celsius. In another aspect, the first polymeric composition
has a melting temperature greater than about 120 degrees Celsius
and less than about 170 degrees Celsius, and optionally greater
than about 130 degrees Celsius, and less than about 160 degrees
Celsius.
[0255] In a further aspect, when the melting temperature is greater
than 100 degrees Celsius, the integrity of articles formed from or
incorporating the first polymeric composition is preserved if the
articles briefly encounter similar temperatures, for example,
during shipping or storage. In another aspect, when the melting
temperature is greater than 100 degrees Celsius, or greater than
120 degrees Celsius, articles formed from or incorporating the
first polymeric composition can be steamed without melting or
uncontrollably fusing any polyester components incorporated in the
articles for purposes such as fill, zonal surface, or comfort
features, as well as stretch yarn used for snugness and fit
features.
[0256] In one aspect, when the melting temperature is greater than
120 degrees Celsius, materials incorporating the first or second
polymeric composition disclosed herein are unlikely to soften
and/or become tacky during use on a hot paved surface, a court
surface, an artificial or natural soccer pitch, or a similar
playing surface, track, or field. In one aspect, the higher the
melting temperature of the first or second polymeric composition
and the greater its enthalpy of melting, the greater the ability of
an article of footwear or athletic equipment incorporating or
constructed from the first or second polymeric composition to
withstand contact heating excursions, frictional surface heating
events, or environmental heating excursions. In one aspect, such
heat excursions may arise when the articles contact hot ground,
court, or turf surfaces, or from frictional heating that comes from
rubbing or abrasion when the articles contact another surface such
as the ground, another shoe, a ball, or the like.
[0257] In another aspect, when the melting temperature is less than
about 210 degrees Celsius, or less than about 200 degrees Celsius,
or less than about 190 degrees Celsius, or less than about 180
degrees Celsius, or less than about 175 degrees Celsius, but
greater than about 120 degrees Celsius, or greater than about 110
degrees Celsius, or greater than about 103 degrees Celsius, polymer
coated yarns can be melted for the purposes of molding and/or
thermoforming a given region of textiles knitted therefrom in order
to impart desirable design and aesthetic features in a short period
of time.
[0258] In one aspect, a melting temperature lower than 140 degrees
Celsius can prevent or mitigate the risk dye migration from
polyester yarns incorporated in the footwear or other articles. In
a further aspect, dye migration from package-dyed polyester yarns
or filaments is a diffusion-limited process and short periods of
exposure to temperatures greater than 140 degrees Celsius, such as
during thermoforming, do not extensively damage, discolor, or
otherwise render the appearance of the footwear or other articles
unacceptable. However, in another aspect, if the melting
temperature of the polymer coating is greater than about 210
degrees Celsius, thermal damage and dye migration may occur.
[0259] In one aspect, a high melting enthalpy indicates a longer
heating time is required to ensure a polymer is fully melted and
will flow well. In another aspect, a low melting enthalpy requires
less heating time to ensure full melting and good flow.
[0260] In a further aspect, high cooling exotherms indicate rapid
transitions from molten to solid. In another aspect, higher
recrystallization temperatures indicate polymers are capable of
solidifying at higher temperatures. In one aspect, high-temperature
solidification can be beneficial for thermoforming. In one aspect,
recrystallization above 95 degrees Celsius can promote rapid
setting after thermoforming, reduce cycle time, reduce cooling
demands, and improve stability of shoe components during assembly
and use.
[0261] In one aspect, viscosity of the coating compositions
disclosed herein can affect the properties and processing of the
coating compositions. In a further aspect, high viscosities at low
shear rates (e.g., less than 1 reciprocal second) indicate
resistance to flow, displacement, and more solid-like behavior. In
another aspect, low viscosities at higher shear rates (e.g.,
greater than 10 reciprocal seconds) lend themselves to high-speed
extrusion. In one aspect, as viscosity increases, the ability to
flow and deform adequately to coat core yarn substrate becomes
challenging. In another aspect, materials that exhibit high shear
thinning indices (e.g., where viscosity at 10 or 100 reciprocal
seconds is lower than at 1 reciprocal second) can be challenging to
extrude and may melt fracture if coated or extruded at a velocity
that is too high.
[0262] In one aspect, the first polymeric composition of the film,
fibers, filaments, yarn, and textile has a melt flow index of at
least 0.2 grams per 10 minutes, optionally at least 2, at least 5,
at least 10, at least 15, at least 20, at least 25, at least 30, at
least 40, or at least 50 grams per 10 minutes, as determined using
the Method to Determine the Melt Flow Index (ASTM D1238-13) at 160
degrees Celsius using a weight of 2.16 kg. In another aspect, when
thermoformed, the first polymeric composition of the film, fibers,
filaments, and yarn has a melt flow index of at least 0.2 grams per
10 minutes, optionally at least 5 grams per 10 minutes, at least 10
grams per 10 minutes, at least 15 grams per 10 minutes, at least 20
grams per 10 minutes, at least 25 grams per 10 minutes, at least 30
grams per 10 minutes, at least 40 grams per 10 minutes, or at least
50 grams per 10 minutes, as determined using the Method to
Determine the Melt Flow Index (ASTM D1238-13) at 200 degrees
Celsius using a weight of 10 kg. In one aspect, having a suitable
melt flow rate or melt flow index allows the first polymeric
composition to re-flow adequately around and between the knitted or
woven textile fibers as disclosed herein. In another aspect, having
a suitable melt flow rate allows a skin-like structure to form when
the knitted or woven textile is thermoformed.
[0263] In one aspect, the first polymeric composition of the film,
fibers, filaments, yarn, and textile has a durometer Shore A
hardness of about 50 to about 90 Shore A, optionally from about 55
to about 85 Shore A, from about 60 to about 80 Shore A, from about
60 to about 70 Shore A, or from about 67 to about 77 shore A.
[0264] In one aspect, the first polymeric composition of the film,
fibers, filaments, yarn, or textile has a specific gravity from
about 0.8 to about 1.5, optionally from about 0.8 to about 1.30, or
from about 0.88 to about 1.20. In another aspect, the first
polymeric composition of the film, fibers, filaments, yarn, or
textile has a specific gravity of from about 0.80 grams per cubic
centimeter to about 1.30 grams per cubic centimeter, or from about
1.0 grams per cubic centimeter to about 1.2 grams per cubic
centimeter as determined by the Method to Determine Specific
Gravity (ASTM D792).
[0265] In one aspect, the first polymeric composition of the film,
fibers, filaments, yarn, or textile have two or more of the first
properties, or optionally three or more, four or more, five or
more, six or more, seven or more, or all ten first properties
provided above.
[0266] In one or more aspects, the textile described herein can
exhibit a modulus of from about 1 megapascal to about 500
megapascals. In certain aspects, the coated yarns can exhibit a
modulus of from about 5 megapascals to about 150 megapascals, or of
from about 20 megapascals to about 130 megapascals, or of from
about 30 megapascals to about 120 megapascals, or of from about 40
megapascals to about 110 megapascals. The term "modulus" as used
herein refers to a respective testing method described below in the
Property Analysis And Characterization Procedures section. In one
aspect, a material having a high modulus is relatively stiffer than
a material having a low modulus, which is more flexible. In another
aspect, when the first polymeric compositions are used as coatings
for yarns and incorporated into textiles and articles as described
herein, textiles and articles comprising thermoplastic polymeric
compositions having a lower modulus will be more flexible than
articles comprising thermoplastic polymeric compositions having a
high modulus.
[0267] In addition to the first properties, when thermoformed, the
first polymeric composition of the film, fibers, filaments, yarn,
or textile has one or more second properties. In one aspect, when
thermoformed, the first polymeric composition of the film, fibers,
filaments, yarn, or textile has a glass transition temperature less
than 50 degrees Celsius, optionally less than 30 degrees Celsius,
less than 0 degrees Celsius, less than -10 degrees Celsius, less
than -20 degrees Celsius, or less than -30 degrees Celsius. In one
aspect, when thermoformed, the first polymeric composition of the
film, fibers, filaments, and yarn has a stress at break greater
than 7 megapascals, optionally greater than 8 megapascals, as
determined using Method to Determine the Modulus, Tenacity, and
Elongation (yarn) at 25 degrees Celsius. In one aspect, when
thermoformed, the first polymeric composition of the film, fibers,
filaments, and yarn has a tensile stress at 300 percent modulus
greater than 2 megapascals, optionally greater than 2.5
megapascals, or greater than 3 megapascals as determined using
Method to Determine the Modulus, Tenacity, and Elongation (yarn) at
25 degrees Celsius. In one aspect, when thermoformed, the first
polymeric composition of the film, fibers, filaments, and yarn has
an elongation at break greater than 400 percent, optionally greater
than 450 percent, optionally greater than 500 percent, or greater
than 550 percent as determined using Method to Determine the
Modulus, Tenacity, and Elongation (yarn) at 25 degrees Celsius. In
another aspect, when thermoformed, the first polymeric composition
of the film, fibers, filaments, and yarn has two or more of the
second properties, or optionally three or more, or all four second
properties.
[0268] In one aspect, the textiles described herein or articles
comprising the textiles described herein can be subjected to Akron
Abrasion testing as described in the Property Analysis and
Characterization Procedures. In one aspect, after 300 cycles of
Akron Abrasion testing, the textiles or articles have a mass loss
of from 0 to 0.05 weight percent, optionally from 0 to 0.04 weight
percent, or from 0 to 0.03 weight percent, or from 0 to 0.02 weight
percent after 300 cycles. In another aspect, after 3000 cycles of
Akron Abrasion testing, the textiles or articles have a mass loss
of from 0 to 0.2 weight percent, or of from 0 to 0.15 weight
percent, or of from 0 to 0.1 weight percent, or of from 0 to 0.05
weight percent. In still another aspect, the textiles described
herein or articles comprising the textiles described herein can be
subjected to Stoll Abrasion testing as described in the Property
Analysis and Characterization Procedures. In one aspect, the
articles or textiles do not show significant Stoll Abrasion loss or
degradation after at least 1600 cycles, or after at least 2000
cycles, or after at least 2500 cycles.
[0269] In one aspect, the textiles disclosed herein can be
subjected to Bally Flex testing as described in the Property
Analysis and Characterization Procedures. In one aspect, the
textiles to not exhibit cracking after at least 100 cycles in a dry
Bally flex test. In another aspect, the textiles do not exhibit
cracking after at least 15,000 cycles in a wet Bally flex test.
[0270] In another aspect, when the textiles disclosed herein are
included as components of an upper for an article of footwear, a
textile-ball impact test or a boot-ball impact test can be
performed as described in the Property Analysis and
Characterization Procedures. In one aspect, the textile or an upper
comprising the textile produces a ball spin rate of from about 220
revolutions per minute to about 240 revolutions per minute, or of
about 220 revolutions per minute to about 230 revolutions per
minute. In a further aspect, the revolutions per minute can be
right-handed (positive, or clockwise) or left-handed (negative, or
counterclockwise). In one aspect, a higher number of revolutions
per minute is desirable for generating a ball path with suitable
curvature for avoiding opposing players on, for example, a soccer
(football) field.
[0271] In one aspect, following thermoforming, the first polymeric
composition has one or more first properties selected from: [0272]
a) an Akron abrasion of from 0.00 to 0.50 cubic centimeters,
optionally 0.00 to 0.40 cubic centimeters, 0.00 to 0.30 cubic
centimeters, 0.00 to 0.20 cubic centimeters, or 0.00 to 0.10 cubic
centimeters as determined using the Akron Abrasion Test; [0273] b)
a DIN abrasion of from 0.00 to 0.30 cubic centimeters, from 0.00 to
0.20 cubic centimeters, 0.00 to 0.10 cubic centimeters, or 0.00 to
0.05 cubic centimeters, as determined using the DIN Abrasion Test;
[0274] c) a dry dynamic coefficient of friction (COF) of from 0.5
to 1.0, optionally of 0.7 to 1.0, 0.8 to 1.0, 0.9 to 1.0, or
greater than 1.0, as determined using the Coefficient of Friction
Test; [0275] d) a wet dynamic COF of from 0.25 to 0.50, optionally
of 0.30 to 0.50, of 0.35 to 0.50, 0.40 to 0.50, or greater than
0.50, as determined using the Coefficient of Friction Test; [0276]
e) a dry dynamic COF of 0.15 to 0.3, optionally of 0.2 to 0.3, 0.25
to 0.3, or greater than 0.3, using the Coefficient of Friction
Test; [0277] f) a wet dynamic COF of 0.15 to 0.3, optionally of 0.2
to 0.3, 0.25 to 0.3, or greater than 0.3, using the Coefficient of
Friction Test; [0278] g) a melting temperature from about 100
degrees C. to about 210 degrees C., optionally from about 110
degrees C. to about 195 degrees C., from about 120 degrees C. to
about 180 degrees C., or from about 120 degrees C. to about 170
degrees C.; [0279] h) a melt flow rate of at least 0.2 grams to at
least 50 grams per 10 minutes, optionally at least 2 to at least
50, at least 5 to at least 50, at least 10 to at least 50, at least
15 to at least 50, at least 20 to at least 50 to at least 50, at
least 25 to at least 50, at least 30 to at least 50, at least 40 to
at least 50, or at least 50 grams per 10 minutes, as determined
using ASTM D1238-13 at 160 degrees C. using a weight of 2.16 kg;
[0280] i) a melt flow rate of at least 0.2 grams to at least 50
grams per 10 minutes, optionally at least 2 to at least 50, at
least 5 to at least 50, at least 10 to at least 50, at least 15 to
at least 50, at least 20 to at least 50 to at least 50, at least 25
to at least 50, at least 30 to at least 50, at least 40 to at least
50, or at least 50 grams per 10 minutes, as determined using ASTM
D1238-13 at 200 degrees C. using a weight of 10 kg; [0281] j) a
durometer from about 50 to about 90 Shore A, optionally from about
55 to about 85 Shore A, from about 60 to about 80 Shore A, or from
about 60 to about 70 Shore A; [0282] k) a glass transition
temperature of from -10 degrees Celsius to 50 degrees Celsius,
optionally from -10 degrees Celsius to 30 degrees Celsius, or from
-10 degrees Celsius to 20 degrees Celsius, or from -10 degrees
Celsius to 10 degrees Celsius; [0283] l) a specific gravity from
about 0.8 to about 1.5, optionally from about 0.85 to about 1.30,
or from about 0.88 to about 1.20; [0284] m) a mass loss of less
than 0.05 weight percent after 300 cycles, optionally from about
0.01 weight percent to about 0.05 weight percent after 300 cycles;
[0285] n) a mass loss of less than 0.20 weight percent after 3,000
cycles, optionally from about 0.01 weight percent to about 0.20
weight percent, about 0.1 weight percent to about 0.20 weight
percent, or about 0.5 weight percent to about 0.20 weight percent
after 3,000 cycles; [0286] o) a Stoll abrasion resistance of at
least 1,600 cycles, or about 1,600 cycle to about 2,500 cycles;
[0287] p) a Bally Flex of at least 100 cycles, or from about 100
cycles to about 1,000 cycles; and [0288] q) a wet Bally Flex of at
least 5,000 cycles, or from about 5,000 cycles to about 20,000
cycles.
[0289] In one aspect, following thermoforming, knitted or woven
textiles comprising the first polymer composition possesses
desirable performance properties. In a further aspect, the
disclosed thermoformed knitted or woven textiles outperform
traditional materials included in uppers for articles of footwear
such as Kangaroo leather and Duragon skin (a trade name referring
to a preformed, polyurethane laminated skin on a polyester
textile). For example, the thermoformed knit textiles showed
similar dry and wet coefficients of friction (e.g., boot-to-ball
interaction) as the laminated Duragon skin; however, the knitted
textile as described herein can be produced in a streamlined, more
integrated, lower waste manner of construction. In other aspects,
the thermoformed textiles and/or footwear uppers containing the
coated yarns disclosed herein exhibit higher wet and dry COF values
overall, and a lower degree of difference between dry COF and wet
COF than DURAGON skin. In other aspects, following thermoforming,
the first polymeric composition has one or more properties selected
from: [0290] a) a stress at break of at least 7 megapascals to 8
megapascals, optionally greater than 8 megapascals, as determined
using Method to Determine the Modulus (plaque) at 25 degrees
Celsius; [0291] b) a tensile stress at 300 percent modulus of at
least 2 megapascals to 3 megapascals, optionally 2.5 megapascals to
3 megapascals, or greater than 3 megapascals as determined using
Method to Determine the Modulus (plaque) at 25 degrees Celsius;
[0292] c) an elongation at break of at least 450 percent to 550
percent, optionally from 500 percent to 550 percent, or greater
than 550 percent as determined using Method to Determine the
Modulus (plaque) at 25 degrees C.; [0293] d) a difference between
the dry dynamic coefficient of friction and the dry static
coefficient of friction of from 0 to 20 percent as determined by
the Method for Determining Coefficient of Friction described in the
Property Analysis and Characterization Procedures; [0294] e) a
difference between the wet dynamic coefficient of friction and the
wet static coefficient of friction of from 0 to 20 percent as
determined by the Method for Determining Coefficient of Friction
described in the Property Analysis and Characterization Procedures;
and [0295] f) a difference between the wet static coefficient of
friction and the dry static coefficient of friction of from 0 to 20
percent as determined by the Method for Determining Coefficient of
Friction described in the Property Analysis and Characterization
Procedures.
[0296] In certain aspects, the films, fibers, and yarns described
herein can exhibit a tenacity greater than 1 gram/denier. In one
aspect, the films, fibers, and yarns described herein can exhibit a
tenacity of from about 1 gram/denier to about 5 grams/denier. In
one or more aspects, the films, fibers, and yarns described herein
can exhibit a tenacity of from about 1.5 grams/denier to about 4.5
grams/denier. In one aspect, the films, fibers, and yarns described
herein can exhibit a tenacity of from about 2 grams/denier to about
4.5 grams/denier. "Tenacity" as used herein refers to a property of
a fiber or yarn, and is determined using the respective testing
method and sampling procedure described below in the Property
Analysis and Characterization Procedures section.
[0297] In certain aspects, it can be desired to utilize a yarn that
is suitable for use on commercial knitting equipment. A
free-standing shrinkage of a yarn at 50 degrees Celsius is one
property that can be predictive of a suitable yarn for use on a
commercial knitting machine. In certain aspects, a films, fibers,
filaments, and yarns described herein can exhibit a free-standing
shrinkage when heated from 20 degrees Celsius to 70 degrees Celsius
of less than 15 percent. In various aspects, the films, fibers, and
yarns described herein can exhibit free-standing shrinkage when
heated from 20 degrees Celsius to 70 degrees Celsius of about 0
percent to about 60 percent, about 0 percent to about 30 percent,
or about 0 percent to about 15 percent. The term "free-standing
shrinkage" as used herein refers to a property of a yarn and a
respective testing method described below in the Property Analysis
and Characterization Procedures section.
[0298] In one or more aspects, the free-standing shrinkage of a
yarn at 70 degrees Celsius can be a useful indicator of the ability
of a yarn to be exposed to certain environmental conditions without
any substantial changes to the physical structure of the yarn. In
certain aspects, a yarn comprising the low processing temperature
polymeric composition can exhibit a free-standing shrinkage when
heated from 20 degrees Celsius to 70 degrees Celsius of from about
0% to about 60%. In one or more aspects, a yarn comprising the low
processing temperature polymeric composition can exhibit a
free-standing shrinkage when heated from 20 degrees Celsius to 70
degrees Celsius of from about 0% to about 30%. In one aspect, a
yarn comprising the low processing temperature polymeric
composition can exhibit a free-standing shrinkage when heated from
20 degrees Celsius to 70 degrees Celsius of from about 0% to about
20%.
[0299] As discussed above, in certain aspects, the first polymeric
composition as described herein and the second polymeric
composition have differing properties. In various aspects, these
differing properties allow for the coated fibers as described
herein, during a thermoforming process, to melt and flow, and
subsequently cool and solidify into a different structure than that
prior to the thermoforming process (e.g., thermoform from a yarn to
a melted yarn component), while the an uncoated fiber cannot deform
or melt during such a process and can maintain its structure (e.g.,
as a yarn), when the thermoforming process is conducted at a
temperature below the melting temperature of the uncoated fibers.
In such aspects, the melted yarn component formed from the coated
fibers as described herein during the thermoforming process can be
integrally connected to the non-altered structure (e.g., a yarn or
fiber), which can provide three-dimensional structure and/or other
properties targeted to specific spots on an article of wear.
Exemplary Thermoplastic Elastomers
[0300] In various aspects, the polymeric compositions described
herein comprise one or more thermoplastic elastomers. In an aspect,
an "elastomer" can be defined as a material having an elongation at
break greater than 400 percent as determined using ASTM D-412-98 at
25 degrees Celsius. In another aspect, the elastomer can be formed
into a plaque, wherein the plaque has a break strength of from 10
to 35 kilogram-force (kgf), or of from about 10 to about 25
kilogram-force, or of from about 10 to about 20 kilogram-force, or
of from about 15 to about 35 kilogram-force, or of from about 20 to
about 30 kilogram-force. In another aspect, tensile breaking
strength or ultimate strength, if adjusted for cross-sectional
area, can be greater than 70 kilogramforce per square centimeter,
or greater than 80 kilogramforce per square centimeter. In another
aspect, the elastomer plaque can have a strain to break of from 450
percent to 800 percent, or from 500 to 800 percent, or from 500 to
750 percent, or from 600 to 750 percent, or from 450 to 700
percent. In still another aspect, the elastomer plaque can have a
load at 100 percent strain of from 3 to 8 kilogram-force per
millimeter, or of about 3 to about 7 kilogram-force per millimeter,
about 3.5 to about 6.5 kilogram-force per millimeter, or about 4 to
about 5 kilogram-force per millimeter. In one aspect, the elastomer
plaque can have a toughness of from 850 kilogrammillimeters to 2200
kilogrammillimeters, or of from about 850 kilogrammillimeters to
about 2000 kilogrammillimeters, or of from about 900
kilogrammillimeters to about 1750 kilogrammillimeters, or of from
about 1000 kilogrammillimeters to about 1500 kilogrammillimeters,
or of from about 1500 kilogrammillimeters to about 2000
kilogrammillimeters. In an aspect, the elastomer plaque can have a
stiffness of from about 35 to about 155, or of from about 50 to
about 150, or of from about 50 to about 100, or of from about 50 to
about 75, or of from about 60 to about 155, or of from about 80 to
about 150. In still another aspect, the elastomer plaque can have a
tear strength of from about 35 to about 80, or of from about 35 to
about 75, or of from about 40 to about 60, or of from about 45 to
about 50.
[0301] In aspects, exemplary thermoplastic elastomers include
homo-polymers and co-polymers. The term "polymer" refers to a
polymerized molecule having one or more monomer species, and
includes homopolymers and copolymers. The term "copolymer" refers
to a polymer having two or more monomer species, and includes
terpolymers (i.e., copolymers having three monomer species). In
certain aspects, the thermoplastic elastomer can be a random
co-polymer. In one aspect, the thermoplastic elastomer can be a
block co-polymer. For example, the thermoplastic elastomer can be a
block co-polymer having repeating blocks of polymeric units of the
same chemical structure (segments) which are relatively harder
(hard segments), and repeating blocks of polymeric segments which
are relatively softer (soft segments). In various aspects, in block
co-polymers, including block co-polymers having repeating hard
segments and soft segments, physical crosslinks can be present
within the blocks or between the blocks or both within and between
the blocks. Particular examples of hard segments include isocyanate
segments and polyamide segments. Particular examples of soft
segments include polyether segments and polyester segments. As used
herein, the polymeric segment can be referred to as being a
particular type of polymeric segment such as, for example, an
isocyanate segment, a polyamide segment, a polyether segment, a
polyester segment, and the like. It is understood that the chemical
structure of the segment is derived from the described chemical
structure. For example, an isocyanate segment is a polymerized unit
including an isocyanate functional group. When referring to a block
of polymeric segments of a particular chemical structure, the block
can contain up to 10 mol percent of segments of other chemical
structures. For example, as used herein, a polyether segment is
understood to include up to 10 mol percent of non-polyether
segments.
[0302] In one aspect, the first polymeric composition comprises a
polymeric component consisting of all the polymers present in the
polymeric composition; optionally wherein and the polymeric
component comprises two or more polymers, wherein the two or more
polymers differ from each other in chemical structure of individual
segments of each of the two or more polymers, or in molecular
weight of each of the two or more polymers, or in both.
[0303] In various aspects, the thermoplastic elastomer can include
one or more of a thermoplastic copolyester elastomer, a
thermoplastic polyether block amide elastomer, a thermoplastic
polyurethane elastomer, a polyolefin based-copolymer elastomer, a
thermoplastic styrenic copolymer elastomer, a thermoplastic ionomer
elastomer, or any combination thereof. In one aspect, the first
polymeric composition comprises a thermoplastic elastomeric
styrenic copolymer. In a further aspect, the thermoplastic
elastomeric styrenic copolymer can be a styrene butadiene styrene
(SBS) block copolymer, a styrene ethylene/butylene styrene (SEBS)
resin, a styrene acrylonitrile (SAN) resin, or any combination
thereof. In one aspect, the first polymeric composition comprises a
thermoplastic elastomeric polyester polyurethane, a thermoplastic
polyether polyurethane, or any combination thereof. In some
aspects, the thermoplastic elastomeric polyester polyurethane can
be an aromatic polyester, an aliphatic composition, or a
combination thereof. It should be understood that other
thermoplastic polymeric materials not specifically described below
are also contemplated for use in the coated fiber as described
herein and/or the an uncoated fiber. In one aspect, the first
polymeric composition comprising the thermoplastic elastomer has a
melting temperature greater than about 110 degrees Celsius and less
than about 170 degrees Celsius. In another aspect, the first
polymeric composition comprising the thermoplastic elastomer has a
melting temperature of about 110 degrees Celsius to about 170
degrees Celsius, about 115 degrees Celsius to about 160 degrees
Celsius, about 120 degrees Celsius to about 150 degrees Celsius,
about 125 degrees Celsius to about 140 degrees Celsius, about 110
degrees Celsius to about 150 degrees Celsius, or about 110 degrees
Celsius to about 125 degrees Celsius.
[0304] In various aspects, the thermoplastic elastomer has a glass
transition temperature (T.sub.g) less than 50 degrees Celsius when
determined in accordance with ASTM D3418-97 as described herein
below. In some aspects, the thermoplastic elastomer has a glass
transition temperature (T.sub.g) of about -60 degrees Celsius to
about 50 degrees Celsius, about -25 degrees Celsius to about 40
degrees Celsius, about -20 degrees Celsius to about 30 degrees
Celsius, about -20 degrees Celsius to about 20 degrees Celsius, or
of about -10 degrees Celsius to about 10 degrees Celsius, when
determined in accordance with ASTM D3418-97 as described herein
below. In one aspect, the glass transition temperature of the
thermoplastic elastomer is selected such that articles
incorporating the coated yarns disclosed herein, wherein the coated
yarns comprise a coating material comprising the thermoplastic
elastomer, the thermoplastic material is above its glass transition
temperature during normal wear when incorporated into an article of
footwear (i.e., is more rubbery and less brittle).
[0305] In one aspect, the thermoplastic elastomer comprises: (a) a
plurality of first segments; (b) a plurality of second segments;
and, optionally, (c) a plurality of third segments. In various
aspects, the thermoplastic elastomer is a block copolymer. In some
aspects, the thermoplastic elastomer is a segmented copolymer. In
further aspects, the thermoplastic elastomer is a random copolymer.
In still further aspects, the thermoplastic elastomer is a
condensation copolymer.
[0306] In a further aspect, the thermoplastic elastomer can have a
weight average molecular weight of about 50,000 Daltons to about
1,000,000 Daltons; about 50,000 Daltons to about 500,000 Daltons;
about 75,000 Daltons to about 300,000 Daltons; about 100,000
Daltons to about 200,000 Daltons.
[0307] In a further aspect, the thermoplastic elastomer can have a
ratio of first segments to second segments from about 1:1 to about
1:2 based on the weight of each of the first segments and the
second segments; or of about 1:1 to about 1:1.5 based on the weight
of each of the first segments and the second segments.
[0308] In a further aspect, the thermoplastic elastomer can have a
ratio of first segments to third segments from about 1:1 to about
1:5 based on the weight of each of the first segments and the third
segments; about 1:1 to about 1:3 based on the weight of each of the
first segments and the third segments; about 1:1 to about 1:2 based
on the weight of each of the first segments and the third segments;
about 1:1 to about 1:3 based on the weight of each of the first
segments and the third segments.
[0309] In a further aspect, the thermoplastic elastomer can have
first segments derived from a first component having a
number-average molecular weight of about 250 Daltons to about 6000
Daltons; about 400 Daltons to about 6,000 Daltons; about 350
Daltons to about 5,000 Daltons; or about 500 Daltons to about 3,000
Daltons.
[0310] In some aspects, the thermoplastic elastomer can comprise
phase separated domains. For example, a plurality of first segments
can phase-separate into domains comprising primarily the first
segments. Moreover, a plurality of second segments derived from
segments having a different chemical structure can phase-separate
into domains comprising primarily the second segments. In some
aspects, the first segments can comprise hard segments, and the
second segments can comprise soft segments. In other aspects, the
thermoplastic elastomer can comprise phase-separated domains
comprising a plurality of first copolyester units.
[0311] In one aspect, prior to thermoforming, the first polymeric
composition has a glass transition temperature glass transition
temperature of from about 20 degrees Celsius to about -60 degrees
Celsius. In one aspect, prior to thermoforming, the first polymeric
composition has a Taber Abrasion Resistance of from about 10
milligrams to about 40 milligrams as determined by ASTM D3389. In
one aspect, prior to thermoforming, the first polymeric composition
has a Durometer Hardness (Shore A) of from about 60 to about 90 as
determined by ASTM D2240. In one aspect, prior to thermoforming,
the first polymeric composition has a specific gravity of from
about 0.80 g/cm.sup.3 to about 1.30 g/cm.sup.3 as determined by
ASTM D792. In one aspect, prior to thermoforming, the first
polymeric composition has a melt flow index of about 2 grams/10
minutes to about 50 grams/10 minutes at 160 degrees Celsius using a
test weight of 2.16 kilograms. In one aspect, prior to
thermoforming, the first polymeric composition has a melt flow rate
greater than about 2 grams/10 minutes at 190 degrees Celsius or 200
degrees Celsius when using a test weight of 10 kilograms. In one
aspect, prior to thermoforming, the first polymeric composition has
a modulus of about 1 megapascal to about 500 megapascals.
Thermoplastic Polyurethane Elastomers
[0312] In certain aspects, the thermoplastic elastomer is a
thermoplastic polyurethane elastomer. The thermoplastic
polyurethane elastomer can be a thermoplastic block polyurethane
co-polymer. The thermoplastic polyurethane co-polymer can be a
copolymer comprising hard segments and soft segments, including
blocks of hard segments and blocks of soft segments. The hard
segments can comprise or consist of isocyanate segments. In the
same or alternative aspects, the soft segments can comprise or
consist of polyether segments, or polyester segments, or a
combination of polyether segments and polyester segments. In one
aspect, the thermoplastic material, or the polymeric component of
the thermoplastic material, can comprise or consist essentially of
an elastomeric thermoplastic polyurethane hard segments and soft
segments, such as an elastomeric thermoplastic polyurethane having
repeating blocks of hard segments and repeating blocks of soft
segments.
[0313] In aspects, one or more of the thermoplastic polyurethane
elastomer can be produced by polymerizing one or more isocyanates
with one or more polyols to produce copolymer chains having
carbamate linkages (--N(CO)O--) as illustrated below in Formula 1,
where the isocyanate(s) each preferably include two or more
isocyanate (--NCO) groups per molecule, such as 2, 3, or 4
isocyanate groups per molecule (although, single-functional
isocyanates can also be optionally included, e.g., as chain
terminating units).
##STR00001##
In these embodiments, each R.sub.1 and R.sub.2 independently is an
aliphatic or aromatic segment. Optionally, each R.sub.2 can be a
hydrophilic segment.
[0314] Unless otherwise indicated, any of the functional groups or
chemical compounds described herein can be substituted or
unsubstituted. A "substituted" group or chemical compound, such as
an alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl,
heteroaryl, alkoxyl, ester, ether, or carboxylic ester refers to an
alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl,
heteroaryl, alkoxyl, ester, ether, or carboxylic ester group, has
at least one hydrogen radical that is substituted with a
non-hydrogen radical (i.e., a substituent). Examples of
non-hydrogen radicals (or substituents) include, but are not
limited to, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl,
ether, aryl, heteroaryl, heterocycloalkyl, hydroxyl, oxy (or oxo),
alkoxyl, ester, thioester, acyl, carboxyl, cyano, nitro, amino,
amido, sulfur, and halo. When a substituted alkyl group includes
more than one non-hydrogen radical, the substituents can be bound
to the same carbon or two or more different carbon atoms.
[0315] Additionally, the isocyanates can also be chain extended
with one or more chain extenders to bridge two or more isocyanates.
This can produce polyurethane copolymer chains as illustrated below
in Formula 2, wherein R.sub.3 includes the chain extender. As with
each R.sub.1 and R.sub.3, each R.sub.3 independently is an
aliphatic or aromatic segment.
##STR00002##
[0316] Each segment R.sub.1, or the first segment, in Formulas 1
and 2 can independently include a linear or branched C.sub.3-30
segment, based on the particular isocyanate(s) used, and can be
aliphatic, aromatic, or include a combination of aliphatic
portions(s) and aromatic portion(s). The term "aliphatic" refers to
a saturated or unsaturated organic molecule that does not include a
cyclically conjugated ring system having delocalized pi electrons.
In comparison, the term "aromatic" refers to a cyclically
conjugated ring system having delocalized pi electrons, which
exhibits greater stability than a hypothetical ring system having
localized pi electrons.
[0317] Each segment R.sub.1 can be present in an amount of 5
percent to 85 percent by weight, from 5 percent to 70 percent by
weight, or from 10 percent to 50 percent by weight, based on the
total weight of the reactant monomers.
[0318] In aliphatic embodiments (from aliphatic isocyanate(s)),
each segment R.sub.1 can include a linear aliphatic group, a
branched aliphatic group, a cycloaliphatic group, or combinations
thereof. For instance, each segment R.sub.1 can include a linear or
branched C.sub.3-20 alkylene segment (e.g., C.sub.4-15 alkylene or
C.sub.6-10 alkylene), one or more C.sub.3-8 cycloalkylene segments
(e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl,
cycloheptyl, or cyclooctyl), and combinations thereof.
[0319] Examples of suitable aliphatic diisocyanates for producing
the polyurethane copolymer chains include hexamethylene
diisocyanate (HDI), isophorone diisocyanate (IPDI),
butylenediisocyanate (BDI), bisisocyanatocyclohexylmethane (HMDI),
2,2,4-trimethylhexamethylene diisocyanate (TMDI),
bisisocyanatomethylcyclohexane, bisisocyanatomethyltricyclodecane,
norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI),
4,4'-dicyclohexylmethane diisocyanate (H12MDI),
diisocyanatododecane, lysine diisocyanate, and combinations
thereof.
[0320] In aromatic embodiments (from aromatic isocyanate(s)), each
segment R.sub.1 can include one or more aromatic groups, such as
phenyl, naphthyl, tetrahydronaphthyl, phenanthrenyl, biphenylenyl,
indanyl, indenyl, anthracenyl, and fluorenyl. Unless otherwise
indicated, an aromatic group can be an unsubstituted aromatic group
or a substituted aromatic group, and can also include
heteroaromatic groups. "Heteroaromatic" refers to monocyclic or
polycyclic (e.g., fused bicyclic and fused tricyclic) aromatic ring
systems, where one to four ring atoms are selected from oxygen,
nitrogen, or sulfur, and the remaining ring atoms are carbon, and
where the ring system is joined to the remainder of the molecule by
any of the ring atoms. Examples of suitable heteroaryl groups
include pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl,
imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isooxazolyl,
thiadiazolyl, oxadiazolyl, furanyl, quinolinyl, isoquinolinyl,
benzoxazolyl, benzimidazolyl, and benzothiazolyl.
[0321] Examples of suitable aromatic diisocyanates for producing
the polyurethane copolymer chains include toluene diisocyanate
(TDI), TDI adducts with trimethyloylpropane (TMP), methylene
diphenyl diisocyanate (MDI), xylene diisocyanate (XDI),
tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene
diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI),
1,5-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate
(PPDI), 3,3'-dimethyldiphenyl-4, 4'-diisocyanate (DDDI),
4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene
diisocyanate, and combinations thereof. In some embodiments, the
copolymer chains are substantially free of aromatic groups.
[0322] In particular aspects, the polyurethane copolymer chains are
produced from diisocyanates including HMDI, TDI, MDI, H.sub.12
aliphatics, and combinations thereof. For example, the coated fiber
as described herein of the present disclosure can comprise one or
more polyurethane copolymer chains are produced from diisocynates
including HMDI, TDI, MDI, H.sub.12 aliphatics, and combinations
thereof.
[0323] In certain aspects, polyurethane chains which are
crosslinked (e.g., partially crosslinked polyurethane copolymers
which retain thermoplastic properties) or which can be crosslinked,
can be used in accordance with the present disclosure. It is
possible to produce crosslinked or crosslinkable polyurethane
copolymer chains using multi-functional isocyanates. Examples of
suitable triisocyanates for producing the polyurethane copolymer
chains include TDI, HDI, and IPDI adducts with trimethyloylpropane
(TMP), uretdiones (i.e., dimerized isocyanates), polymeric MDI, and
combinations thereof.
[0324] Segment R.sub.3 in Formula 2 can include a linear or
branched C.sub.2-C.sub.10 segment, based on the particular chain
extender polyol used, and can be, for example, aliphatic, aromatic,
or polyether. Examples of suitable chain extender polyols for
producing the polyurethane copolymer chains include ethylene
glycol, lower oligomers of ethylene glycol (e.g., diethylene
glycol, triethylene glycol, and tetraethylene glycol),
1,2-propylene glycol, 1,3-propylene glycol, lower oligomers of
propylene glycol (e.g., dipropylene glycol, tripropylene glycol,
and tetrapropylene glycol), 1,4-butylene glycol, 2,3-butylene
glycol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol,
1,4-cyclohexanedimethanol, 2-ethyl-1,6-hexanediol,
1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol,
dihydroxyalkylated aromatic compounds (e.g., bis(2-hydroxyethyl)
ethers of hydroquinone and resorcinol,
xylene-.alpha.,.alpha.-diols, bis(2-hydroxyethyl) ethers of
xylene-.alpha.,.alpha.-diols, and combinations thereof.
[0325] Segment R.sub.2 in Formula 1 and 2 can include a polyether
group, a polyester group, a polycarbonate group, an aliphatic
group, or an aromatic group. Each segment R.sub.2 can be present in
an amount of 5 percent to 85 percent by weight, from 5 percent to
70 percent by weight, or from 10 percent to 50 percent by weight,
based on the total weight of the reactant monomers.
[0326] Optionally, in some examples, the thermoplastic polyurethane
elastomer can be a thermoplastic polyurethane having relatively
high degree of hydrophilicity. For example, the thermoplastic
polyurethane can be a thermoplastic polyether polyurethane in which
segment R.sub.2 in Formulas 1 and 2 includes a polyether group, a
polyester group, a polycarbonate group, an aliphatic group, or an
aromatic group, wherein the aliphatic group or aromatic group is
substituted with one or more pendant group having relatively
greater degree of hydrophilicity (i.e., relatively "hydrophilic"
groups). The relatively "hydrophilic" groups can be selected from
the group consisting of hydroxyl, polyether, polyester, polylactone
(e.g., polyvinylpyrrolidone (PVP)), amino, carboxylate, sulfonate,
phosphate, ammonium (e.g., tertiary and quaternary ammonium),
zwitterion (e.g., a betaine, such as poly(carboxybetaine (pCB) and
ammonium phosphonates such as phosphatidylcholine), and
combinations thereof. In such examples, this relatively hydrophilic
group or segment of R.sub.2 can form portions of the polyurethane
backbone, or can be grafted to the polyurethane backbone as a
pendant group. In some examples, the pendant hydrophilic group or
segment can be bonded to the aliphatic group or aromatic group
through a linker. Each segment R.sub.2 can be present in an amount
of 5 percent to 85 percent by weight, from 5 percent to 70 percent
by weight, or from 10 percent to 50 percent by weight, based on the
total weight of the reactant monomers.
[0327] In some examples, at least one R.sub.2 segment of the
thermoplastic polyurethane elastomer includes a polyether segment
(i.e., a segment having one or more ether groups). Suitable
polyethers include, but are not limited to polyethylene oxide
(PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF),
polytetramethylene oxide (P T.sub.mO), and combinations thereof.
The term "alkyl" as used herein refers to straight chained and
branched saturated hydrocarbon groups containing one to thirty
carbon atoms, for example, one to twenty carbon atoms, or one to
ten carbon atoms. The term C, means the alkyl group has "n" carbon
atoms. For example, C.sub.4 alkyl refers to an alkyl group that has
4 carbon atoms. C.sub.1-7 alkyl refers to an alkyl group having a
number of carbon atoms encompassing the entire range (i.e., 1 to 7
carbon atoms), as well as all subgroups (e.g., 1-6, 2-7, 1-5, 3-6,
1, 2, 3, 4, 5, 6, and 7 carbon atoms). Non-limiting examples of
alkyl groups include, methyl, ethyl, n-propyl, isopropyl, n-butyl,
sec-butyl (2-methylpropyl), t-butyl (1,1-dimethylethyl),
3,3-dimethylpentyl, and 2-ethylhexyl. Unless otherwise indicated,
an alkyl group can be an unsubstituted alkyl group or a substituted
alkyl group.
[0328] In some examples of the thermoplastic polyurethane
elastomer, the at least one R.sub.2 segment includes a polyester
segment. The polyester segment can be derived from the
polyesterification of one or more dihydric alcohols (e.g., ethylene
glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butanediol,
1,3-butanediol, 2-methylpentanediol-1,5,diethylene
glycol,1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol,
cyclohexanedimethanol, and combinations thereof) with one or more
dicarboxylic acids (e.g., adipic acid, succinic acid, sebacic acid,
suberic acid, methyladipic acid, glutaric acid, pimelic acid,
azelaic acid, thiodipropionic acid and citraconic acid and
combinations thereof). The polyester also can be derived from
polycarbonate prepolymers, such as poly(hexamethylene carbonate)
glycol, poly(propylene carbonate) glycol, poly(tetramethylene
carbonate)glycol, and poly(nonanemethylene carbonate) glycol.
Suitable polyesters can include, for example, polyethylene adipate
(PEA), poly(1,4-butylene adipate), poly(tetramethylene adipate),
poly(hexamethylene adipate), polycaprolactone, polyhexamethylene
carbonate, poly(propylene carbonate), poly(tetramethylene
carbonate), poly(nonanemethylene carbonate), and combinations
thereof.
[0329] In various of the thermoplastic polyurethane elastomer, at
least one R.sub.2 segment includes a polycarbonate segment. The
polycarbonate segment can be derived from the reaction of one or
more dihydric alcohols (e.g., ethylene glycol, 1,3-propylene
glycol, 1,2-propylene glycol, 1,4-butanediol, 1,3-butanediol,
2-methylpentanediol-1,5, diethylene glycol, 1,5-pentanediol,
1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, and
combinations thereof) with ethylene carbonate.
[0330] In various examples of the thermoplastic polyurethane
elastomer, at least one R.sub.2 segment can include an aliphatic
group substituted with one or more groups having a relatively
greater degree of hydrophilicity, i.e., a relatively "hydrophilic"
group. The one or more relatively hydrophilic group can be selected
from the group consisting of hydroxyl, polyether, polyester,
polylactone (e.g., polyvinylpyrrolidone), amino, carboxylate,
sulfonate, phosphate, ammonium (e.g., tertiary and quaternary
ammonium), zwitterion (e.g., a betaine, such as poly(carboxybetaine
(pCB) and ammonium phosphonates such as phosphatidylcholine), and
combinations thereof. In some examples, the aliphatic group is
linear and can include, for example, a C.sub.1-20 alkylene chain or
a C.sub.1-20 alkenylene chain (e.g., methylene, ethylene,
propylene, butylene, pentylene, hexylene, heptylene, octylene,
nonylene, decylene, undecylene, dodecylene, tridecylene,
ethenylene, propenylene, butenylene, pentenylene, hexenylene,
heptenylene, octenylene, nonenylene, decenylene, undecenylene,
dodecenylene, tridecenylene). The term "alkylene" refers to a
bivalent hydrocarbon. The term C.sub.n means the alkylene group has
"n" carbon atoms. For example, C.sub.1-6 alkylene refers to an
alkylene group having, e.g., 1, 2, 3, 4, 5, or 6 carbon atoms. The
term "alkenylene" refers to a bivalent hydrocarbon having at least
one double bond.
[0331] In some cases, at least one R.sub.2 segment includes an
aromatic group substituted with one or more relatively hydrophilic
group. The one or more hydrophilic group can be selected from the
group consisting of hydroxyl, polyether, polyester, polylactone
(e.g., polyvinylpyrrolidone), amino, carboxylate, sulfonate,
phosphate, ammonium (e.g., tertiary and quaternary ammonium),
zwitterionic (e.g., a betaine, such as poly(carboxybetaine (pCB)
and ammonium phosphonate groups such as phosphatidylcholine), and
combinations thereof. Suitable aromatic groups include, but are not
limited to, phenyl, naphthyl, tetrahydronaphthyl, phenanthrenyl,
biphenylenyl, indanyl, indenyl, anthracenyl, fluorenylpyridyl,
pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl,
tetrazolyl, oxazolyl, isooxazolyl, thiadiazolyl, oxadiazolyl,
furanyl, quinolinyl, isoquinolinyl, benzoxazolyl, benzimidazolyl,
and benzothiazolyl groups, and combinations thereof.
[0332] In various aspects, the aliphatic and aromatic groups can be
substituted with one or more pendant relatively hydrophilic and/or
charged groups. In some aspects, the pendant hydrophilic group
includes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more)
hydroxyl groups. In various aspects, the pendant hydrophilic group
includes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more)
amino groups. In some cases, the pendant hydrophilic group includes
one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) carboxylate
groups. For example, the aliphatic group can include one or more
polyacrylic acid group. In some cases, the pendant hydrophilic
group includes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or
more) sulfonate groups. In some cases, the pendant hydrophilic
group includes one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or
more) phosphate groups. In some examples, the pendant hydrophilic
group includes one or more ammonium groups (e.g., tertiary and/or
quaternary ammonium). In other examples, the pendant hydrophilic
group includes one or more zwitterionic groups (e.g., a betaine,
such as poly(carboxybetaine (pCB) and ammonium phosphonate groups
such as a phosphatidylcholine group).
[0333] In some aspects, the R.sub.2 segment can include charged
groups that are capable of binding to a counterion to ionically
crosslink the thermoplastic elastomer and form ionomers. In these
aspects, for example, R.sub.2 is an aliphatic or aromatic group
having pendant amino, carboxylate, sulfonate, phosphate, ammonium,
or zwitterionic groups, or combinations thereof.
[0334] In various cases when a pendant hydrophilic group is
present, the pendant "hydrophilic" group is at least one polyether
group, such as two polyether groups. In other cases, the pendant
hydrophilic group is at least one polyester. In various cases, the
pendant hydrophilic group is polylactone group (e.g.,
polyvinylpyrrolidone). Each carbon atom of the pendant hydrophilic
group can optionally be substituted with, e.g., a C.sub.1-6 alkyl
group. In some of these aspects, the aliphatic and aromatic groups
can be graft polymeric groups, wherein the pendant groups are
homopolymeric groups (e.g., polyether groups, polyester groups,
polyvinylpyrrolidone groups).
[0335] In some aspects, the pendant hydrophilic group is a
polyether group (e.g., a polyethylene oxide group, a polyethylene
glycol group), a polyvinylpyrrolidone group, a polyacrylic acid
group, or combinations thereof.
[0336] As described herein, the thermoplastic polyurethane
elastomer can be physically crosslinked through e.g., nonpolar or
polar interactions between the urethane or carbamate groups on the
polymers (the hard segments. In these aspects, component R.sub.1 in
Formula 1, and components R.sub.1 and R.sub.3 in Formula 2, forms
the portion of the polymer often referred to as the "hard segment",
and component R.sub.2 forms the portion of the polymer often
referred to as the "soft segment". In these aspects, the soft
segment can be covalently bonded to the hard segment. In some
examples, the thermoplastic polyurethane elastomer having
physically crosslinked hard and soft segments can be a hydrophilic
thermoplastic polyurethane elastomer (i.e., a thermoplastic
polyurethane elastomer including hydrophilic groups as disclosed
herein).
[0337] In one aspect, prior to thermoforming, the thermoplastic
polyurethane elastomer is an aromatic polyester thermoplastic
elastomeric polyurethane or an aliphatic polyester thermoplastic
elastomeric polyurethane having the following properties: (1) a
glass transition temperature glass transition temperature of from
about 20 degrees Celsius to about -60 degrees Celsius; (2) a Taber
Abrasion Resistance of from about 10 milligrams to about 40
milligrams as determined by ASTM D3389; (3) a Durometer Hardness
(Shore A) of from about 60 to about 90 as determined by ASTM D2240;
(4) a specific gravity of from about 0.80 g/cm.sup.3 to about 1.30
g/cm.sup.3 as determined by ASTM D792; (5) a melt flow index of
about 2 grams/10 minutes to about 50 grams/10 minutes at 160
degrees Celsius using a test weight of 2.16 kilograms; (6) a melt
flow rate greater than about 2 grams/10 minutes at 190 degrees
Celsius or 200 degrees Celsius when using a test weight of 10
kilograms; and (7) a modulus of about 1 megapascal to about 500
megapascals.
[0338] Commercially available thermoplastic polyurethane elastomers
having greater hydrophilicity suitable for the present use include,
but are not limited to those under the tradename "TECOPHILIC", such
as TG-500, TG-2000, SP-80A-150, SP-93A-100, SP-60D-60 (Lubrizol,
Countryside, Ill.), "ESTANE" (e.g., 58238, T470A; Lubrizol,
Countryside, Ill.), and "ELASTOLLAN" (e.g., 9339, B70A; BASF).
[0339] In various aspects, the thermoplastic polyurethane elastomer
can be partially covalently crosslinked, as previously described
herein.
Thermoplastic Styrenic Copolymer Elastomers
[0340] In certain aspects, the thermoplastic elastomer is a
thermoplastic elastomeric styrenic copolymer. Examples of these
copolymers include, but are not limited to, styrene butadiene
styrene (SBS) block copolymer, a styrene ethylene/butylene styrene
(SEBS) resin, a polyacetal resin (POM) a styrene acrylonitrile
resin (SAN), or a blend, alloy, or compound thereof. Exemplary
commercially available thermoplastic elastomeric styrenic
copolymers include MONOPRENE IN5074, SP066070, and SP16975 (Teknor
Apex, Pawtucket, R.I., USA), which are styrene ethylene/butylene
styrene (SEBS) resins. In some aspects, blends, alloys, and
compounds should be melt compatible or can be compatibilized with
additives, oils, or grafted chemical moieties in order to achieve
miscibility.
[0341] In one aspect, the thermoplastic elastomeric styrenic
copolymer includes at least one block as illustrated below in
Formula 3:
##STR00003##
[0342] In another aspect, the thermoplastic elastomeric styrenic
copolymer can be a SBS block copolymer comprising a first
polystyrene block (block m of Formula 4), a polybutadiene block
(block o of Formula 4), and a second polystyrene block (block p of
Formula 4), wherein the SBS block copolymer has the general
structure shown in Formula 4 below:
##STR00004##
[0343] In another aspect, the thermoplastic elastomeric styrenic
copolymer can be an SEBS block copolymer comprising a first
polystyrene block (block x of Formula 5), a polyolefin block
(blocky of Formula 5), wherein the polyolefin block comprises
alternating polyethylene blocks (block v of Formula 5) and
polybutylene blocks (block w of Formula 4), and a second
polystyrene block (block z of Formula 5) as seen in Formula 5
below.
##STR00005##
[0344] In one aspect, SEBS polymers have a density from about 0.88
grams per cubic centimeter to about 0.92 grams per cubic
centimeter. In a further aspect, SEBS polymers can be as much as 15
to 25 percent less dense than cross-linked rubbers, cross-linked
polyurethanes, and thermoplastic polyurethane materials. In a
further aspect, a less dense coating composition offers weight
savings and per part cost savings for the same material of volume
employed while achieving similar performance.
Additives
[0345] In some aspects, the films, fibers, and yarns described
herein can further comprise an additive. The additive can be
incorporated directly into the films, fibers, and yarns, or
alternatively, applied thereto. Additives that can be used include,
but are not limited to, dyes, pigments, colorants, ultraviolet
light absorbers, hindered amine light stabilizers, antioxidants,
processing aids or agents, plasticizers, lubricants, emulsifiers,
pigments, dyes, optical brighteners, rheology additives, catalysts,
heat stabilizers, flow-control agents, slip agents, lubricating
agents, crosslinking agents, crosslinking boosters, halogen
scavengers, smoke inhibitors, flameproofing agents, antistatic
agents, fillers, or mixtures of two or more of the foregoing. When
used, an additive can be present in an amount of from about 0.01
weight percent to about 10 weight percent, about 0.025 weight
percent to about 5 weight percent, or about 0.1 weight percent to 3
weight percent, where the weight percent is based upon the sum of
the material components in the film, fiber, filament or yarn.
[0346] Individual components can be mixed together with the other
components of the thermoplastic elastomer(s) in a continuous mixer
or a batch mixer, e.g., in an intermeshing rotor mixer, such as an
Intermix mixer, a twin screw extruder, in a tangential rotor mixer
such as a Banbury mixer, using a two-roll mill, or some
combinations of these to make a composition comprising a
thermoplastic polymer and an additive. The mixer can blend the
components together via a single step or multiple steps, and can
mix the components via dispersive mixing or distributive mixing to
form the resulting thermoplastic composition. This step is often
referred to as "compounding."
[0347] All technical and scientific terms used herein, unless
defined otherwise, have the same meaning as commonly understood by
one of ordinary skill in the art to which this disclosure belongs.
It will be further understood that terms, such as those defined in
commonly used dictionaries, should be interpreted as having a
meaning that is consistent with their meaning in the context of the
specification and relevant art and should not be interpreted in an
idealized or overly formal sense unless expressly defined
herein.
[0348] The terms "comprises," "comprising," "including," and
"having," are inclusive and therefore specify the presence of
features, steps, operations, elements, and/or components, but do
not preclude the presence or addition of one or more other
features, steps, operations, elements, components, and/or groups
thereof.
[0349] As used in the specification and the appended claims, the
singular forms "a," "an" and "the" include plural referents unless
the context clearly dictates otherwise. Thus, for example,
reference to "a coated fiber," "an uncoated fiber," or "a knit
upper," including, but not limited to, two or more such coated
fibers.
[0350] As used herein, the term "and/or" includes any and all
combinations of one or more of the associated listed items.
[0351] The terms first, second, third, etc. can be used herein to
describe various elements, components, regions, layers and/or
sections. These elements, components, regions, layers and/or
sections should not be limited by these terms. These terms can be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms do not imply a
sequence or order unless clearly indicated by the context. Thus, a
first element, component, region, layer or section discussed below
could be termed a second element, component, region, layer or
section without departing from the teachings of the example
configurations.
[0352] As used herein, the modifiers "upper," "lower," "top,"
"bottom," "upward," "downward," "vertical," "horizontal,"
"longitudinal," "transverse," "front," "back" etc., unless
otherwise defined or made clear from the disclosure, are relative
terms meant to place the various structures or orientations of the
structures of the article of footwear in the context of an article
of footwear worn by a user standing on a flat, horizontal
surface.
[0353] It should be noted that ratios, concentrations, amounts, and
other numerical data can be expressed herein in a range format.
Where the stated range includes one or both of the limits, ranges
excluding either or both of those included limits are also included
in the disclosure, e.g. the phrase "x to y" includes the range from
`x` to `y` as well as the range greater than `x` and less than `y`.
The range can also be expressed as an upper limit, e.g. `about x,
y, z, or less` and should be interpreted to include the specific
ranges of `about x`, `about y`, and `about z` as well as the ranges
of `less than x`, less than y', and `less than z`. Likewise, the
phrase `about x, y, z, or greater` should be interpreted to include
the specific ranges of `about x`, `about y`, and `about z` as well
as the ranges of `greater than x`, greater than y', and `greater
than z`. In addition, the phrase "about `x` to `y`", where `x` and
`y` are numerical values, includes "about `x` to about `y`". It is
to be understood that such a range format is used for convenience
and brevity, and thus, should be interpreted in a flexible manner
to include not only the numerical values explicitly recited as the
limits of the range, but also to include all the individual
numerical values or sub-ranges encompassed within that range as if
each numerical value and sub-range is explicitly recited. To
illustrate, a numerical range of "about 0.1 percent to 5 percent"
should be interpreted to include not only the explicitly recited
values of about 0.1 percent to about 5 percent, but also include
individual values (e.g., 1 percent, 2 percent, 3 percent, and 4
percent) and the sub-ranges (e.g., 0.5 percent, 1.1 percent, 2.4
percent, 3.2 percent, and 4.4 percent) within the indicated
range.
[0354] As used herein, the terms "about," "approximate," "at or
about," and "substantially" mean that the amount or value in
question can be the exact value or a value that provides equivalent
results or effects as recited in the claims or taught herein. That
is, it is understood that amounts, sizes, formulations, parameters,
and other quantities and characteristics are not and need not be
exact, but can be approximate and/or larger or smaller, as desired,
reflecting tolerances, conversion factors, rounding off,
measurement error and the like, and other factors known to those of
skill in the art such that equivalent results or effects are
obtained. In some circumstances, the value that provides equivalent
results or effects cannot be reasonably determined. In such cases,
it is generally understood, as used herein, that "about" and "at or
about" mean the nominal value indicated .+-.10 percent variation
unless otherwise indicated or inferred. In general, an amount,
size, formulation, parameter or other quantity or characteristic is
"about," "approximate," or "at or about" whether or not expressly
stated to be such. It is understood that where "about,"
"approximate," or "at or about" is used before a quantitative
value, the parameter also includes the specific quantitative value
itself, unless specifically stated otherwise.
[0355] Reference to "a" chemical compound" refers to one or more
molecules of the chemical compound, rather than being limited to a
single molecule of the chemical compound. Furthermore, the one or
more molecules can or cannot be identical, so long as they fall
under the category of the chemical compound. Thus, for example, "a
polyamide" is interpreted to include one or more polymer molecules
of the polyamide, where the polymer molecules can or cannot be
identical (e.g., different molecular weights and/or isomers).
[0356] The terms "at least one" and "one or more of" an element are
used interchangeably, and have the same meaning that includes a
single element and a plurality of the elements, and can also be
represented by the suffix "(s)" at the end of the element. For
example, "at least one polyamide", "one or more polyamides", and
"polyamide(s)" can be used interchangeably and have the same
meaning.
[0357] As used herein, the terms "optional" or "optionally" means
that the subsequently described component, event or circumstance
can or cannot occur, and that the description includes instances
where said component, event or circumstance occurs and instances
where it does not.
[0358] The term "receiving", such as for "receiving an upper for an
article of footwear", when recited in the claims, is not intended
to require any particular delivery or receipt of the received item.
Rather, the term "receiving" is merely used to recite items that
will be referred to in subsequent elements of the claim(s), for
purposes of clarity and ease of readability.
[0359] As used herein the terms "weight percent" and "wt percent,"
which can be used interchangeably, indicate the percent by weight
of a given component based on the total weight of the composition,
unless otherwise specified. That is, unless otherwise specified,
all wt percent values are based on the total weight of the
composition. It should be understood that the sum of wt percent
values for all components in a disclosed composition or formulation
are equal to 100.
[0360] Compounds are described using standard nomenclature. For
example, any position not substituted by any indicated group is
understood to have its valence filled by a bond as indicated, or a
hydrogen atom. A dash ("-") that is not between two letters or
symbols is used to indicate a point of attachment for a
substituent. For example, --CHO is attached through carbon of the
carbonyl group. Unless defined otherwise, technical and scientific
terms used herein have the same meaning as is commonly understood
by one of skill in the art to which this invention belongs.
[0361] Unless otherwise specified, temperatures referred to herein
are determined at standard atmospheric pressure (i.e., 1 ATM).
Property Analysis and Characterization Procedures
[0362] Evaluation of various properties and characteristics
described herein are by various testing procedures as described
herein below.
[0363] Sample Coefficient of Friction. The static or dynamic
coefficient of friction (COF) of a textile or plaque sample is
determined using test method ASTM D1894. In this method, a sample
is cut to size and mounted on the sled, and a 100 gram weight plate
is placed on the sled. During the test, the weighted sled is pulled
across a test surface of the material being tested. For example,
static and dynamic wet and dry COF can be determined by pulling the
sled across a concrete surface to determine the COF of the sample
and concrete. The coefficient of friction of the sample against
that surface is captured by recording the normal force (100 grams
plus sled weight) and measuring the applied force required to drag
the sled across the test surface. The coefficient of friction (COF)
is then calculated from the ratio of the two forces. Dry COF is
determined by testing a dry sample against a dry testing surface,
and wet COF is determined by testing a sample wetted with water by
soaking it in room temperature water for 10 minutes against a test
surface wetted with room temperature water.
[0364] Textile-Ball Coefficient of Friction Test. The static and
dynamic coefficient of friction (COF) of a sample prepared using
the Component Sampling Procedure or the Textile Sampling Procedure
described below against a sample from a panel of a "MERLIN" soccer
ball (Nike Inc., Beaverton, Oreg., USA) is determined using a
modified version of test method ASTM D1894. In this method, the
sample is cut to size and mounted on an acrylic substrate, and the
ball material is cut to size and mounted on the sled. Once the ball
material has been mounted on the sled, the sled has a contact
footprint of 3.9 inches by 1 inch, and a weight of approximately
1.7 kilograms. During the test, the sample and ball material are
positioned with the outer surface of the ball material contacting
the surface of the sample which is intended form the outer surface
of an article of footwear, and the sled is pulled across the
sample. Dry samples and dry ball material are used to determine the
static or dynamic dry COF. To determine the static or dynamic wet
COF, the sample and the ball material are both soaked in room
temperature water for 10 minutes immediately prior to testing. Each
measurement is repeated at least 3 times, and the results of the
runs are averaged.
[0365] Whole Footwear Coefficient of Friction Test. Testing on
whole articles of footwear to determine the outsole's COF is
performed using the SATRA TM144 test method, which forms the basis
for the EN ISO 13287 and ASTM F2913-11 test methods. Testing is
conducted on whole articles of footwear, i.e., an upper attached to
a sole structure including the outsole to be tested. The whole
article of footwear can either be a new, unworn article of
footwear, or can be an article of footwear which has been
mechanically abraded in accordance with the Whole Footwear Abrasion
Test. Each article of footwear to be tested is aged 24 hours in the
test lab prior to performing testing. This test is run using heel
and forefoot substrate contact modes to generate coefficient of
friction data. Each article of footwear can be tested on one of two
surfaces in wet and dry conditions: (1) quarry tile, and (2) smooth
concrete. Footwear tested using the Whole Footwear Coefficient of
Friction Test when new can subsequently be subjected to abrasion
using the Whole Footwear Abrasion Test and then re-tested using the
Whole Footwear Coefficient of Friction Test to simulate the
traction and slip resistance of the footwear on surfaces after the
equivalent of many days or miles worth of simulated wear.
Coefficient of friction is calculated from the applied force to
laterally translate the outsole of the shoe across the substrate
divided by the applied normal force loaded on the sample as
specified in the test method.
[0366] Whole Footwear Abrasion Test. Biomechanical abrasion testing
is performed on outsoles of whole articles of footwear using the
SATRA TM362 testing method. In this test, a walking action over a
real wear surface is simulated. Sample footwear is mounted on a
mechanical leg and a flooring mechanism rotates to simulate turns
during walking with the forepart of the sole in contact with the
walking surface. The force applied by the footwear on the sample
flooring surface follows a distinct profile that can be adjusted by
adding or subtracting weights. A standard load of 180 pounds is
used, and the speed can be adjusted to replicate normal walking,
running, and/or sprinting. The walking surface is a textured
concrete slab. Samples are conditioned for 24 hours in a climate
controlled lab and inserted into the machine. Each sample is tested
for 48 hours of simulated foot strikes, or about 96,000 steps,
which approximates 100 miles of walking. Mass loss is recorded at
24 hours and at 48 hours of testing.
[0367] Melting and Glass Transition Temperature Test. The melting
temperature and/or glass transition temperature are determined for
a sample prepared according to Material Sampling Procedure
described below, using a commercially available Differential
Scanning calorimeter ("DSC") in accordance with ASTM D3418-97.
Briefly, a 10-60 milligram sample is placed into an aluminum DSC
pan and then the lid is sealed with a crimper press. The DSC is
configured to scan from -100 degrees Celsius to 225 degrees Celsius
with a 20 degree Celsius/minute heating rate, hold at 225 degrees
Celsius for 2 minutes, and then cool down to 25 degrees Celsius at
a rate of -20 degrees Celsius/minute. The DSC curve created from
this scan is then analyzed using standard techniques to determine
the glass transition temperature and the melting temperature.
Melting enthalpy is calculated by integrating the melting endotherm
and normalizing by the mass of the sample. Crystallization enthalpy
upon cooling is calculated by integrating the cooling endotherm and
normalizing by the mass of the sample.
[0368] Deformation Temperature Test. The Vicat softening
temperature is determined for a sample prepared according to
Material Sampling Procedure or the Component Sampling Procedure
described below, according to the test method detailed in ASTM Tm
D1525-09 Standard Test Method for Vicat Softening Temperature of
Plastics, preferably using Load A and Rate A. Briefly, the Vicat
softening temperature is the temperature at which a flat-ended
needle penetrates the specimen to the depth of 1 millimeter under a
specific load. The temperature reflects the point of softening
expected when a material is used in an elevated temperature
application. It is taken as the temperature at which the specimen
is penetrated to a depth of 1 millimeter by a flat-ended needle
with a 1 square millimeter2 circular or square cross-section. For
the Vicat A test, a load of 10 Newtons (N) is used, whereas for the
Vicat B test, the load is 50 Newtons. The test involves placing a
test specimen in the testing apparatus so that the penetrating
needle rests on its surface at least 1 millimeter from the edge. A
load is applied to the specimen per the requirements of the Vicat A
or Vicat B test. The specimen is then lowered into an oil bath at
23.degree. C.degrees Celsius. The bath is raised at a rate of 50
degrees Celsius or 120 degrees Celsius per hour until the needle
penetrates 1 millimeter. The test specimen must be between 3 and
6.5 millimeter thick and at least 10 millimeter in width and
length. No more than three layers can be stacked to achieve minimum
thickness.
[0369] Melt Flow Index Test. The melt flow index is determined for
a sample prepared according to the Material Sampling Procedure
described below according to the test method detailed in ASTM
D1238-13 Standard Test Method for Melt Flow Rates of Thermoplastics
by Extrusion Plastometer, using Procedure A described therein.
Briefly, the melt flow index measures the rate of extrusion of
thermoplastics through an orifice at a prescribed temperature and
load. In the test method, approximately 7 grams of the material is
loaded into the barrel of the melt flow apparatus, which has been
heated to a temperature specified for the material. A weight
specified for the material is applied to a plunger and the molten
material is forced through the die. A timed extrudate is collected
and weighed. Melt flow index values are calculated in g/10 min for
a given applied load and applied temperature. As described in ASTM
D1238-13, melt flow index can be determined at 160 degrees Celsius
using a weight of 2.16 kg, or at 200 degrees Celsius using a weight
of 10 kg.
[0370] Molten Polymer Viscosity Test. The test is conducted using 2
millimeter plaques or films prepared according to the Plaque or
Film Sampling Procedure described below. A circular die is used to
cut 50 millimeter specimen discs of from the plaque or film. Test
specimens are mounted on a 50 millimeter diameter aluminum parallel
plate on an ARES-G2 (displacement controlled) rheometer. The top
plate is lowered so that the test specimens are in contact with
both disc surfaces under a defined normal force load and the stage
is heated to 210 degrees Celsius. Samples are equilibrated until
molten, for a defined dwell time of minutes, and oscillatory shear
frequency sweeps are applied at low strain amplitudes to gather
rate-dependent data. The ratio of the applied shear stress required
to generate the oscillatory motion at a given shear frequency rate
yields the measured viscosity value. Shear rate-dependent viscosity
data can be gathered from 0.1 reciprocal seconds to 1000 reciprocal
seconds.
[0371] Plaque Modulus Test. The modulus for sample prepared
according to the Plaque or Film Sampling Procedure described below
is determined according to the test method detailed in ASTM D412-98
Standard Test Methods for Vulcanized Rubber and Thermoplastic
Rubbers and Thermoplastic Elastomers-Tension, with the following
modifications. The sample dimension is the ASTM D412-98 Die C, and
the sample thickness used is 2.0 millimeters plus or minus 0.5
millimeters. The grip type used is a pneumatic grip with a metal
serrated grip face. The grip distance used is 75 millimeters. The
loading rate used is 500 millimeters/minute. The modulus (initial)
is calculated by taking the slope of the stress (MPa) versus the
strain in the initial linear region. This test can also be used to
determine other tensile properties such as break strength, strain
to break, load at 100 percent strain, toughness, stiffness, tear
strength, and the like.
[0372] Yarn Denier and Thickness Test. To determine denier, a
sample of yarn is prepared according to the Yarn Sampling Procedure
described below. A known length of the yarn sample and its
corresponding weight are measured. This is converted to grams per
9000 meters of yarn. To determine the thickness of a coated yarn,
the yarn is first cut with a razor and observed under a microscope,
where coating thickness relative to core yarn diameter is
determined to scale.
[0373] Yarn Modulus, Tenacity, and Elongation Test. The modulus for
a yarn is determined for a sample prepared according to the Yarn
Sampling Procedure described above, and tested according to the
test method detailed in EN ISO 2062 (Textiles-Yarns from
Packages)--Determination of Single-End Breaking Force and
Elongation at Break Using Constant Rate of Extension (CRE) Tester.
The following modifications to the test method are used. 5 test
specimens are prepared with a sample length of 600 millimeters. The
equipment used is an Instron Universal Testing System. Instron
Pneumatic cord and Thread Grips or similar pneumatic grips are
installed, with a grip distance of 250 millimeters. Grip distance
is set to 145+1 millimeter and gauge length is set at 250+2
millimeters when using Instron Pneumatic Cord and Thread Grips. The
pre-loading is set to 5 grams and the loading rate used is 250
millimeters/minute. The modulus (initial) is calculated by taking
the slope of the stress (MPa) versus the strain in the initial
linear region. Maximum tensile force value is recorded. Tenacity
and elongation of the yarn sample are determined according to the
test method detailed in EN ISO 2062 with the pre-load set to 5
grams. Elongation is recorded at the maximum tensile force value
applied prior to breaking. Tenacity can be calculated as the ratio
of load required to break the specimen to the linear density of the
specimen.
[0374] Durometer Hardness Test. The hardness of a material is
determined for a sample prepared according to the Material Sampling
Procedure, the Component Sampling Procedure, the Plaque or Film
Sampling Procedure, or the Textile Sampling Procedure described
below, according to the test method detailed in ASTM D-2240
Durometer Hardness, using a Shore A scale.
[0375] Specific Gravity Test. The specific gravity for a sample
prepared according to the Material Sampling Procedure, the
Component Sampling Procedure, the Plaque or Film Sampling
Procedure, the Yarn Sampling Procedure, or the Textile Sampling
Procedure described below is determined according to the test
method detailed in ASTM D792 using volume displacement.
[0376] Yarn Shrinkage Test. The free-standing shrinkage of yarns
can be determined by the following method. A yarn sample is
prepared according to the Yarn Sampling Procedure described below,
and is cut to a length of approximately 30 millimeters with minimal
tension at approximately room temperature (e.g., 20 degrees
Celsius). The cut sample is placed in a 50 degrees Celsius or 70
degrees Celsius oven for 90 seconds. The sample is removed from the
oven and measured. The percentage of shrink is calculated using the
pre- and post-oven measurements of the sample, by dividing the
post-oven measurement by the pre-oven measurement, and multiplying
by 100.
[0377] Cold Ross Flex Test. The cold Ross flex test is determined
using a sample prepared according to the Plaque or Film Sampling
Procedure described below according the following test method. The
purpose of this test is to evaluate the resistance to cracking of a
sample under repeated flexing to 60 degrees in a cold environment.
The plaque sample is sized to fit inside the flex tester machine.
Each material is tested as five separate samples. The flex tester
machine is capable of flexing samples to 60 degrees at a rate of
100.+-.5 cycles per minute. The mandrel diameter of the machine is
10 millimeters. Suitable machines for this test include the Emerson
AR-6, the Satra S T.sub.m 141 F, the Gotech GT-7006, and the Shin
II Scientific SI-LTCO (DaeSung Scientific). The sample(s) are
inserted into the machine according to the specific parameters of
the flex machine used. The machine is placed in a freezer set to -6
degrees Celsius for the test. The motor is turned on to begin
flexing with the flexing cycles counted until the sample cracks.
Cracking of the sample means that the surface of the material is
physically split. Visible creases of lines that do not actually
penetrate the surface are not cracks. The sample is measured to a
point where it has cracked but not yet broken in two.
[0378] Bally Flex Test. The Bally flex test, which is based on
standard methods including ISO 5402, ISO 32100, SATRA TM55, DIN
53351, and BS-3144, is conducted as follows, using samples prepared
according to the Component Sampling Procedure, the Plaque or Film
Sampling Procedure, or the Textile Sampling Procedure described
below. A minimum of 6 samples are required for this test method.
Samples are 60 millimeters.times.75 millimeters and can be hand cut
or die cut. Each sample is folded and inserted into the testing
equipment such that it protrudes from the bottom clamp a distance
equal to the sample thickness. The folded front edge of the sample
is perpendicular to the base of the testing machine. The samples
are then repeatedly flexed. Samples are visually inspected during
the test period. If a sample has cracked, the approximate number of
cycles when cracking occurred is noted. If this sample is the only
sample being tested on the machine, the test is stopped since the
material has failed. If other samples are being tested, the testing
continues until either all samples have failed or until 100,000
cycles have been completed, whichever occurs first.
[0379] Wet Bally Flex Test. The wet Bally flex test is designed to
assess the ability of a sample textile, film, or other specimen to
resist water penetration from repeated flexing and is conducted as
follows using samples prepared according to the Component Sampling
Procedure, the Plaque or Film Sampling Procedure, or the Textile
Sampling Procedure described below. At a minimum, 4 samples are
required. Specimens are 60 millimeters.times.75 millimeters and can
be hand cut or die cut. 1 gram of sodium chloride is dissolved in 1
liter of distilled water and stirred to create a sodium chloride
solution. The sodium chloride solution is poured into a water tank
and placed into the testing machine. A Gotech GT-7071-DWN
instrument (Gotech Testing Machines, Taichung City, Taiwan) or
similar instrument can be used for analysis. Specimens are folded
into a U shape and clamped into the instrument such that the side
of the specimens to be tested for water penetration faces outward.
The samples are then repeatedly flexed. If a specimen remains
intact through at least 5000 cycles of flexing, it can be
considered "water resistant." If a sample remains intact for at
least 15,000 cycles of flexing, it can be considered "waterproof."
If a specimen leaks, triggering a sensor, before all cycles have
been conducted, the specimen is said to fail.
[0380] Stoll Abrasion Test. Abrasion resistance, including abrasion
resistance simulating footwear upper scuffing, can be measured
using the Stoll abrasion test, using samples prepared according to
the Component Sampling Procedure, the Plaque or Film Sampling
Procedure, or the Textile Sampling Procedure described below. The
minimum number of samples for Stoll abrasion testing is 3. Samples
used herein were hand cut or die cut into circles having a 112
millimeter diameter. The Stoll abrasion test is described more
fully in ASTM D3886 and can be performed on the Atlas Universal
Wear Tester. In the Stoll abrasion test, an abrading medium is
moved over the stationary, mounted test sample and the visual
appearance of the sample is monitored. The Stoll abrasion test is
performed under pressure to simulate wear under normal usage.
[0381] Akron Abrasion Test. Abrasion resistance, including abrasion
resistance simulating footwear sole structure scuffing of
ground-contacting areas can be measured using the Akron abrasion
test, using samples prepared according to the Component Sampling
Procedure, the Plaque or Film Sampling Procedure, or the Textile
Sampling Procedure described below. A sample strip is cut from a
sample, wherein the strip is approximately 2-3 millimeters thick,
0.5 inches (127 millimeters) wide, and 8 inches (2032 millimeters)
long. The strip is mounted to the perimeter of a rubber wheel, and
the wheel is mounted so the strip is pushed against an abrasive
grit surface at a slight angle (approximately 15 degrees) and under
a known force (approximately 6 pounds or 2.72 kilograms). The strip
is run for a number of cycles to prepare the surface, cleaned with
a brush and vacuum, and weighed. The strip is then mounted against
the abrasive wheel and run for about 3000 additional cycles, then
cleaned and weighed again. Mass loss can be adjusted based on the
density of the material. The measured mass and volume losses
represent the abrasion level of resistance.
[0382] DIN Abrasion Test. Samples are prepared according to the
Component Sampling Procedure, the Plaque or Film Sampling
Procedure, or the Textile Sampling Procedure described below
Abrasion loss is tested on cylindrical samples with a diameter of
16.+-.0.2 millimeters and a minimum thickness of 6 millimeters cut
using a ASTM standard hole drill. The abrasion loss is measured
using Method B of ASTM D 5963-97a on a Gotech GT-7012-D abrasion
test machine. The tests are performed as 22 degrees Celsius with an
abrasion path of 40 meters. The Standard Rubber #1 used in the
tests has a density of 1.336 grams per cubic centimeter
(g/cm.sup.3). The smaller the abrasion loss volume, the better the
abrasion resistance.
[0383] Water Penetration Test. Water penetration for a sample is
determined as follows, using for a sample prepared according to the
Component Sampling Procedure, the Plaque or Film Sampling
Procedure, or the Textile Sampling Procedure described below. The
specimen to be tested is mounted on a support base with a surface
at a 45 degree angle to the horizontal. The support base includes a
152 millimeter diameter specimen holder inner ring. A specimen is
allowed to equilibrate in the laboratory environment for at least 2
hours prior to testing. Test specimens are cut into 220 millimeter
diameter circles. Thicker or harder materials such as leather or
stiff synthetic leather will have 3 notches cut into the outer edge
of the sample. Specimens may be hand cut or die cut. Test specimens
for softer materials are cut to the same size, with length
direction marked on the test specimens. Backing paper is prepared
from white or off-white paper towels, coffee filters, or similar
thin, absorbent papers. Backing paper is also cut into 220
millimeter diameter circles. One backing paper is prepared per test
specimen and backing paper is not reused. The backing paper and a
specimen are placed in a sample fixture, which is in turn placed in
a spray testing device. The sample length direction should be
parallel with the water flow direction. A funnel is adjusted to a
height of 6 inches (152.4 millimeters) between a spray nozzle and
the test specimen. The spray nozzle must be over the center of the
test specimen. 250.+-.2 milliliters of distilled water are added to
the funnel, which causes water to spray onto the test specimen.
Within 10 seconds of spraying ending, the top surface is evaluated
for water repellency. After the top surface is evaluated, the
sample fixture is removed from the support base and the backing
paper is evaluated to determine if water penetrated through the
sample. Water penetration is reported after visual assessment and
samples are rated as "pass" or "fail" according to the degree of
wetting. If no sticking or wetting of the top surface is observed,
if slight random sticking or wetting of the top surface is
observed, or if wetting of the top surface is observed at spray
points, the sample is considered to pass. Further wetting beyond
the spray points and/or including the back surface indicates the
sample has failed the water penetration test.
[0384] Textile-Ball Impact Test. Test samples of textiles are
prepared according to the Component Sampling Procedure or the
Textile Sampling Procedure described below. A 10 inch by 8 inch
test sample of the textile is mounted on the outer surface on a
metal cylinder having a 10 inch circumference. The test sample and
cylinder are mounted on the swinging arm of a robot, the swinging
arm is swung at a rate of 50 miles per hour, and impacts the
equator of a stationary ball. The ball used is a regulation size
Nike "MERLIN" soccer ball inflated to 0.80 bar. A high speed video
camera is used to record the ball position immediately following
the impact. Using the position in space and rotation of the ball
across multiple frames of the images recorded by the high-speed
video camera, software is then used to calculate the velocity and
spin rate of the ball immediately after impact. Each measurement is
repeated at least 3 times, and the results of the runs are
averaged.
[0385] Upper-Ball Impact Test. A whole men's size 10.5 football
boot, or the upper of a men's size 10.5 football boot, is mounted
on the swinging arm of a robot, and positioned so the ball impacts
the boot on the medial side of the vamp, on or near the laces (when
the boot includes a lacing structure), and the upper impacts the
equator of the ball when the singing arm of the robot is swung at a
rate of 50 miles per hour. The ball used is a regulation size Nike
"MERLIN" soccer ball inflated to 0.80 bar. A high speed video
camera is used to record the ball position immediately following
the impact. Using the position in space and rotation of the ball
across multiple frames of the images recorded by the high-speed
video camera, software is then used to calculate the velocity and
spin rate of the ball immediately after impact. Each measurement is
repeated at least 3 times, and the results of the runs are
averaged.
[0386] Specific Gravity Test
[0387] The specific gravity (SG) is measured for samples taken
using the Plaque Sampling Procedure, or the Component Sampling
Procedure, using a digital balance or a Densicom Tester (Qualitest,
Plantation, Fla., USA). Each sample is weighed (g) and then is
submerged in a distilled water bath (at 22 degrees C. plus or minus
2 degrees C.). To avoid errors, air bubbles on the surface of the
samples are removed, e.g., by wiping isopropyl alcohol on the
sample before immersing the sample in water, or using a brush after
the sample is immersed. The weight of the sample in the distilled
water is recorded. The specific gravity is calculated with the
following formula:
S . G . = Weight of the sample in air ( g ) Weight of sample in air
( g ) - Weight of sample in water ( g ) ##EQU00001##
Sampling Procedures
[0388] Using the Tests described above, various properties of the
materials disclosed herein and articles formed therefrom can be
characterized using samples prepared with the following sampling
procedures:
[0389] Material Sampling Procedure. The Material Sampling Procedure
can be used to obtain a neat sample of a polymeric composition or
of a polymer, or, in some instances, a sample of a material used to
form a polymeric composition or a polymer. The material is provided
in media form, such as flakes, granules, powders, pellets, and the
like. If a source of the polymeric material or polymer is not
available in a neat form, the sample can be cut from a component or
element containing the polymeric material or polymer, such as a
composite element or a sole structure, thereby isolating a sample
of the material.
[0390] Plaque or Film Sampling Procedure. A sample of a polymeric
composition or a polymer is prepared. A portion of the polymer or
polymeric composition is then be molded into a film or plaque sized
to fit the testing apparatus. For example, when using a Ross
flexing tester, the plaque or film sample is sized to fit inside
the Ross flexing tester used, the sample having dimensions of about
15 centimeters (cm) by 2.5 centimeters (cm) and a thickness of
about 1 millimeter (mm) to about 4 millimeters (mm) by
thermoforming the polymeric composition or polymer in a mold. For a
plaque sample of a polymer, the sample can be prepared by melting
the polymer, charging the molten polymer into a mold,
re-solidifying the polymer in the shape of the mold, and removing
the solidified molded sample from the mold. Alternatively, the
sample of the polymer can be melted and then extruded into a film
which is cut to size. For a sample of a polymeric composition, the
sample can be prepared by blending together the ingredients of the
polymeric composition, melting the thermoplastic ingredients of the
polymeric composition, charging the molten polymeric composition
into a mold, re-solidifying the polymeric composition in the shape
of the mold, and removing the solidified molded sample from the
mold. Alternatively, the sample of the polymer material can be
prepared by mixing and melting the ingredients of the polymeric
composition, and then the molten polymeric composition can be
extruded into a film which is cut to size. For a film sample of a
polymer or polymeric composition, the film is extruded as a web or
sheet having a substantially constant film thickness for the film
(within .+-.10 percent of the average film thickness) and cooled to
solidify the resulting web or sheet. A sample having a surface area
of 4 square centimeters is then cut from the resulting web or
sheet. Alternatively, if a source of the film material is not
available in a neat form, the film can be cut from a substrate of a
footwear component, or from a backing substrate of a co-extruded
sheet or web, thereby isolating the film. In either case, a sample
having a surface area of 4 square centimeters is then cut from the
resulting isolated film.
[0391] Component Sampling Procedure. This procedure can be used to
obtain a sample of a material from a component of an article of
footwear, an article of footwear, a component of an article of
apparel, an article of apparel, a component of an article of
sporting equipment, or an article of sporting equipment, including
a sample of a polymeric composition or of a textile, or a portion
of a textile, such as thermoformed network. A sample including the
material in a non-wet state (e.g., at 25 degrees Celsius and 20
percent relative humidity) is cut from the article or component
using a blade. If the material is bonded to one or more additional
materials, the procedure can include separating the additional
materials from the material to be tested. For example, to test a
material on a ground-facing surface of sole structure, the opposite
surface can be skinned, abraded, scraped, or otherwise cleaned to
remove any adhesives, yarns, fibers, foams, and the like which are
affixed to the material to be tested. The resulting sample includes
the material and may include any additional materials bonded to the
material.
[0392] The sample is taken at a location along the article or
component that provides a substantially constant material thickness
for the material as present on the article or component (within
plus or minus 10 percent of the average material thickness), such
as, for an article of footwear, in a forefoot region, midfoot
region, or a heel region of a ground-facing surface. For many of
the test protocols described above, a sample having a surface area
of 4 square centimeters (cm.sup.2) is used. The sample is cut into
a size and shape (e.g., a dogbone-shaped sample) to fit into the
testing apparatus. In cases where the material is not present on
the article or component in any segment having a 4 square
centimeter surface area and/or where the material thickness is not
substantially constant for a segment having a 4 square centimeter
surface area, sample sizes with smaller cross-sectional surface
areas can be taken and the area-specific measurements are adjusted
accordingly.
[0393] Yarn Sampling Procedure. Yarn to be tested is stored at room
temperature (20 degrees Celsius to 24 degrees Celsius) for 24 hours
prior to testing. The first 3 meters of material are discarded. A
sample yarn is cut to a length of approximately 30 millimeters with
minimal tension at approximately room temperature (e.g., 20 degrees
Celsius).
[0394] Textile Sampling Procedure. A textile to be tested is stored
at room temperature (20 degrees Celsius to 24 degrees Celsius) for
24 hours prior to testing. The textile sample is cut to size as
dictated by the test method to be used, with minimal tension at
approximately room temperature (e.g., 20 degrees Celsius).
[0395] Before proceeding to the Examples, it is to be understood
that this disclosure is not limited to particular aspects
described, and as such may, of course, vary. Other systems,
methods, features, and advantages of foam compositions and
components thereof will be or become apparent to one with skill in
the art upon examination of the following drawings and detailed
description. It is intended that all such additional systems,
methods, features, and advantages be included within this
description, be within the scope of the present disclosure, and be
protected by the accompanying claims. It is also to be understood
that the terminology used herein is for the purpose of describing
particular aspects only, and is not intended to be limiting. The
skilled artisan will recognize many variants and adaptations of the
aspects described herein. These variants and adaptations are
intended to be included in the teachings of this disclosure and to
be encompassed by the claims herein.
Aspects
[0396] The following listing of exemplary aspects supports and is
supported by the disclosure provided herein.
[0397] Aspect 1. A textile, comprising:
a first network of yarns including a first coated yarn, the first
coated yarn comprising a first core yarn and a first coating
including a first polymeric composition disposed on at least a
portion of an outer surface of the first core yarn, wherein the
first polymeric composition is a thermoplastic elastomeric
composition.
[0398] Aspect 2. The textile of Aspect 1, wherein the textile is a
knit or crochet textile, and the first network of yarns includes
connected loops of the first coated yarn.
[0399] Aspect 3. The textile of Aspect 1, wherein the textile is a
woven textile, and the first network of yarns includes interlaced
sets of yarns comprising the first coated yarn in a warp direction,
or in a weft direction, or in both the warp and weft
directions.
[0400] Aspect 4. The textile of Aspect 1, wherein the textile is a
non-woven textile, and the first network of yarns includes
entangled or bonded yarns comprising the first coated yarn.
[0401] Aspect 5. The textile of Aspect 4, wherein the entangled or
bonded yarns comprise mechanically entangled yarns, thermally
bonded yarns, yarns bonded by a solvent treatment, chemically
bonded yarns, or any combination thereof.
[0402] Aspect 6. The textile of any of Aspects 1-5, wherein the
first core yarn comprises a second polymeric composition, and
wherein the first polymeric composition of the first coating has a
first melting temperature.
[0403] Aspect 7. The textile of Aspect 6, wherein the second
polymeric composition is a second thermoplastic composition having
a second deformation temperature, and the second deformation
temperature is at least 20 degrees Celsius (C) greater, or
optionally at least 50 degrees C. greater, or optionally at least
100 degrees C. greater than the first melting temperature of the
first thermoplastic composition.
[0404] Aspect 8. The textile of Aspect 6 or 7, wherein the second
polymeric composition is a second thermoset composition.
[0405] Aspect 9. The textile of any of Aspects 1-8, wherein the
first core yarn comprises a first core yarn composition comprising
a polyester or a polyamide.
[0406] Aspect 10. The textile of any of Aspects 1-9, wherein the
first core yarn has a linear density from about 100 denier to about
300 denier, or has a diameter of from about 60 to 200 microns.
[0407] Aspect 11. The textile of any of Aspects 1-10, wherein the
first coating is axially centered surrounding the core yarn, and
the first coating thickness leads to a nominal average outer
diameter of the coated yarn of up to about 1.0 millimeter.
[0408] Aspect 12. The textile of any of Aspects 1-11, wherein the
first coating is axially centered surrounding the first core yarn,
and the first coating thickness leads to a nominal average outer
diameter of the coated yarn of about 0.1 millimeters to about 0.6
millimeters.
[0409] Aspect 13. The textile of any of Aspects 1-12, wherein the
first coating has an average radial coating thickness of about 50
micrometers to about 200 micrometers.
[0410] Aspect 14. The textile of any of Aspects 1-13, wherein the
first polymeric composition has a melting temperature greater than
about 110 degrees C. and less than about 190 degrees C.
[0411] Aspect 15. The textile of any of Aspects 1-13, wherein the
first polymeric composition has a melting temperature greater than
about 120 degrees C. and less than about 170 degrees C., and
optionally greater than about 130 degrees C., and less than about
160 degrees C.
[0412] Aspect 16. The textile of any of Aspects 1-15, wherein the
first polymeric composition has a glass transition temperature
glass transition temperature of less than 20 degrees C.
[0413] Aspect 17. The textile of any of Aspects 1-16, wherein the
first polymeric composition has a glass transition temperature
glass transition temperature of from about 20 degrees C. to about
-60 degrees C.
[0414] Aspect 18. The textile of any of Aspects 1-17, wherein the
first polymeric composition has a Taber Abrasion Resistance of from
about 10 milligrams to about 40 milligrams as determined by ASTM
D3389.
[0415] Aspect 19. The textile of any of Aspects 1-18, wherein the
first polymeric composition has a Durometer Hardness (Shore A) of
from about 60 to about 90, from about 60 to about 90, or from about
65 to about 85, or from about 70 to about 80 as determined by ASTM
D2240.
[0416] Aspect 20. The textile of any of Aspects 1-19, wherein the
first polymeric composition has a specific gravity of from about
0.80 grams per cubic centimeter to about 1.30 grams per cubic
centimeter, or from about 1.0 grams per cubic centimeter to about
1.2 grams per cubic centimeter as determined by ASTM D792.
[0417] Aspect 21. The textile of any of Aspects 1-20, wherein the
first polymeric composition has a melt flow index of about 2
grams/10 minutes to about 50 grams/10 minutes at 160 degrees C.
using a test weight of 2.16 kilograms as determined using ASTM
D1238-13.
[0418] Aspect 22. The textile of any of Aspects 1-21, wherein the
first polymeric composition has a melt flow index greater than
about 2 grams/10 minutes at 190 degrees C. or 200 degrees C. when
using a test weight of 10 kilograms as determined using ASTM
D1238-13.
[0419] Aspect 23. The textile of any of Aspects 1-22, wherein the
first polymeric composition has a modulus of about 1 megapascal to
about 500 megapascals as determined using the Plaque Modulus
Test.
[0420] Aspect 24. The textile of any of Aspects 1-23, wherein the
first polymeric composition comprises a polymeric component
consisting of all the polymers present in the polymeric
composition; optionally wherein and the polymeric component
comprises two or more polymers, wherein the two or more polymers
differ from each other in chemical structure of individual segments
of each of the two or more polymers, or in molecular weight of each
of the two or more polymers, or in both.
[0421] Aspect 25. The textile of any of Aspects 1-24, wherein the
first polymeric composition comprises a thermoplastic elastomeric
styrenic copolymer, a thermoplastic elastomeric polyurethane, or a
combination thereof; optionally wherein the polymeric component of
the first polymeric composition consists of the thermoplastic
elastomeric styrenic copolymer, the thermoplastic elastomeric
polyurethane, or the combination thereof.
[0422] Aspect 26. The textile of Aspect 25, wherein the
thermoplastic elastomeric styrenic copolymer comprises a styrene
butadiene styrene (SBS) block copolymer, a styrene
ethylene/butylene styrene (SEBS) copolymer, a styrene acrylonitrile
copolymer (SAN), or any combination thereof.
[0423] Aspect 27. The textile of Aspect 25, wherein the
thermoplastic elastomeric polyurethane comprises a thermoplastic
elastomeric polyester polyurethane, a thermoplastic polyether
polyurethane, or any combination thereof.
[0424] Aspect 28. The textile of Aspect 27, wherein the
thermoplastic elastomeric polyurethane comprises an aromatic
polyester thermoplastic elastomeric polyurethane.
[0425] Aspect 29. The textile of any of Aspects 25-28, wherein the
thermoplastic elastomeric polyurethane comprises an aliphatic
polyester thermoplastic elastomeric polyurethane.
[0426] Aspect 30. The textile of any of Aspects 1-29, wherein the
textile further comprises a lubricating composition.
[0427] Aspect 31. The textile of Aspect 30, wherein the lubricating
composition is from about 0.1 weight percent to about 3 weight
percent of the textile.
[0428] Aspect 32. The textile of Aspect 30 or 31, wherein the
lubricating composition comprises mineral oil, silicone oil, or a
combination thereof.
[0429] Aspect 33. The textile of any of Aspects 1-32, wherein the
first coated yarn has a stress at break greater than 7 megapascals,
optionally greater than 8 megapascals, or greater than 8
megapascals as determined using ASTM DE-412 at 25 degrees C.
[0430] Aspect 34. The textile of any of Aspects 1-33, wherein the
first coated yarn has a tensile stress at 300 percent modulus
greater than 2 megapascals, optionally greater than 2.5
megapascals, or greater than 3 megapascals as determined using ASTM
DE-412 at 25 degrees C.
[0431] Aspect 35. The textile of any of Aspects 1-34, wherein the
first coated yarn has an elongation at break greater than 450
percent, optionally greater than 500 percent, or greater than 550
percent as determined using the Yarn Modulus, Tenacity and
Elongation Test.
[0432] Aspect 36. The textile of any of Aspects 1-35, wherein the
first coated yarn has a tenacity of about 1 gram per denier to
about 10 grams per denier as determined using the Yarn Modulus,
Tenacity and Elongation Test.
[0433] Aspect 37. A textile, comprising:
[0434] a thermoformed network of yarns, the thermoformed network
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition.
[0435] Aspect 38. The textile of Aspect 37, wherein the
thermoformed network of yarns is the thermoformed product of a
first textile comprising a first network of yarns including a first
coated yarn comprising the first core yarn and a first coating, the
first coating including the first polymeric composition, wherein,
in the thermoformed network, the first polymeric composition
consolidating the thermoformed network of yarns is the re-flowed
and re-solidified product of the first polymeric composition of the
first coating of the first coated yarn.
[0436] Aspect 39. The textile of Aspect 37 or 38, wherein the
thermoformed network of yarns is the thermoformed product of a
textile according to any one of Aspects 1 to 36.
[0437] Aspect 40. The textile of any of Aspects 37 to 39, wherein,
when the textile has a mass loss of less than 0.05 weight percent
after 300 cycles as determined by the Akron Abrasion Test.
[0438] Aspect 41. The textile of any of Aspects 37 to 39, wherein
the textile has a mass loss of less than 0.20 weight percent after
3,000 cycles as determined by the Akron Abrasion Test.
[0439] Aspect 42. The textile of any of Aspects 37 to 41, wherein
the textile passes at least 1,200 cycles, or optionally at least
1,300 cycles, or at least 1,600 cycles of the Stoll Abrasion
Test.
[0440] Aspect 43. The textile of any of Aspects 37 to 42, wherein
the textile passes at least at least 75 cycles, or at least 100
cycles, or at least 125 cycles of the Bally Flex Test.
[0441] Aspect 44. The textile of any of Aspects 37 to 43, wherein
the textile passes at least 3,000 cycles, or at least 5,000 cycles,
or at least 7,000 cycles of the Wet Bally Flex Test.
[0442] Aspect 45. The textile of any of Aspects 37 to 44, wherein
the textile produces a ball spin rate of at least 220 revolutions
per minute, or a ball spin rate of about 220 revolutions per minute
to about 240 revolutions per minute, as determined using the
Textile-Ball Impact Test.
[0443] Aspect 46. The textile of any of Aspects 37 to 45, wherein
the first polymeric composition has an abrasion loss of less than
0.50 cubic centimeters, optionally less than 0.40 cubic
centimeters, less than 0.30 cubic centimeters, less than 0.20 cubic
centimeters, or less than 0.10 cubic centimeters as determined
using the Akron Abrasion Test.
[0444] Aspect 47. The textile of any of Aspects 37 to 46, wherein
the first polymeric composition has an abrasion loss of less than
0.30 cubic centimeters, less than 0.20 cubic centimeters, less than
0.10 cubic centimeters, less than 0.05 cubic centimeters, or less
than 0.30 cubic centimeters, as determined using the DIN Abrasion
Test.
[0445] Aspect 48. The textile of any of Aspects 37 to 47, wherein
the first polymeric composition has a dry dynamic coefficient of
friction of at least 1.0 as determined against dry smooth concrete
using the Sample Coefficient of Friction Test.
[0446] Aspect 49. The textile of any of Aspects 37 to 48, wherein
the first polymeric composition has a wet dynamic coefficient of
friction of at least 0.5 as determined against wet smooth concrete
using the Sample Coefficient of Friction Test.
[0447] Aspect 50. The textile of any of Aspects 37 to 49, wherein
the difference between the dry dynamic coefficient of friction and
the wet coefficient of the first polymeric composition as determine
against smooth concrete is less than 40 percent, optionally less
than 30 percent, or less than 20 percent as determined using the
Sample Coefficient of Friction Test.
[0448] Aspect 51. The textile of any of Aspects 37 to 50, wherein
the thermoformed network of the textile has a dry dynamic
coefficient of friction of at least 0.8 as determined against dry
smooth concrete using the Sample Coefficient of Friction Test.
[0449] Aspect 52. The textile of any of Aspects 37 to 51, wherein
the first thermoformed network of the textile has a wet dynamic
coefficient of friction of at least 0.5 as determined against wet
smooth concrete using the Sample Coefficient of Friction Test.
[0450] Aspect 53. The textile of any of Aspects 37 to 52, wherein
the difference between the dry dynamic coefficient of friction and
the wet coefficient of the thermoformed network of the textile as
determine against smooth concrete is less than 50 percent,
optionally less than 40 percent, or less than 30 percent as
determined using the Sample Coefficient of Friction Test.
[0451] Aspect 54. The textile of any of Aspects 37 to 53, wherein
the difference between the static coefficient of friction of the
dry surface and the wet surface of the textile is less than 40
percent, optionally less than 30 percent, or less than 20 percent
as determined using the Sample Coefficient of Friction Test.
[0452] Aspect 55. The textile of any of Aspects 37 to 54, wherein
the thermoformed network of the textile has a dry dynamic
coefficient of friction of at least 1.0 as determined using the
Textile-Ball Coefficient of Friction Test.
[0453] Aspect 56. The textile of any of Aspects 37 to 55, wherein
the first thermoformed network of the textile has a wet dynamic
coefficient of friction of at least 0.5 as determined using the
Textile-Ball Coefficient of Friction Test.
[0454] Aspect 57. The textile of any of Aspects 37 to 56, wherein
the difference between the dry dynamic coefficient of friction and
the wet dynamic coefficient of friction is less than 40 percent,
optionally less than 30 percent, or less than 20 percent as
determined using the Textile-Ball Coefficient of Friction Test.
[0455] Aspect 58. The textile of any of Aspects 37 to 57, wherein
the thermoformed network of the textile has a dry static
coefficient of friction of at least 1.2 as determined using the
Textile-Ball Coefficient of Friction Test.
[0456] Aspect 59. The textile of any of Aspects 37 to 58, wherein
the thermoformed network of the textile has a wet static
coefficient of friction of at least 0.9 as determined using the
Textile-Ball Coefficient of Friction Test.
[0457] Aspect 60. The textile of any of Aspects 37 to 59, wherein
the difference between the dry static coefficient of friction and
the wet static coefficient of friction of the thermoformed network
of the textile is less than 40 percent, optionally less than 30
percent, or less than 20 percent as determined using the
Textile-Ball Coefficient of Friction Test.
[0458] Aspect 61. An article comprising the textile according to
any one of Aspects 1 to 60.
[0459] Aspect 62. The article of Aspect 61, wherein the article is
a component of an article of apparel, footwear, or sporting
equipment, or is an article of apparel, footwear, or sporting
equipment.
[0460] Aspect 63. An upper for an article of footwear,
comprising:
[0461] a textile, wherein the textile comprises a first network of
yarns including a first coated yarn, the first coated yarn
comprising a first core yarn and a first coating including a first
polymeric composition disposed on at least a portion of an outer
surface of the first core yarn, wherein the first polymeric
composition is a thermoplastic elastomeric composition.
[0462] Aspect 64. The upper of Aspect 63, wherein the textile
defines at least a portion of a surface of the upper configured to
be externally-facing when the upper is part of a finished article
of footwear.
[0463] Aspect 65. The upper of Aspect 63, wherein the textile
defines at least a portion of the surface of the upper configured
to be externally-facing when the upper is part of a finished
article of footwear, or defines at least a portion of a surface of
the upper configured to be internally-facing when the upper is part
of a finished article of footwear, or forms at least a portion of
an interior layer of the upper when the upper is part of a finished
article of footwear, or any combination thereof.
[0464] Aspect 66. The upper of any of Aspects 63 to 65, wherein the
textile is a textile according to any one of Aspects 1 to 36.
[0465] Aspect 67. An upper for an article of footwear,
comprising:
[0466] a first textile comprising a thermoformed network of yarns
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition.
[0467] Aspect 68. The upper of Aspect 67, wherein the textile
defines at least a portion of a surface of the upper configured to
be externally-facing when the upper is part of a finished article
of footwear.
[0468] Aspect 69. The upper of Aspect 67, wherein the textile
defines at least a portion of the surface of the upper configured
to be externally-facing when the upper is part of a finished
article of footwear, or defines at least a portion of a surface of
the upper configured to be internally-facing when the upper is part
of a finished article of footwear, or forms at least a portion of
an interior layer of the upper when the upper is part of a finished
article of footwear, or any combination thereof.
[0469] Aspect 71. The upper of any of Aspects 67 to 70, wherein the
textile comprises the textile of any of Aspects 1 to 60.
[0470] Aspect 72. The upper of any of Aspects 67-71, wherein the
textile defines at least a portion of a surface of the upper
configured to be externally-facing when the upper is part of a
finished article of footwear.
[0471] Aspect 73. The upper of any of Aspects 67-71, wherein the
textile defines from about 15 percent to about 100 percent, or from
about 15 percent to about 35 percent, or from about 40 percent to
about 70 percent, or from about 75 percent to about 100 percent of
the total surface area of the upper configured to be
externally-facing when the upper is part of a finished article of
footwear.
[0472] Aspect 74. The upper of any of Aspects 67-73, wherein the
thermoformed network of the thermoformed textile defines at least a
portion of a surface of the upper configured to be
externally-facing when the upper is part of a finished article of
footwear.
[0473] Aspect 75. The upper of any of Aspects 67-74, wherein the
thermoformed network includes an externally-facing side, the
externally-facing side of the thermoformed network defines at least
a portion of the surface of the upper configured to be
externally-facing when the upper is part of a finished article of
footwear, and about 15 percent to 100 percent, or about 15 percent
to 35 percent, or about 40 percent to 70 percent, or about 75
percent to 100 percent of a total surface area of the
externally-facing side of the thermoformed network comprises the
first polymeric composition.
[0474] Aspect 76. The upper of any of Aspects 67-75, wherein the
first polymeric composition comprises about 15 percent to 95
percent by weight, or about 15 percent to 35 percent by weight, or
about 40 percent to 70 percent by weight, or about 75 percent to 95
percent by weight of the textile, based on a total weight of the
textile present in the upper.
[0475] Aspect 77. The upper of any of Aspects 67-76, wherein the
textile produces a ball spin rate of at least 210 revolutions per
minute, or a ball spin rate of about 210 revolutions per minute to
about 230 revolutions per minute, as determined using the
Upper-Ball Impact Test.
[0476] Aspect 78. An outsole for an article of footwear,
comprising:
[0477] a textile comprising a thermoformed network of yarns
comprising a first core yarn and a first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns, and wherein the
first polymeric composition is a thermoplastic elastomeric
composition.
[0478] Aspect 79. The outsole of Aspect 78, wherein the
thermoformed network defines at least a portion of an
externally-facing surface of the outsole, optionally wherein the
externally-facing surface is configured to be ground-facing or
ground-contacting when the outsole is part of a finished article of
footwear.
[0479] Aspect 80. The outsole of Aspect 78 or 79, wherein the
thermoformed textile defines at least a portion of a heel region, a
toe region, or a midfoot region, or any combination thereof, of the
outsole.
[0480] Aspect 81. The outsole of any of Aspects 78 to 80, wherein
the thermoformed network of the textile, when new, has a dry
dynamic coefficient of friction of greater than 1.0 as determined
against smooth concrete using the Whole Footwear Coefficient of
Friction Test.
[0481] Aspect 82. The outsole of any of Aspects 78 to 81, wherein
the thermoformed network of the textile, when new, has a wet
dynamic coefficient of friction of greater than 0.5 as determined
against smooth concrete using the Whole Footwear Coefficient of
Friction Test.
[0482] Aspect 83. The outsole of any of Aspects 78 to 82, wherein
the difference between the dry dynamic coefficient of friction and
the wet dynamic coefficient of friction of the thermoformed network
of the textile, when new, is less than 40 percent, optionally less
than 30 percent, or less than 20 percent as determined against
smooth concrete using the Whole Footwear Coefficient of Friction
Test.
[0483] Aspect 84. The outsole of any of Aspects 78 to 83, wherein
the thermoformed network of the textile, after being abraded
according to the Whole Footwear Abrasion Test, has a dry dynamic
coefficient of friction of greater than 0.9 as determined against
smooth concrete using the Whole Footwear Coefficient of Friction
Test.
[0484] Aspect 85. The outsole of any of Aspects 78 to 84, wherein
the thermoformed network of the textile, after being abraded
according to the Whole Footwear Abrasion Test, has a wet dynamic
coefficient of friction of greater than 0.5 as determined against
smooth concrete using the Whole Footwear Coefficient of Friction
Test.
[0485] Aspect 86. The outsole of any of Aspects 78 to 85, wherein
the difference between the dry dynamic coefficient of friction and
the wet dynamic coefficient of friction of the thermoformed network
of the textile, after being abraded according to the Whole Footwear
Abrasion Test, is less than 40 percent, optionally less than 30
percent, or less than 20 percent as determined against smooth
concrete using the Whole Footwear Coefficient of Friction Test.
[0486] Aspect 87. The outsole of any of Aspects 78 to 86, wherein
the thermoformed network defines at least a portion of a surface of
the outsole configured to be ground-contacting when the outsole is
part of a finished article of footwear, and the thermoformed
network further comprises a layer of a third polymeric composition,
wherein the third polymeric composition is a thermoplastic
elastomeric composition comprising a thermoplastic elastomeric
styrenic copolymer; wherein a first side of the layer defines the
surface of the outsole configured to be ground-contacting when the
outsole is part of a finished article of footwear, and a second
side of the yarn opposite the first side is thermally bonded to a
first side of the textile via the first polymeric composition of
the textile.
[0487] Aspect 88. The outsole of Aspect 87, wherein the layer of
the third polymeric composition is an extruded layer or an
injection molded layer or a film layer.
[0488] Aspect 89. The outsole of Aspect 87 or 88, wherein the
thermoplastic elastomeric styrenic copolymer of the first polymeric
composition and the thermoplastic elastomeric styrenic copolymer of
the third polymeric component each have the same chemical
structure, or the first polymeric composition and the third
polymeric composition each have melting temperatures within about
10 degrees C. of each other, or both.
[0489] Aspect 90. The outsole of any of Aspects 87-89, wherein the
layer of the third polymeric composition has a thickness of from
about 0.1 millimeter to about 5 millimeters.
[0490] Aspect 91. The outsole of any of Aspects 78-90, wherein the
textile comprises the textile of any of Aspects 1 to 60.
[0491] Aspect 92. A method of making a textile, the method
comprising:
[0492] forming a first network of yarns including a first coated
yarn, the first coated yarn comprising a first core yarn and a
first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition.
[0493] Aspect 93. The method of Aspect 92, wherein the textile is a
textile according to any one of Aspects 1-36.
[0494] Aspect 94. A method of making a textile, the method
comprising:
[0495] thermoforming a first textile comprising a first network of
yarns including a first coated yarn, the first coated yarn
comprising a first core yarn and a first coating including a first
polymeric composition disposed on at least a portion of an outer
surface of the first core yarn, wherein the first polymeric
composition is a thermoplastic elastomeric composition; thereby
forming a thermoformed network of yarns comprising the first core
yarn and the first polymeric composition, wherein the first
polymeric composition consolidates the thermoformed network of
yarns by surrounding at least a portion of the first core yarn and
occupying at least a portion of spaces between yarns in the
thermoformed network of yarns.
[0496] Aspect 95. The method of Aspect 94, wherein the first
textile is a textile according to any one of Aspects 1 to 60.
[0497] Aspect 96. A textile made according to any one of Aspects 92
to 95.
[0498] Aspect 97. A method of making an upper for an article of
footwear, the method comprising:
[0499] affixing a first textile to a second component, wherein the
first textile comprises a first network of yarns including a first
coated yarn, the first coated yarn comprising a first core yarn and
a first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition.
[0500] Aspect 98. A method of making an upper for an article of
footwear, the method comprising:
[0501] thermoforming an upper comprising a first textile, wherein
the first textile comprises a first network of yarns including a
first coated yarn, the first coated yarn comprising a first core
yarn and a first coating including a first polymeric composition
disposed on at least a portion of an outer surface of the first
core yarn, wherein the first polymeric composition is a
thermoplastic elastomeric composition; and wherein the
thermoforming comprises melting, reflowing, and re-solidifying the
first polymeric composition within the first textile, forming a
thermoformed textile comprising a thermoformed network of yarns
comprising the first core yarn and the first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns.
[0502] Aspect 99. A method of making an upper for an article of
footwear, the method comprising:
[0503] affixing a first textile to a second component, wherein the
first textile comprises a thermoformed network of yarns comprising
a first core yarn and a first polymeric composition, wherein the
first polymeric composition consolidates the thermoformed network
of yarns by surrounding at least a portion of the first core yarn
and occupying at least a portion of spaces between yarns in the
thermoformed network of yarns, and wherein the first polymeric
composition is a thermoplastic elastomeric composition.
[0504] Aspect 100. The method of any of Aspects 97 to 99, wherein
the first textile is a textile according to any one of Aspects 1 to
60.
[0505] Aspect 101. An upper made according to the method of any one
of Aspects 97 to 100.
[0506] Aspect 102. A method for making an outsole for an article of
footwear, the method comprising thermoforming a first textile;
wherein the thermoforming comprises thermoforming the textile on a
sole component, or on a molding surface, optionally wherein the
molding surface is a molding surface having the dimensions of the
outsole; wherein the first textile comprises a first network of
yarns including a first coated yarn, the first coated yarn
comprising a first core yarn and a first coating including a first
polymeric composition disposed on at least a portion of an outer
surface of the first core yarn, wherein the first polymeric
composition is a thermoplastic elastomeric composition; and wherein
the thermoforming comprises melting, reflowing, and re-solidifying
the first polymeric composition within the first textile, forming a
thermoformed textile comprising a thermoformed network of yarns
comprising the first core yarn and the first polymeric composition,
wherein the first polymeric composition consolidates the
thermoformed network of yarns by surrounding at least a portion of
the first core yarn and occupying at least a portion of spaces
between yarns in the thermoformed network of yarns.
[0507] Aspect 103. The method of Aspect 102, wherein the first
textile has a first side and a second side, wherein the method
further comprises thermally bonding a layer comprising a third
polymeric composition to the first side or the second side of the
first textile, wherein the third polymeric composition of the layer
defines a surface of the outsole configured to be externally-facing
or ground-facing or ground-contacting when the outsole is in a
finished article of footwear.
[0508] Aspect 104. The method of Aspect 103, wherein the method
comprises thermally bonding a sheet comprising the third polymeric
composition to the first textile before, during or after the step
of thermoforming the first textile.
[0509] Aspect 105. The method of Aspect 103, wherein the method
comprises extruding or injection molding the third polymeric
composition on the first side or the second side of the first
textile before, during or after thermoforming the first
textile.
[0510] Aspect 106. The method of any one of Aspects 102-105,
wherein the first textile is a textile according to any one of
Aspects 1 to 60.
[0511] Aspect 107. An outsole made according to the method of any
one of Aspects 102 to 106.
[0512] Aspect 108. A method of making an article, comprising:
[0513] affixing a first textile to a second component, wherein the
first textile comprises a first network of yarns including a first
coated yarn, the first coated yarn comprising a first core yarn and
a first coating including a first polymeric composition disposed on
at least a portion of an outer surface of the first core yarn,
wherein the first polymeric composition is a thermoplastic
elastomeric composition.
[0514] Aspect 109. A method of making an article, the method
comprising:
[0515] thermoforming a first textile, wherein the first textile
comprises a first network of yarns including a first coated yarn,
the first coated yarn comprising a first core yarn and a first
coating including a first polymeric composition disposed on at
least a portion of an outer surface of the first core yarn, wherein
the first polymeric composition is a thermoplastic elastomeric
composition; and wherein the thermoforming comprises melting,
reflowing, and re-solidifying the first polymeric composition
within the first textile, forming a thermoformed textile comprising
a thermoformed network of yarns comprising the first core yarn and
the first polymeric composition, wherein the first polymeric
composition consolidates the thermoformed network of yarns by
surrounding at least a portion of the first core yarn and occupying
at least a portion of spaces between yarns in the thermoformed
network of yarns.
[0516] Aspect 110. A method of making an article, the method
comprising:
[0517] affixing a first textile to a second component, wherein the
first textile comprises a thermoformed network of yarns comprising
a first core yarn and a first polymeric composition, wherein the
first polymeric composition consolidates the thermoformed network
of yarns by surrounding at least a portion of the first core yarn
and occupying at least a portion of spaces between yarns in the
thermoformed network of yarns, and wherein the first polymeric
composition is a thermoplastic elastomeric composition; optionally
wherein the article is a component of an article of footwear,
apparel or sporting equipment, or is an article of footwear,
apparel or sporting equipment.
[0518] Aspect 111. The method of any one of Aspects 108 to 110,
wherein the first textile is a textile according to any one of
Aspects 1 to 60.
[0519] Aspect 112. An article made by the method of any one of
Aspects 108 to 111.
[0520] From the foregoing, it will be seen that aspects herein are
well adapted to attain all the ends and objects hereinabove set
forth together with other advantages which are obvious and which
are inherent to the structure.
[0521] It will be understood that certain features and
subcombinations are of utility and may be employed without
reference to other features and subcombinations. This is
contemplated by and is within the scope of the claims.
[0522] Since many possible aspects may be made without departing
from the scope thereof, it is to be understood that all matter
herein set forth or shown in the accompanying drawings is to be
interpreted as illustrative and not in a limiting sense.
[0523] While specific elements and steps are discussed in
connection to one another, it is understood that any element and/or
steps provided herein is contemplated as being combinable with any
other elements and/or steps regardless of explicit provision of the
same while still being within the scope provided herein. Since many
possible aspects may be made of the disclosure without departing
from the scope thereof, it is to be understood that all matter
herein set forth or shown in the accompanying drawings is to be
interpreted as illustrative and not in a limiting sense.
Examples
[0524] The present disclosure is more particularly described in the
following examples that are intended as illustrations only, since
numerous modifications and variations within the scope of the
present disclosure will be apparent to those skilled in the
art.
Polymer Screening
[0525] Thermoplastic polyurethane elastomers and thermoplastic
styrenic copolymer elastomers were evaluated as candidates for the
preparation of coated yarns, textiles and other articles as
described herein. Several properties were determined for each
polymer, and the results are summarized in Tables 1 and 2. The
hardness of the polymers was determined using the Durometer
Hardness Test, the specific gravity was determined using the
Specific Gravity Test, the DIN abrasion loss was determined using
the DIN Abrasion Test, and the coefficients of friction were
determined using the Sample Coefficient of Friction Test as
disclosed herein.
TABLE-US-00001 TABLE 1 DIN abrasion Material Polymer Durometer
Specific mass loss Grade type Supplier (Shore A) Gravity
(milligrams) Monprene SEBS Teknor 76 A 0.897 374 66070 TPE Apex
Ellastolan TPU BASF 0.7944 SP9339 Estane TPU Lubrizol 75 A 1.17 65
58238 Estane TPU Lubrizol 77 A 1.14 74 T470A-3
TABLE-US-00002 TABLE 2 Smooth Rough Rough Percent Percent Smooth
Dry Wet Dry Wet Difference Difference Concrete concrete Concrete
Concrete (Dry- (Dry- (Dynamic (Dynamic (Dynamic (Dynamic Wet)/Dry
Wet)/Dry Material Grade COF) COF) COF) COF) Smooth Rough Monprene
66070 1.211 0.873 0.830 0.717 72 28 Ellastolan SP9339 1.434 0.629
1.091 0.652 44 56 Estane 58238 1.039 0.483 0.835 0.450 46 54 Estane
T470A-3 1.055 0.463 0.873 0.537 44 56
Properties of Coated Yarns
[0526] Coated yarns coated with polymeric compositions including
polymers under investigation were made and their properties were
investigated. A comparison of hardness values, glass transition
temperature, melting temperature, tensile strength, and elongation
at break is provided in Table 3, where the hardness of the polymer
was determined using the Durometer Hardness Test, the glass
transition temperatures and the melting temperatures of the
polymers were determined using the Melting and Glass Transition
Temperature Test, and the yarn tensile strength and elongation were
determined using the Yarn Modulus, Tenacity, and Elongation Test
disclosed herein:
TABLE-US-00003 TABLE 3 Properties of Control and Test Coated Yarns
Glass Transition Melting Tensile Elongation Yarn Polymer Polymer
Durometer Temp. (degrees Temp. (degrees Strength at Break Sample
Supplier Grade (Shore A) Celsius) Celsius) (Megapascals) (percent)
WC1 Lubrizol Estane 75 .+-. 3 -68 150 48.3 680 58238 WC2 Lubrizol
Estane 77 .+-. 3 -50 150 28 840 T470A-3 Hard Lubrizol Esdex 92 .+-.
3 -39 150 62 480 TPU 219UN
[0527] Differential scanning calorimetry studies to evaluate
melting and recrystallization behavior of polymers under
investigation for use as coatings for yarn were conducted according
to the Melting and Glass Transition Temperature Test described
herein. Results are presented in Table 4:
TABLE-US-00004 TABLE 4 Polymer Melting and Cooling Data Melting
Behavior Peak Recrystallization Behavior (Cooling after Melting)
Melting Onset of Melting Onset of Peak Enthalpy Tem. Melting Temp.
Enthalpy Crystalization Crystalization (Joules Polymer Polyol
(degrees (degrees (degrees (Joules (degrees (degrees per DSC Data
Type Type Celsius) Celsius) Celsius) per gram) Celsius) Celsius)
gram) Estane 58238 TPU Aromatic -44 134.79 149.31 7.4591 69.6 48.2
4.1687 Polyester Estane T470A-3 TPU Polyester -49 134.5 155.05
9.9512 100.47 85.6 7.3121 Monprene SP66070 SEBS N/A <-35 150.39
164.25 22.057 113.5 104.21 20.677 Monprene SP16074H SEBS N/A
<-35 144.87 159.65 23.482 110.97 107.1 24.995 Monprene IN15074
SEBS N/A <-35 145.13 160.33 21.563 110.54 103.78 23.006
[0528] Rheology data for molten polymers was collected according to
the Molten Polymer Viscosity Test described herein. Results are
presented in Table 5:
TABLE-US-00005 TABLE 5 Molten Polymer Rheology Data Viscosity at 1
Viscosity at 10 Viscosity at 100 Reciprocal Reciprocal Reciprocal
Second Seconds Seconds (Pascal (Pascal (Pascal Material seconds)
seconds) seconds) Estane 58238 690 640 465 Estane T470A-3 545 525
400 Monprene SP 66070 170 170 145 Monprene SP 16074H 20500 3000 550
Monprene SP 15074 22900 5300 1150
[0529] These results indicate that Estane 58238, Estane T470A-3,
and Monprene SP66070 are particularly well-suited for high flow
rate extrusion on fast moving fibers (e.g. core yarn).
[0530] Solid state tensile properties for the polymers useful as
yarn coating compositions are presented in Table 6, as determined
using the Plaque Modulus Test described herein:
TABLE-US-00006 TABLE 6 Solid State Tensile Properties Break Strain
to Load at 100 Material Polymer Strength Break Percent Strain
Toughness Tear Grade Type (kg f) (Percent) (kg f/mm) (kg .times.
mm) Stiffness Strength Rubber A Rubber 14.0 709 3.2 927 37.9 35
Estane TPU 34.2 792 3.8 2176 63.8 78.8 58238 Estane TPU 30.5 690
4.7 1737 84.3 76.6 T470A-3 Monprene SEBS 13.3 717 5.0 1495 102.9
60.9 SP 66070 Monprene SEBS 10.1 450 7.7 865 154.1 49.9 IN
15074
Traction and Abrasion Losses of Plaques
[0531] 2 millimeter thick plaques of material were used to test for
traction and abrasion properties. Plaques were tested according to
the Sample Coefficient of Friction Test described herein.
[0532] Cross-linked rubber materials are known to exhibit reduced
material or mass loss during abrasion testing, while thermoplastic
materials have typically not been able to match the balance of
traction and abrasion loss provided by cross-linked rubbers.
However, the polymers tested showed good traction performance
relative to known rubber outsole formulations. Results obtained in
accordance with the Durometer Hardness Test, the Specific Gravity
Test, the DIN Abrasion Test, and the Sample Coefficient of Friction
Test described herein can be seen in Tables 7. Table 8 presents the
results of whole shoe tests using outsoles comprising thermoformed
textiles as described herein, obtained in accordance with the Whole
Footwear Coefficient of Friction Test and the Whole Footwear
Abrasion Test disclosed herein. Table 9 shows hardness and Akron
abrasion loss results for thermoformed textiles described herein
when used as outsoles, as obtained using the Durometer Hardness
Test and the Akron Abrasion Test as disclosed herein.
TABLE-US-00007 TABLE 7 Dry and Wet Coefficient of Friction for 2
Millimeter Flat Plaques 2 mm Flat Plaque Geometry DIN Smooth Dry
Concrete Smooth Wet Concrete Polymer and Rubber Comparisons
Abrasion 3 .times. 3 .times. Material Polymer Durometer Specific
Mass Loss Dynamic Standard Dynamic Standard Grade Type Form
Supplier (Shore A) Gravity (mg) COF Deviation COF Deviation Rubber
A Rubber Solid N/A 67-70 1.16 70 1.305 0.050 0.470 0.030 Rubber B
Rubber Solid N/A 66-68 1.07 57 1.592 0.037 0.341 0.020 Estane
T470A-3 TPU Solid Lubrizol 77 1.14 74 1.055 0.017 0.463 0.010
Estane 58238 TPU Solid Lubrizol 75 1.17 65 1.039 0.012 0.483 0.044
Monprene SEBS TPE Solid Teknor Apex 76 0.89 374 1.211 0.024 0.873
0.022 SP66070 Monprene SEBS TPE Solid Teknor Apex 75 0.89 66 1.235
0.030 0.470 0.020 IN15074
TABLE-US-00008 Whole Footwear Outsole Abrasion and Coefficient of
Friction Testing Polymer and Rubber Comparisons Footwear Abrasion
Mass Whole Traction Loss (Grams) Footwear Footwear Traction (After
at 96 Hours, Abrasion (Before Abrasion) Abrasion) 180 Pound Dry Wet
Dry Wet Load, 1 Concrete Concrete Concrete Concrete Type
Strike/Second COF COF COF COF TPU 1.6 1.03 0.65 0.92 0.58 TPU 1.4
1.08 0.53 0.91 0.56 SEBS 2.2 1.05 0.63 1.12 0.64
TABLE-US-00009 TABLE 9 Hardness and Abrasion Loss for Thermoformed
Outsoles Density Polymer Polymer Polymer Akron (grams COF Dry COF
Wet Polymer Abrasion Polymer Akron Sample Polymer Durometer per
cubic Concrete Concrete DIN (cubic Abrasion Name Type Usage (Shore
A) centimeter) Smooth Smooth Abrasion centimeters) (grams) Rubber A
Butadiene Outsole 66 1.15 1.305 0.470 70 0.248 0.29 synthetic
rubber rubber blend Rubber B Peroxide Outsole 66 1.08 1.592 0/341
57 0.2 0.22 cured rubber rubber blend WC2 - Plaque TPU Estane
Polymer test 72 1.13 1.055 0.463 74 T470A-3 plaque WC1 - Plaque TPU
Estane Polymer test 70 1.17 1.039 0.483 65 58238 plaque WC3 -
Plaque TPE Polymer test 70 0.9 1.211 0.873 374 Monprene plaque
SP066070 WC2 - Fused TPU Estane 0.4 millimeter 72 1.52 0.51 0.13
Knit T470A-3 yarn in knit WC1 - Fused TPU Estane 0.4 millimeter 70
0.85 0.52 0.06 Knit 58238 yarn in knit WC3 - Fused TPE 0.4
millimeter 70 1.06 0.52 0.32 Knit Monprene yarn in knit
SP066070
[0533] Yarn candidate coatings are abbreviated herein and in Tables
8 and 9 as follows with respect to coated yarns: WC1=coated with or
plaque formed from Estane 58238 TPU, WC2=coated with or plaque
formed from Estane T470A-3 TPU, WC3=coated with or plaque formed
from Monprene SP66070 TPE.
[0534] Solid polymers and corresponding coated yarns were tested
for abrasion mass loss and traction using the Akron Abrasion Test
and the Sample Coefficient of Friction Test as described herein.
Traction properties of the thermoformed knit textiles were
comparable to polymer test plaques and to rubber outsole materials,
indicating that the thermoformed knit textiles were successfully
thermoformed to form thermoformed networks (Table 9). Additionally,
Akron abrasion material losses measured for the thermoformed knit
textiles were comparable to the rubber control references. Mass
loss measured for Akron abrasion test strips 0.5 inches wide and 8
inches long were comparable to much larger outsole areas of whole
shoe mass as described in Table 8. Thus, test strips and whole shoe
performance are consistent and thermoformed knit textiles were
shown to be acceptable as outsole materials as they did not lose
material out of scale with representative rubbers and further, the
thermoformed knit textiles exhibited sufficient traction properties
to perform as outsoles.
Evaluation of Coated Yarns
[0535] Two sample types of coated yarns were prepared into flat
knit textile swatches. The first swatch used UNIFI polyethylene
terephthalate (polyester) yarn (158 denier, tenacity of 7.131 grams
per denier, 23.42 percent elongation) as the core yarn, and was
coated with a polymeric composition consisting essentially of
Estane 58238 at a thickness of about 0.4 millimeters. The second
swatch used the same UNIFI polyethylene terephthalate yarn core
yarn, but was coated with a polymeric composition consisting
essentially of Monprene TPE SP66070 at a thickness of about 0.4
millimeters. The flat knit textile swatches were thermoformed
either without texture or with a herringbone texture prior to
testing.
[0536] There are two versions knit for each type of coated yarn:
single yarn end edge-2 knit structures (1.times.1) and two yarn end
edge-2 knit structures (1.times.2) that have one end of yarn on the
surface of the thermoformed network of the thermoformed textile, or
two ends of yarn (for a greater concentration of the polymeric
coating) at the surface of the thermoformed network, respectively.
The knit structure of the swatches also included an end of the
uncoated UNIFI PET yarn. The description of the knit structures,
i.e., (1.times.1) and (1.times.2), identifies the number of ends of
yarn used, where the first number corresponds to the number of
uncoated polyester yarns present and the second number corresponds
to the number of coated yarns present. The edge-2 knit structure is
a double-bed knit structure with tuck knit stitches connecting the
two faces of the knit textile. One face of the textile is
exclusively uncoated polyester yarn and the other is exclusively
the coated yarn under evaluation, with the tuck stitches connecting
the two exterior facing knit surfaces. Tuck stitches are
constructed from the same coated yarns as the outer face yarn.
[0537] All samples were tested for Akron abrasion in accordance
with the Akron Abrasion Test, and wet/dry traction COF testing
according to the Sample Coefficient of Friction test on court and
concrete. The results are provided in Tables 10 and 11.
[0538] Overall, the thermoformed textiles knitted from the coated
yarn with a coating consisting essentially of the SEBS-based
Monprene demonstrated a high dynamic coefficient of friction on
concrete and court (Table 10). The thermoformed textiles including
the Monprene coated yarn demonstrated higher coefficients of
friction when thermoformed flat on smooth concrete and court. The
thermoformed textiles including the Monprene coated yarn
demonstrated good coefficients of friction when tested dry and when
wet.
[0539] The thermoformed textiles knitted from the coated yarn with
a coating consisting essentially of the Estane demonstrated higher
coefficients of friction when thermoformed flat and tested on
smooth concrete and court; the herringbone texture demonstrated a
greater coefficient of friction when tested on rough concrete.
(Table 10). The thermoformed textiles including the Estane coated
yarn demonstrated a good coefficient of friction when tested dry
and wet (with some exceptions).
[0540] Overall, the thermoformed 1.times.2 knit textiles exhibited
less volumetric loss on abrasion testing than the thermoformed
1.times.1 knit textiles. The thermoformed textiles including the
Estane coated yarn exhibited less volumetric loss than the
thermoformed textiles including the Monprene coated yarn.
TABLE-US-00010 TABLE 10 Traction Results Outsole Dry Smooth Wet
Smooth Dry Wet Dry Rough Wet Rough Texture Concrete Concrete Court
Court Concrete Concrete Monprene Coated Yarn, Not Textured 1.06
.+-. 0.32 0.52 .+-. 0.21 0.96 .+-. 0.12 0.49 .+-. 0.78 0.88 .+-.
0.15 0.51 .+-. 0.07 1 .times. 1 knit Herringbone 0.96 .+-. 0.25
0.50 .+-. 0.31 0.63 .+-. 0.02 0.35 .+-. 0.40 0.78 .+-. 0.21 0.57
.+-. 0.04 Texture Monprene Coated Yarn, Not Textured 1.06 .+-. 0.32
0.50 .+-. 0.04 1.04 .+-. 0.13 0.42 .+-. 0.54 0.82 .+-. 0.23 0.51
.+-. 0.02 1 .times. 2 knit Herringbone 0.98 .+-. 0.38 0.53 .+-.
0.29 0.46 .+-. 0.08 0.36 .+-. 0.26 0.89 .+-. 0.12 0.54 .+-. 0.08
Texture Estane Coated Yarn, Not Textured 0.85 .+-. 0.15 0.53 .+-.
0.12 1.01 .+-. 0.15 0.39 .+-. 0.36 0.51 .+-. 0.25 0.35 .+-. 0.02 1
.times. 1 knit Herringbone 1.02 .+-. 0.12 0.46 .+-. 0.28 0.38 .+-.
0.21 0.23 .+-. 0.21 0.78 .+-. 0.11 0.32 .+-. 0.04 Texture Estane
Coated Yarn, Not Textured 0.72 .+-. 0.36 0.43 .+-. 0.07 0.95 .+-.
0.04 0.91 .+-. 0.04 0.44 .+-. 0.11 0.34 .+-. 0.02 1 .times. 2 knit
Herringbone 0.76 .+-. 0.14 0.47 .+-. 0.31 0.55 .+-. 0.32 0.57 .+-.
0.32 0.67 .+-. 0.14 0.34 .+-. 0.02 Texture Typical Nike Not
Textured 1.35 .+-. 0.05 0.47 .+-. 0.03 1.25 .+-. 0.17 0.44 .+-. 0.1
0.945 .+-. 0.02 0.455 .+-. 0.03 rubber outsole formulation
TABLE-US-00011 TABLE 11 Abrasion Resistance Results Mass Mass Mass
Abrasion Average before after 300 after 3000 Resistance
Thermoformed Specific testing cycle break-in (+300) cycles (cubic
centimeter Sample Texture Gravity (grams) (grams) (grams) loss)
Monprene Coated Yarn, Flat 0.815 40.5613 40.5172 40.1456 0.456 1
.times. 1 knit Monprene Coated Yarn, Flat 0.800 41.0536 41.015
40.695 0.400 1 .times. 2 knit Estane Coated Yarn, Flat 0.939
42.9179 42.9107 42.8502 0.064 1 .times. 1 knit Estane Coated Yarn,
Flat 0.895 43.7073 43.6934 43.658 0.040 1 .times. 2 knit Estane
Coated Yarn, Flat 0.895 43.7073 43.6934 43.658 0.040 1 .times. 2
knit
Textile and Article Thermoforming Processes
[0541] Coated and uncoated yarns were knit into edge-2 1.times.2 or
1.times.1 swatches and lightly pressed in a t-shirt press at 20
pounds per square inch and 150 degrees Celsius for 20 seconds to
avoid fraying. The swatches were cut into outsole shapes and placed
into a rubber-phylon mold having the cavity size of a standard
rubber mold but coated for heating and cooling cycles similar to a
phylon mold. The empty mold was preheated to the melting
temperature of the polymer plus 15 degrees Celsius as measured by a
thermocouple. The cut outsole shapes were placed into the mold with
uncoated polyester yarn side up and pressed for 45 seconds, then
cooled for at least 60 seconds, or 90 seconds if time allowed. In
some cases, the edge-2 1.times.1 swatches were not large enough
material to fill the mold. When the swatches were not large enough
to fill the mold, silicone, rubber, or other material was added to
fill the mold. Tested temperatures, polymers present in the yarn
coating, and times are provided in Table 12:
TABLE-US-00012 TABLE 12 Thermoforming Processing Conditions Melting
Processing Temperature Temperature (degrees (degrees Material Grade
Celsius) Celsius) Monprene 66070 160 175 Estane 58238 130 145
Estane T470A-3 150 165
[0542] When a regular thermoforming process was used, this was
conducted on a DMT Press with a total heating time of 35 to 45
seconds and a pressure of 30 bar. The process was stopped when the
thermocouple reached 130 degrees Celsius or 150 degrees Celsius
depending on the end point.
[0543] When a flat molding process was used, this was conducted on
a Kukdong heat press with a total heating time of from 30 seconds
to 60 seconds or until the textile reached 150 degrees Celsius as
measured by thermocouple. Temperature was held for 0 to 10 seconds
as needed. The heating pressure was 0.1 megapascals and the heat
press set point was 190 degrees Celsius. Heating was stopped when
the thermocouple reached 150 degrees Celsius, with some samples
receiving an additional dwell time of 10 seconds as indicated. Cold
pressing at 20 degrees Celsius was then carried out at 0.1
megapascals for 30 seconds.
[0544] When infrared (IR) heating and/or thermoforming was used,
coated yarns were knitted into an exemplary upper and the upper was
placed in a Flash Activator with the surface of the upper to be
heated facing the heating elements. In some experiments, the
surface of a knit upper configured to be externally-facing was
placed facing the heating elements, while in other experiments, the
surface of the knit upper configured to be internally-facing was
placed facing the heating elements. However, the knit textile can
be laid flat, heated, and then formed, or heated on a last in three
dimensions and formed. The knit textile was exposed to IR flash
heat for about 23 seconds, which was sufficient for the local
temperature of the irradiated surface to reach 160 degrees Celsius
or more. The upper and last were then removed from the Flash
Activator and temperature was measured with a heat gun while moving
the upper to a vacuum machine in order to verify the temperature
was greater than the melting point of the polymeric composition of
the yarn coating. The knit upper was then positioned on a vacuum
stage so that the newly thermoformed surface of the textile of the
upper contacted the desired template master pattern for forming. A
textured embossing pad (rubber, plastic, or silicone) was placed
face down on the thermoformed surface of the upper such that the
thermoformed surface is in contact with the silicone pad molding
pattern. The embossing pad can be at room temperature or heated to
120 to 200 degrees Celsius depending on the length of time needed
to maintain a higher temperature on the molten polymeric
composition of the coating. The embossing pad and knit textile of
the upper were pressed in a vacuum machine for 60 seconds. The
vacuum was released and discharged to reveal the surface of the
thermoformed network of the thermoformed knit textile.
Abrasion Resistance of Textiles
[0545] Shown in Table 13 are abrasion mass losses for
unthermoformed knit textiles and thermoformed knit textiles which
were thermoformed in a flat configuration as determined after 300
and 3000 cycles of abrasion testing using the Akron Abrasion Test.
The knit textiles were knit using the UNIFI polyester core yarn
described above coated with a polymeric composition comprising a
thermoplastic styrene copolymer elastomer (Monprene 66070) or a
thermoplastic polyurethane elastomer (Estane 58238). The knit
structure of the knit textile included either 1 end (1.times.1) or
2 ends (1.times.2) of the coated yarn and 1 end of the uncoated
UNIFI polyester yarn knit on the surface of the knit textile which
was tested. The knit structures are those described above.
TABLE-US-00013 TABLE 13 Akron Abrasion Loss at 300 Cycles and 3000
Cycles for Thermoformed and Unthermoformed Knit Textiles Mass at
Mass Loss at Mass Loss at Mass Loss at Initial Mass 300 Cycles 300
Cycles 3000 Cycles 3000 Cycles Sample Test Material Form and
Structure (grams) (grams) (milligrams) (grams) (milligrams) Rubber
A Flat Sheet Rubber 48.400 48.3461 53.7 48.0663 334 Monprene 66070
1 .times. 1 Knit 40.741 40.7395 1.9 40.5382 203 Knit Structure
Unthermoformed Flat Thermoformed 40.561 40.5172 44.1 40.1456 416
Knit Monprene 66070 1 .times. 2 Knit, 41.537 41.5271 9.4 41.3315
205 Knit Structure Unthermoformed Flat Thermoformed 41.054 41.015
38.6 40.695 359 Knit Estane 58238 1 .times. 1 Knit, 42.177 42.1746
2.8 41.6774 500 Knit Structure Unthermoformed Flat Thermofomed
42.918 42.9107 7.2 42.8502 68 Knit Estane 58238 1 .times. 2 Knit,
44.510 44.5051 4.9 44.3383 172 Knit Structure Unthermoformed Flat
Thermoformed 43.707 43.6934 13.9 43.658 49 Knit
[0546] The thermoformed knit textiles showed performance equal to
or superior to conventional rubber, and showed similar performance
regardless of whether 1 or 2 ends were used at the top knit
surface.
Durability and Weatherization
[0547] Durability and weatherization were assessed as a function of
knit structure and processing conditions using the Stoll Abrasion
Test, Bally Flex Test, Wet Bally Flex Test, and Water Resistance
Test as described herein. A knit textile was produced using yarns
coated with a polymeric composition comprising a thermoplastic
elastomer (Estane T470A-3) (WC2 yarns), and thermoformed by heating
in a press manufactured by Kukdong Machinery (Busan, Korea) under
flat molding conditions to 150 degrees Celsius. For some samples,
the textile was held in the press for an additional 10 seconds of
dwell time after reaching the temperature of 150 degrees Celsius.
"Knit A" samples were knit samples having a knit structure in
which, when thermoformed, 75-100 percent of the total surface area
of the thermoformed network was defined by the re-flowed and
re-solidified polymeric composition. "Knit B" samples were knit
samples having a knit structure in which, when thermoformed, 40-70
percent of the total surface area of the thermoformed network was
defined by the re-flowed and re-solidified polymeric composition.
"Knit C" samples were knit samples having a knit structure in
which, when thermoformed, 15-35 percent of the total surface area
of the thermoformed network was defined by the re-flowed and
re-solidified polymeric composition. Performance of the Wet Bally
Flex Test and Water Resistance Test were performed on textile
samples having at least 90 percent of their surface area covered by
thermoformed network in order to minimize water transmission
through the sample.
TABLE-US-00014 TABLE 14 Durability and Weatherization as a Function
of Knit Structure and Processing Thermoformed Stoll Bally Wet Bally
Water Knit Samples Abrasion Flex Flex Resistance Knit A 2500 100
Knit A with 10 2500 100 15000 80 Second Dwell Knit B 1200 100 Knit
B with 10 2200 100 Second Dwell Knit C 600 100
Textile-to-Ball and Upper-to-Ball Interactions
[0548] Thermoformed textiles and uppers for articles of footwear
including the thermoformed textiles were manufactured, where the
region of the textile or upper tested included a thermoformed
network comprising a polymeric as disclosed herein. "Knit A", "Knit
B", and "Knit C" are as described above.
[0549] from the knit textiles were knit using coated yarns, wherein
the coating included a polymeric composition comprising a
thermoplastic polyurethane elastomer (Estane T470A-3). The coated
yarn included a 0.4 millimeter coating of the polymeric composition
on a 150-600 denier multifilament polyester yarn. Dry and wet
coefficients of friction are presented in Table 15:
TABLE-US-00015 TABLE 15 Dry and Wet Static and Dynamic Coefficients
of Friction (COF) for Thermoformed Knit Textiles Dry Wet Drop
Average Average Average Average in COF Sample Textile Static
Standard Dynamic Static Standard Dynamic When Type COF Deviation
COF COF Deviation COF Wet Duragon (Polyurethane 1.35 0.04 1.15 0.86
0.04 0.57 -36% Laminated Skin on Polyester Textile) Thermoformed
Knit A 1.55 0.07 1.46 1.15 0.04 0.76 -26% (Knit from Estane T470A-3
coated yarn) Thermoformed Knit B 1.42 0.11 1.22 0.94 0.06 0.51 -34%
(Knit from Estane T470A-3 coated yarn Thermoformed Knit C 1.21 0.07
0.97 0.91 0.04 0.54 -25% (Knit from Estane T470A-3 coated yarn)
[0550] Thermoformed knit samples showed similar dry and wet
coefficients of friction (e.g., boot-to-ball interaction) as the
laminated Duragon skin. but in a streamlined, more integrated,
lower waste manner of construction.
[0551] Kangaroo leather displays little change between wet COF and
dry COF, but both wet and dry COF are low for this material
overall. DURAGON skin displays higher wet COF and dry COF but also
a large difference between these two values. Thermoformed textiles
and/or footwear uppers containing the coated yarns disclosed herein
exhibit higher wet and dry COF values overall, and a lower degree
of difference between dry COF and wet COF than DURAGON skin.
[0552] Samples of knit textiles "Knit A", "Knit B", and "Knit C"
thermoformed at 150 degrees C. as described above were tested using
the Ball Speed and Spin After Textile-Ball Impact Test described
above. Control samples of Duragon polyurethane film laminated on a
PET knit and kangaroo leather were subjected to the same test.
TABLE-US-00016 TABLE 16 Material Effect on Soccer Ball Spin Rate
Ball Spin Rate (revolutions Standard Sample per minute) Deviation
Duragon Film 226.5 10.0 Thermoformed Knit C (Knit with 229.0 7.0
Estane T470A-3 coated yarn) Thermoformed Knit B (Knit with 229.0
4.0 Estane T470A-3 coated yarn) Thermoformed Knit A (Knit 236.0 8.0
with Estane T470A-3 coated yarn) Kangaroo Leather 223.0 7.0
[0553] Uppers for full soccer boots were constructed from the yarns
coated with a polymeric composition comprising a thermoplastic
polyurethane elastomer (either Estane 58238 or Estane T470A-3),
thermoformed under different processing conditions, and tested
using the Ball Speed and Spin After Upper-Ball Impact Test
described above. Results are presented in Table 17:
TABLE-US-00017 TABLE 17 Full Lasted Boot Kick Test on Ball Average
Ball Thermo- Spin Rate Textile forming Type of (revolutions
Standard Description Conditions Boot per minute) Deviation Textile
+ Duragon N/A Commercially 204 7 Polyurethane available Laminate
Skin Upper A (Knit with 130 Test 218 7 Estane 58238 degrees Coated
Yarn) Celsius Upper B (Knit with 150 Test 217 6 Estane 58238
degrees Coated Yarn) Celsius Upper C (Knit with 170 Test 212 9
Estane 58238 degrees Coated Yarn) Celsius Upper D (Knit with 130
Test 219 6 Estane T470A-3 degrees Coated Yarn) Celsius Upper E
(Knit with 150 Test 212 9 Estane T470A-3 degrees Coated Yarn)
Celsius Upper F (Knit with 170 Test 212 8 Estane T470A-3 degrees
Coated Yarn) Celsius Upper G (Knit with 170 Comparative 205 7 90
Shore A TPU degrees test Coated Yarn) Celsius
[0554] These results indicate the 90 Shore A TPU made into coated
yarn to form a knit and thermoformed upper showed lower spin rates,
which is less desirable. Harder materials (as indicated by Shore A
Durometer values) are more abrasion resistant.
[0555] Each of the thermoformed uppers knit with yarns coated with
a thermoplastic composition comprising a thermoplastic polyurethane
elastomer having a durometer of about 65 to 85 Shore A created
higher levels of ball spin. as compared to thermoformed knit uppers
knit using a yarn coated with a thermoplastic composition
comprising a thermoplastic polyurethane elastomer having a
durometer of about 90 Shore A, and commercially available uppers
formed of DURAGON skin.
* * * * *