U.S. patent application number 17/096626 was filed with the patent office on 2021-05-20 for foamable and foamed textiles, the process of manufacturing the same, and articles incorporating the same.
This patent application is currently assigned to NIKE, Inc.. The applicant listed for this patent is NIKE, Inc.. Invention is credited to Austin Baranek, Katharine Fraser, Stephen J. Hipp, James Molyneux, Kristen E. Orme, Margaret P. St. Clair, Yang Zhao.
Application Number | 20210148010 17/096626 |
Document ID | / |
Family ID | 1000005286360 |
Filed Date | 2021-05-20 |
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United States Patent
Application |
20210148010 |
Kind Code |
A1 |
Baranek; Austin ; et
al. |
May 20, 2021 |
FOAMABLE AND FOAMED TEXTILES, THE PROCESS OF MANUFACTURING THE
SAME, AND ARTICLES INCORPORATING THE SAME
Abstract
A textile component includes a yarn which includes a
thermoplastic material. A blowing agent with at least activation
condition is included into the textile, either by inclusion in the
yarn or impregnating in the textile after forming an un-foamed
textile. Upon triggering the activation condition of the blowing
agent, the blowing agent introduces a plurality of cavities, i.e.
cells, into the thermoplastic material. The textile then comprises
a multicellular foam area of the textile wherein the multicellular
foamed area comprises a multicellular foam surrounding a core yarn.
The textile, in either its un-foamed or foamed condition, can be
incorporated into a variety of articles, such as an article of
footwear.
Inventors: |
Baranek; Austin; (Beaverton,
OR) ; Fraser; Katharine; (Portland, OR) ;
Hipp; Stephen J.; (Hillsboro, OR) ; Molyneux;
James; (Portland, OR) ; Orme; Kristen E.;
(Portland, OR) ; St. Clair; Margaret P.;
(Beaverton, OR) ; Zhao; Yang; (Beaverton,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Assignee: |
NIKE, Inc.
Beaverton
OR
|
Family ID: |
1000005286360 |
Appl. No.: |
17/096626 |
Filed: |
November 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62937092 |
Nov 18, 2019 |
|
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|
62939110 |
Nov 22, 2019 |
|
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|
62937117 |
Nov 18, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2501/043 20130101;
A43B 23/0215 20130101; D03D 15/00 20130101; D10B 2321/021 20130101;
D10B 2401/041 20130101; A43B 1/14 20130101; D10B 2321/08 20130101;
D01D 5/247 20130101; D10B 2401/08 20130101 |
International
Class: |
D01D 5/247 20060101
D01D005/247; A43B 1/14 20060101 A43B001/14; A43B 23/02 20060101
A43B023/02; D03D 15/00 20060101 D03D015/00 |
Claims
1. An upper for an article of footwear comprising: a textile
including a first yarn, the first yarn comprising a core yarn and a
first thermoplastic material forming an unfoamed coating at least
partially surrounding the core yarn; wherein the core yarn
comprises a plurality of fibers or filaments, each of the plurality
of fibers or filaments comprising a core material; and wherein the
first thermoplastic material comprises at least one first
thermoplastic polymer chosen from a thermoplastic polyurethane, a
thermoplastic polyolefin, a thermoplastic polyester, a
thermoplastic polyether, a thermoplastic polyamide, or any
combination thereof; and a chemical blowing agent, wherein the
chemical blowing agent is present in the first thermoplastic
material in an amount effective to foam the unfoamed coating of the
first thermoplastic material into a multicellular foam.
2. The upper for an article of footwear of any claim 1, wherein the
textile is a knitted textile, and the knitted textile further
comprises a second yarn.
3. The upper for an article of footwear of claim 2, wherein the
first yarn is inlayed in the knitted textile between courses of the
second yarn.
4. The upper for an article of footwear of claim 2, wherein the
second yarn is interlooped with at least one loop of the first
yarn.
5. The upper for an article of footwear of claim 1, wherein the
first thermoplastic material comprises the thermoplastic polyolefin
and the thermoplastic polyolefin includes a thermoplastic
ethylene-vinyl acetate copolymer, wherein the chemical blowing
agent is a thermally-activated chemical blowing agent, wherein the
first thermoplastic material further comprises a
thermally-activated cross-linking agent, and wherein the core
material comprises a thermoplastic polyester.
6. An upper for an article of footwear comprising: a textile
comprising a multicellular foam at least partially surrounding and
attached to a core yarn; wherein the core yarn comprises a
plurality of fibers or filaments, each of the plurality of fibers
or filaments comprising a core material; and wherein the
multicellular foam is the product of processing an unfoamed coating
at least partially surrounding the core yarn to expand the unfoamed
coating into the multicellular foam; wherein the multicellular foam
comprises a first polymeric material including at least one first
polymer chosen from a polyurethane, a polyolefin, a polyether, a
polyamide, or any combination thereof; and the degradation product
of a chemical blowing agent.
7. The upper for an article of footwear of claim 6, wherein the
unfoamed coating comprises a first thermoplastic material including
at least one first thermoplastic polymer chosen from a
thermoplastic polyurethane, a thermoplastic polyolefin, a
thermoplastic polyester, a thermoplastic polyether, a thermoplastic
polyamide, or any combination thereof; and a chemical blowing
agent, wherein the chemical blowing agent is present in the first
thermoplastic material in an amount effective to foam the unfoamed
coating of the first thermoplastic material into the multicellular
foam.
8. The upper for an article of footwear of claim 7, wherein the
first polymeric material is a cross-linked polymeric material.
9. The upper for an article of footwear of claim 8, wherein the
unfoamed coating comprises a first thermoplastic material including
at least one first thermoplastic polymer chosen from a
thermoplastic polyurethane, a thermoplastic polyolefin, a
thermoplastic polyester, a thermoplastic polyether, a thermoplastic
polyamide, or any combination thereof; a cross-linking agent; and a
chemical blowing agent, wherein the chemical blowing agent is
present in the first thermoplastic material in an amount effective
to foam the unfoamed coating of the first thermoplastic material
into the multicellular foam.
10. The upper for an article of footwear of claim 7, wherein the
multicellular foam has a hardness from about 30 to about 60 as
measured by an Asker C durometer.
11. The upper for an article of footwear of claim 7, wherein the
textile further comprises a second yarn, and the second yarn is
exposed on a first surface of the textile.
12. The upper for an article of footwear of claim 7, wherein the
multicellular foam defines a foamed area on the first surface of
the textile.
13. The upper for an article of footwear of claim 12, wherein the
textile includes a plurality of the foamed areas, and at least
three of the plurality of foamed areas are regularly spaced or
periodically arranged relative to each other.
14. The upper for an article of footwear of claim 12, wherein the
textile includes a plurality of the foamed areas, and the plurality
of foamed areas are randomly dispersed across the first surface of
the textile.
15. The upper for an article of footwear of claim 12, wherein the
foamed area has a shape, and the shape is a representative
shape.
16. A method for processing an upper for an article of footwear,
the method comprising the steps of: forming a foamed area in a
textile portion of the upper by expanding at least a portion of an
unfoamed coating of a yarn present in the textile into a
multicellular foam by increasing a temperature of the yarn to a
first processing temperature; after expanding the unfoamed coating
into the multicellular foam, decreasing a temperature of the
multicellular foam to a second processing temperature at which the
multicellular foam adheres to the core yarn, adheres to a
surrounding portion of the textile, and solidifies while retaining
its multicellular structure, thereby forming the foamed area in the
textile portion; wherein the yarn comprises a core yarn and a first
thermoplastic material forming the unfoamed coating, the first
thermoplastic material at least partially surrounds the core yarn,
the core yarn comprises a plurality of fibers or filaments, and
each of the plurality of fibers or filaments comprising a core
material; wherein the first thermoplastic material comprises at
least one first thermoplastic polymer chosen from a thermoplastic
polyurethane, a thermoplastic polyolefin, a thermoplastic
polyester, a thermoplastic polyether, a thermoplastic polyamide, or
any combination thereof, the first thermoplastic material further
comprises a blowing agent, and the blowing agent is present in the
first thermoplastic material in an amount effective to expand the
unfoamed coating of the first thermoplastic material into a
multicellular foam; and wherein the first processing temperature is
a temperature at or above a softening temperature of the first
thermoplastic material.
17. The method of claim 16, wherein the multicellular foam is a
cross-linked foam, and the first thermoplastic material further
comprises a cross-linking agent.
18. The method of claim 16, wherein the core material is a second
thermoplastic material, and the first processing temperature is a
temperature at least 20 degrees Celsius below a softening
temperature of the second thermoplastic material.
19. The method of claim 16, wherein the blowing agent is a
thermally-activated blowing agent, and the first processing
temperature is a temperature at or above the activation temperature
of the thermally-activated blowing agent, and optionally, when the
multicellular foam is a cross-linked foam and the first
thermoplastic material further comprises a thermally-activated
cross-linking agent, the first processing temperature is a
temperature at or above the activation temperature of the
thermally-activated cross-linking agent.
20. An upper for an article of footwear made by the method of claim
16.
Description
RELATED APPLICATIONS
[0001] The present patent document claims the benefit of priority
under 35 U.S.C. 119(e) to U.S. Provisional Patent Application
62/937,092, filed on Nov. 18, 2019, to U.S. Provisional Patent
Application 62/939,110, filed on Nov. 22, 2019, and to U.S.
Provisional Patent Application 62/937,117, filed on Nov. 18, 2019.
All of the aforementioned patent applications are hereby
incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a textile made
with a foamable yarn, a method of processing a textile with a
foamable yarn, the textile that results from processing the
foamable yarn, a textile including a processed foamed yarn, an
article incorporating a textile including a foamable yarn, and an
article that incorporates a processed textile including a foamed
yarn.
BACKGROUND
[0003] Textiles have long been used in the manufacture of various
articles of apparel, footwear, and more. The incorporation of a
textile can add desirable texture or other characteristics such as
elasticity, strength, weight, durability, texture, breathability,
cushioning, and other properties. Manufacture of the textile can
include any of a number of techniques, including knitting,
crocheting, weaving, in-laying, among others. These various
techniques can impart different properties to the textile, such as
texture, density, pattern, weave, drape, rigidity, strength,
elasticity, among others. Additionally, various processes of
incorporating yarn into a textile may facilitate the textile
manufacture. An article made of such a textile can be manufactured
efficiently with minimal material waste.
[0004] Additionally, polymeric foamed products have a variety of
advantages including a low raw material consumption, low density,
excellent thermal and acoustic insulation, mechanical dampening and
shock absorption, low water vapor permeability, reduced moisture
absorption, and more. These properties make foams useful in a
variety of sectors, including packaging, thermal/acoustic
insulation, upholstery, footwear and apparel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The embodiments may be better understood with reference to
the following drawings and description. The components in the
figures are not necessarily to scale. In the figures,
like-referenced numerals designate corresponding parts throughout
the different views.
[0006] FIG. 1: a cross-sectional rendering of a foamable textile
before processing;
[0007] FIGS. 2A-2F: cross-sectional renderings of various examples
of a foamed textile after processing with a first surface texture
and a second surface texture;
[0008] FIGS. 3A-3C: cross-sectional renderings of various examples
of multi-layer foamed textiles after processing with a first
surface texture and a second surface texture;
[0009] FIG. 4: a perspective view of a foamable textile before
processing;
[0010] FIG. 5: a perspective view of a foamed textile after
processing with a first surface texture and a second surface
texture;
[0011] FIGS. 6A-6C: cross-sectional views of renderings of an
example of the application of a mold to a foamable textile, foaming
the textile in the mold, and the foamed textile with a first
surface texture and a second surface textures;
[0012] FIGS. 7A-7D: cross-sectional views of renderings of an
example of the application of a mold to a foamable textile, foaming
the foamable textile, molding the textile, and the foamed textile
with a first surface texture and a second surface textures;
[0013] FIG. 8: a perspective view of an exemplary foamed textile
after processing with a variety of surface textures.
DETAILED DESCRIPTION
[0014] The subject-matter of the disclosure may also relate, among
others, to the following aspects:
[0015] I. Unprocessed Textile
[0016] Described herein is a textile 100 comprising at least one
thermoplastic yarn 110. Generally, a textile may be defined as a
structure manufactured from fibers, filaments, or yarns
characterized by flexibility, fineness, and a high ratio of length
to thickness. Textiles generally fall into two categories. The
first category includes textiles produced directly from webs of
fibers, filaments and/or yarns by randomly interlocking the fibers,
filaments and/or yarns to construct non-woven textiles such as
felts. The second category includes textiles formed through a
mechanical manipulation of yarn(s) (e.g., by interlacing or
interlooping one or more yarns) to produce the textile. Examples of
textiles produced through mechanical manipulation include woven
textiles, knitted textiles, crocheted textiles, braided textiles,
and tatted textiles.
[0017] Generally, a yarn is the raw material utilized to form
textiles. In general, yarn is defined as an assembly having a
substantial length and relatively small cross-section that is
formed of at least one filament or a plurality of fibers. Fibers
have a relatively short length and typically utilize spinning or
twisting processes to produce a yarn of suitable length and
tenacity for use in textiles. Common examples of fibers are cotton
and wool. Filaments, however, have a substantially longer length
and may be used alone or can be combined with other filaments to
produce a yarn suitable for use in textiles. Filaments include
naturally occurring materials such as silk, or can be made from a
plurality of synthetic materials such as glass, carbon, or
polymeric materials including rayon, nylon, polyester, and
polyacrylic. Yarn may be formed of a single filament, which is
conventionally referred to as a "monofilament strand" or
"monofilament yarn," or a plurality of individual filaments grouped
together such as by twisting or entangling. Yarn may also include
separate filaments formed of different materials, or the yarn may
include filaments that are each formed of two or more different
materials. Similar concepts also apply to yarns formed from fibers.
Accordingly, yarns may have a variety of configurations that
generally conform to the definition provided above.
[0018] The yarn 110 is comprising at least one thermoplastic
material comprising at least one thermoplastic polymer. The
thermoplastic material has a deformation temperature (at which
point the materials softens) and a melting point (the temperature
at which the thermoplastic material transitions between a solid and
liquid state). In some embodiments, the thermoplastic material
further comprises a blowing agent. In other words, when the
thermoplastic material of the yarn 110 is in an unfoamed state, the
yarn 110 is a "foamable" yarn, and the textile 100 comprising the
"foamable" yarn is a "foamable" textile.
[0019] A thermoplastic is a substance that softens and melts on
heating and hardens when cooling without undergoing a chemical
transformation. The first thermoplastic materials described herein
may comprise a naturally occurring thermoplastic polymeric
material, a regenerated thermoplastic material, a synthetic
thermoplastic material, or some combination thereof.
[0020] The yarn 110 can be incorporated into a variety of textile
structures by mechanically manipulating the yarn 110 through a
variety of means including, but not limited to, knitting, weaving,
crocheting, braiding, tatting, and wrapping, among others. The yarn
110 can be incorporated into a textile structure by inlaying the
yarn 110 into a textile structure. For example, the yarn can be
inlaid during a weaving, knitting, crocheting, braiding or tatting
process. The inlaid yarn 110 can be held in place by one or more
yarns forming the structure of the mechanically manipulated
textile. In knitting and crocheting, inlaying involves positioning
a yarn in the structure of a textile without forming loops with the
yarn. For example, in a double-needle flat knitting process, the
inlaid yarn 110 can be incorporated into the knit structure by
positioning the yarn between the needlebeds, without forming loops
with the inlaid yarn 110. In weaving, the inlaid yarn 110 can form
a portion of the weft yarns. In one embodiment, the yarn 110 can be
both inlaid and knit, crocheted, braided, tatted or woven into the
textile structure, where the yarn 110 is inlaid in a first portion
of the textile structure, and is knit, crocheted, braided, tatted
or woven in a second portion of the textile structure. In another
embodiment, the yarn 110 is only inlaid into the textile
structure.
[0021] In FIGS. 1-8, element 120 is a genericized representation of
a portion of a textile. The portion of the textile represented by
120 may be, but is not limited to, a knitted textile, a woven
textile, a crocheted textile, a braided textile, a tatted textile,
a wrapped textile, or some combination thereof.
[0022] As an example, the foamable textile 100 may be a knitted
structure comprising a first knit yarn and an inlayed yarn 110
wherein the inlayed yarn 110 is the yarn 110 as described above. In
one embodiment, the foamable textile 100 may be a knitted structure
120 of a first knit yarn with an inlayed yarn 130 wherein the
inlayed yarn 130 is the foamable yarn 110 as described above.
Alternatively, the foamable textile 100 may include a yarn
comprising a multicellular foam either in the first knit yarn, a
second knit yarn, or with the inlayed yarn 130. Alternatively, the
first knit yarn 120 may include the foamable yarn 110. In a second
embodiment, the foamable textile 100 may be a woven textile
comprising a first weft yarn and a second warp yarn wherein at
least a portion of the warp yarn comprises a foamable yarn 110.
[0023] In some embodiments, the first thermoplastic material may
include any of a variety of synthetic thermoplastic polymers,
including homopolymers or copolymers or a combination of
homopolymers and copolymers. For instance, the first thermoplastic
material may comprise: a thermoplastic polyurethane, including a
thermoplastic polyurethane consisting essentially of polyurethane
linkages, and a thermoplastic polyurethane copolymer such as a
polyether-polyurethane or a polyester-polyurethane. The first
thermoplastic material may comprise a thermoplastic polyolefin. The
thermoplastic polyolefin may comprise a thermoplastic polyethylene
homopolymer or copolymer, such as an ethylene-vinyl acetate
copolymer or an enthylene-vinyl alcohol copolymer or a
polyethylene-polyamide block copolymer. The thermoplastic
polyolefin may comprise a thermoplastic polypropylene homopolymer
or copolymer. The first thermoplastic material may comprise a
thermoplastic polyester homopolymer or copolymer such as, as
already mentioned, a polyester-polyurethane copolymer. The first
thermoplastic material may comprise a thermoplastic polyether
homopolymer or copolymer such as, as already mentioned, a
polyether-polyurethane copolymer. The first thermoplastic material
may comprise a thermoplastic polyamide homopolymer such as nylon 6,
nylon 11 or nylon 6,6 or a polyamide copolymer such as the
polyethylene-polyamide block copolymer previously mentioned. The
first thermoplastic material may comprise any combination of the
thermoplastic polymers disclosed above, including two or three or
four of the thermoplastic polymers. The first thermoplastic
material can be described as comprising a thermoplastic polymeric
component made up of all the thermoplastic polymers present in the
first thermoplastic material. The first thermoplastic material can
comprise from about 5 weight percent to about 100 weight percent of
the thermoplastic polymer component based on a total weight of the
first thermoplastic material. Alternatively, the thermoplastic
polymer component can comprise from about 15 weight percent to
about 100 weight percent, from about 30 weight percent to about 100
weight percent, from about 50 weight percent to about 100 weight
percent, or from about 70 weight percent to about 100 weight
percent of the first thermoplastic material.
[0024] Additionally, in other embodiments the first thermoplastic
material comprises a thermosetting thermoplastic material. As
described herein, a thermosetting material is a material which is
initially thermoplastic but which cures and becomes a thermoset
material when exposed to specific conditions (e.g., specific types
and levels of heat or light or other types of actinic radiation)
which initiate a chemical reaction such as a crosslinking reaction
within the material. A thermosetting material is understood to be
an uncured and, thus, prior to curing, is thermoplastic. When
cured, a thermosetting material undergoes a chemical change and
becomes a thermoset material. The examples of actinic radiation
that may trigger the curing can include microwave radiation,
radiowave radiation, electron beam radiation, gamma beam radiation,
infrared radiation, ultraviolet light, visible light, or a
combination thereof, among other conditions.
[0025] In some embodiments, the first thermoplastic material
further comprises a cross-linking agent. As understood in the art,
cross-linking agents are chemical products that chemically form
bonds between two hydrocarbon chains. The reaction can be either
exothermic or endothermic, depending on the cross-linking agent
used. The concentration of the cross-linking agent present in the
first thermoplastic material may be sufficient to partially
crosslink the first thermoplastic material, or may be sufficient to
fully crosslink the first thermoplastic material. In one example,
when the first thermoplastic material is a thermosetting
thermoplastic material, the thermosetting thermoplastic material
may comprise a concentration of the cross-linking agent sufficient
to fully crosslink the thermosetting thermoplastic material. One
skilled in the art would be able to select any number of
appropriate cross-linking agents that would be compatible with the
thermoplastic polymer and allow for cross-linking of the first
thermoplastic material under the desired processing conditions
including temperature, pressure, UV light exposure, and the
like.
[0026] In some instances a suitable cross-linking agent comprises a
homobifunctional cross-linking agent. Homobifunctional reagents
consist of identical reactive groups on either end of a spacer arm.
Examples of homobifunctional cross-linking agents include:
di(tert-butylperoxyisopropyl)benzene, dimethyl pimelimidate
dihydrochloride, 3,3'-dithiodipropionic acid
di(N-hydroxysuccinimide ester), suberic acid
bis(3-sulfo-N-hydroxysuccinimide ester) sodium salt, among
others.
[0027] In other instances, a suitable cross-linking agent comprises
a heterobifunctional cross-linking agent. Heterobifunctional
cross-linking agents have two distinct reactive groups, allowing
for cross-linking reactions to progress in a controlled, two-step
reaction. This can reduce the prevalence of dimers and oligomers
while crosslinking. Examples of heterobifunctional cross-linking
agents include: S-acetylthioglycolic acid N-hydroxysuccinimide
ester, 5-azido-2-nitrobenzoic acid N-hydroxysuccinimide ester,
4-azidophenacyl bromide, bromoacetic acid N-hydroxysuccinimide
ester, N-(3-Dimethylaminopropyl)-N'-ethylcarbodiimide
hydrochloride, N-(3-Dimethylaminopropyl)-N'-ethylcarbodiimide
hydrochloride, N-(3-dimethylaminopropyl)-N'-ethylcarbodiimide
hydrochloride, N-(3-dimethylaminopropyl)-N'-ethylcarbodiimide
hydrochloride purum, N-(3-dimethylaminopropyl)-N'-ethylcarbodiimide
hydrochloride, iodoacetic acid N-hydroxysuccinimide ester, among
others.
[0028] In other embodiments, the first thermoplastic material
comprises a blowing agent. As understood in the art, blowing agents
are substances that decompose or vaporize at an activation
temperature to produce quantities of gases or vapors. Accordingly,
they can be categorized as either chemical or physical blowing
agents. A chemical blowing agent is a compound which can release a
gas at its activation temperature. Generally, this released gas
does not chemically react with the thermoplastic polymer serving as
the polymer matrix. The process of evolving gas from the blowing
agent is usually exothermic; however, certain compounds that
decompose through thermal dissociation, such as bicarbonates,
evolve gas in a reversible and endothermic reaction. Chemical
blowing agents can be further subcategorized as inorganic and
organic agents. Inorganic blowing agents are used mainly in rubber
technology but may be used in plastic applications to create
additional cross-linking during the blowing process.
[0029] A physical blowing agent is a compound which can phase
transition to a gas when the temperature, pressure, or temperature
and pressure are changed. At a given pressure, the temperature at
which the physical blowing agent transitions to a gas is the
activation temperature. Physical blowing agents include
low-boiling-point hydrocarbons or inert gasses, liquids, and
supercritical fluids.
[0030] The choice of blowing agent can influence foam quality,
density, homogeneity, and the costs of the foamed product. As
discussed below, the characteristic property of these compounds is
their activation temperature, which determines their practical use
as blowing agents for a given thermoplastic material and for its
processing conditions. In order for the yarn 110 to be able to form
a stable foam, the first thermoplastic material must be deformable
or molten at the activation temperature of the blowing agent. To
that end, the thermoplastic-material deformation temperature may
the same as or may be lower than the blowing-agent activation
temperature.
[0031] In some embodiments, the thermoplastic-material deformation
temperature is at least 10 degrees Celsius below the blowing-agent
activation temperature. In some embodiments, the
thermoplastic-material deformation temperature is at least 20
degrees Celsius below the blowing-agent activation temperature. In
other embodiments, the first thermoplastic material has a softening
temperature or a melting temperature from about 50 degrees Celsius
to about 145 degrees Celsius.
[0032] In some embodiments, the chemical blowing agent has an
activation temperature that is at least 5 degrees Celsius above a
melting temperature of the first thermoplastic material. In other
embodiments, the activation temperature of the blowing agent is at
least 10 degrees Celsius above the melting temperature of the first
thermoplastic material. In further embodiments, the activation
temperature of the blowing agent is at least 20 degrees above the
melting temperature of the first thermoplastic material.
[0033] Other properties that may be considered when selecting a
chemical blowing agent include the following: affinity with the
thermoplastic polymer, maximum production of gases; activation
temperature at which the blowing agent evolves gas, rate of gas
evolution, toxicity, corrosiveness, odor of decomposition products,
effect of decomposition products on the color and other
physicochemical properties of the thermoplastic polymer, cost,
availability, stability against decomposition during storage, and
others.
[0034] In some embodiments, the blowing agent comprises a chemical
blowing agent. In some embodiments, the chemical blowing agent
comprises sodium bicarbonate, ammonium carbonate, ammonium
bicarbonate, calcium azide, azodicarbonamide, hydrazocarbonamide,
benzenesulfonyl hydrazide, dinitrosopentamethylene tetramine,
toluenesulfonyl hydrazide, p,p'-oxybis(benzenesulfonylhydrazide),
azobisisobutyronitrile, barium azodicarboxylate, or any combination
thereof.
[0035] In some embodiments, the blowing agent comprises a physical
blowing agent. In addition to partially halogenated
fluorochlorohydrocarbons, hydrocarbons (e.g. isobutene and pentane)
and inert liquids, gases or supercritical fluids, such as carbon
dioxide or nitrogen or a combination thereof, can serve as physical
blowing agents. Inert liquids, gases and supercritical fluids offer
many advantages, including, low environmentally harmful outputs,
low gas consumption, increased foam volume per weight of blowing
agent used, high cost-effectiveness, non-flammable, non-toxic,
chemically inert, minimal or no residues left behind in the
polymeric foam after processing. Additionally, carbon dioxide has
the advantage of having a higher solubility in many thermoplastic
polymers than other inert compounds, such nitrogen.
[0036] In some embodiments, the blowing agent is present in the
first thermoplastic material in an amount effective to foam the
first thermoplastic material into a multicellular foam 210
structure when the yarn 110 is processed. The amount of blowing
agent may be measured as the concentration of blowing agent by
weight in the first thermoplastic material. An amount of blowing
agent is considered effective when activating the blowing results
in at least a 10 percent increase in the volume of the first
thermoplastic material. In one example, the first thermoplastic
material can comprise from about 1 percent to about 10 percent by
weight, or from about 1 percent to about 5 percent by weight, or
from about 1 percent to about 3 percent by weight of the blowing
agent based on a total weight of the first thermoplastic material.
In another example, the first thermoplastic material comprises a
concentration of the blowing agent sufficient to expand the first
thermoplastic material by at least 100 percent by volume, or by 100
percent to 900 percent by volume, or by 200 percent to 500 percent
by volume, or by 300 percent to 400 percent by volume, based on an
initial volume of the first thermoplastic material prior to
foaming.
[0037] In some embodiments, more than one blowing agent may be
used. The combination of blowing agents may comprise at least two
chemical blowing agents, at least two physical blowing agents, or a
combination of a physical blowing agent and a chemical blowing
agent. Each blowing agent has an activation temperature at the
given processing pressure. These activations temperatures may be
about the same or may differ. By utilizing blowing agents with
different activation temperatures, processing of the yarn 110 into
a multicellular foam 310 structure can take place over a larger
operation window of temperatures. Additionally, by controlling the
temperature to activate a first blowing agent and then increasing
the temperature of the yarn 110 to activate the second blowing
agent, a variety of different desirable foam structures can be
achieved. In some embodiments, two blowing agents may have
activation temperatures that differ by at least about 5 degrees
Celsius. In some embodiments, two blowing agents may have
activation temperatures that differ by at least about 10 degrees
Celsius. In some embodiments, two blowing agents may have
activation temperatures that differ by at least about 20 degrees
Celsius.
[0038] A wide range of additives may also be used. Catalysts speed
up the reaction or, in some cases, reduce the reaction initiation
temperature. As discussed above, blowing agents that form gas
bubbles in the polymer or polymerizing mixture produce foam.
Surfactants may be added to control the size of bubbles. In
addition to the blowing agent and the optional cross-linking agent,
other additives that may be present in the first thermoplastic
material include a chain-extending agent, a filler, a flame
retardant, a coloring material (such as a dye or pigment), an
ultraviolet light absorber, an antioxidant, a lubricant, a
plasticizer, an emulsifier, a rheology modifier, an odorant, a
deodorant, a halogen scavenger, or any combination thereof,
depending on the application. In one example, the other additive is
present in the first thermoplastic material at a concentration of
from about 0.1 weight percent to about 20 weight percent, or from
about 0.2 weight percent to about 10 weight percent, or from about
0.5 weight percent to about 5 weight percent, based on a total
weight of the first thermoplastic material.
[0039] The molecular structure, amount, and reaction temperature of
each ingredient determine the characteristics and subsequent use of
the yarn 110 after processing. Therefore, each formulation may be
designed with the proper ingredients to achieve the desired
properties of the final material. By way of an example, different
blowing agents may require additional additives to maintain thermal
properties. Ultimately, the density of the foam after the yarn 110
is processed is determined by the number and size of the cells,
which is affected, at least in part, by the amount of blowing that
takes place during processing. By mixing different combinations of
the starting materials, the rates of the reactions and overall rate
of cure during processing can be controlled.
[0040] In some embodiments, the yarn 110 may be a monofilament
consisting essentially of the first thermoplastic material. In a
second embodiment the yarn 110 includes a core, comprising a core
material coated with a coating. In some embodiments the coating
comprises the first thermoplastic material. The core may comprise
any of a variety of natural polymeric fibers or filaments,
regenerated fibers or filaments, synthetic polymeric fibers or
filaments, metals, or some combination thereof, to achieve the
desired properties of the yarn 110. The fibers or filaments may be
either plant-derived or animal-derived. Plant-derived fibers may
include cotton, flax, hemp, or jute. Animal-derived fibers or
filaments may include spider silk, silkworm silk, sheep wool, or
alpaca wool. The regenerated material is created by dissolving a
cellulosic material in a solvent and spinning the solution into
fibers or filaments, such as by the viscose method. Examples of
regenerated fibers or filaments may include rayon or modal, among
others. In some embodiments, the core material is a thermoplastic
core material, i.e., a polymeric material having a deformation
temperature at which the core material softens and a melting
temperature at which the core material melts. In other embodiments,
the core material is a thermoset core material, i.e., a core
material which does not have a deformation or melting temperature,
or is a thermoformable core material, i.e., a core material having
a deformation temperature but not a melting temperature.
Additionally, the core may be a single monofilament strand or a
multifilament strand, comprising multiple monofilaments or
multifilament strands. In the instance where the core is a
multifilament strand, the individual filaments of the multifilament
may be aligned, twisted together, knotted, braided, or the like.
For instance, the yarn 110 may include a multifilament twisted or
entangled polyethylene terephthalate (PET) core. Additionally, each
strand of the multifilament core may be, itself, either a
monofilament or multifilament strand. In the instances where a
strand of the multifilament core is, itself, a multifilament
comprising multiple sub-strands, the sub-strands may be aligned,
twisted together, entangled, knotted, braided, or similarly
interconnected. Additionally, in some embodiments, the sub-strands
may be coated in the first thermoplastic material such that it
surrounds the sub-strand itself before the sub-strand is
incorporated into the core.
[0041] The presence of the core in the yarn 110 provides advantages
such as providing tensile strength and/or stretch resistance to the
yarn 110 which are not provided by the first thermoplastic
material, and so would not be present if the first thermoplastic
material coating composition was used alone. The core may provide a
structure enabling the yarn to remain in place during and following
the foaming process. Additionally, when the yarn 110 is combined
with non-foamable or unfoamed yarns in the textile 100, the
presence of the core can provide additional strength to the textile
100. In one example, when the yarn 110 is included in a textile in
a manner such that the yarn 110 has little if any give or freedom
of movement (e.g., when it is inlaid rather than interlooped), the
presence of the core can serve to add lock-out to the portion of
the textile in which yarn 110 is included.
[0042] In some embodiments the core has a percent elongation of
less than about 30 percent, or of less than about 25 percent. For
example, the core may have a percent elongation from about 0.5
percent to about 30 percent or from about 5 percent to about 25
percent.
[0043] In other embodiments, the core has a breaking strength from
about 0.5 to about 10 kilograms force per square centimeter. The
core can have a breaking strength of at least 1.5 kilograms force
per square centimeter, such as from about 1.5 to about 10 kilograms
force per square centimeter, or from about 1.5 kilograms force per
square centimeter to about 4.0 kilograms force per square
centimeter, or from about 2.5 kilograms force per square centimeter
to about 4 kilograms force per square centimeter.
[0044] Another measure of the force required to break a yarn is
tenacity. As used herein, "tenacity" is understood to refer to the
amount of force (expressed in units of weight, for example: pounds,
grams, centinewtons or other units) needed to rupture a yarn (i.e.,
the breaking force or breaking point of the yarn), divided by the
linear mass density of the yarn expressed, for example, in
(unstrained) denier, decitex, or some other measure of weight per
unit length. The amount of force needed to break a yarn (the
"breaking force" of the yarn) is determined by subjecting a sample
of the yarn to a known amount of force by stretching the sample
until it breaks, for example, by inserting each end of a sample of
the yarn into the grips on the measuring arms of an extensometer,
subjecting the sample to a stretching force, and measuring the
force required to break the sample using a strain gauge load cell.
Suitable testing systems can be obtained from Instron (Norwood,
Mass., USA). Yarn tenacity and yarn breaking force are distinct
from burst strength or bursting strength of a textile, which is a
measure of the maximum force that can be applied to the surface of
a textile before the surface bursts.
[0045] Generally, in order for a yarn to withstand the forces
applied in an industrial knitting machine, the minimum tenacity
required is approximately 1.5 grams per denier (g/D). Most
synthetic polymer filament yarns formed from commodity polymeric
materials generally have tenacities in the range of about 1.5 g/D
to about 4 g/D. For example, polyester filament yarns that may be
used in the manufacture of knit uppers for article of footwear have
tenacities in the range of about 2.5 g/D to about 4 g/D. Filament
yarns formed from commodity synthetic polymeric materials which are
considered to have high tenacities generally have tenacities in the
range of about 5 g/D to about 10 g/D. For example, commercially
available package dyed polyethylene terephthalate filament yarn
from National Spinning (Washington, NC, USA) has a tenacity of
about 6 g/D, and commercially available solution dyed polyethylene
terephthalate filament yarn from Far Eastern New Century (Taipei,
Taiwan) has a tenacity of about 7 g/D. Filament yarns formed from
high performance synthetic polymer materials generally have
tenacities of about 11 g/D or greater. For example, filament yarns
formed of aramid typically have tenacities of about 20 g/D, and
filament yarns formed of ultra-high molecular weight polyethylene
(UHMWPE) having tenacities greater than 30 g/D are available from
Dyneema (Stanley, NC, USA) and Spectra (Honeywell-Spectra, Colonial
Heights, Va., USA).
[0046] In one embodiment, the core has a tenacity of at least 1.5
grams per denier (g/D). The core can have a tenacity from about 1.5
g/D to about 4 g/D, or from about 2.5 g/D to about 4 g/D, or from
about 5 g/D to about 35 g/D, or from about 5 g/D to about 10
g/D.
[0047] Linear mass density of the yarn 110 and the core can be
expressed in (unstrained) denier. In one embodiment, the yarn has a
linear mass density from about 100 to about 300,000 denier (D), or
from about 500 to about 200,000 D, or from about 1,000 to about
10,000 D. Similarly, the core may have a linear mass density from
about 60 to about 70,000 D, from about 100 to about 1,000 D, or
from about 150 to about 700 D.
[0048] In some embodiments, the core comprises at least one
filament, and the at least one filament is at least partially
surrounded by the first thermoplastic material. In other
embodiments, the at least one filament is substantially surrounded
by the first thermoplastic material such that the first
thermoplastic material covers at least 75 percent of a surface area
of the at least one filament.
[0049] In a different embodiment the yarn 110 comprises the core
including the core material, and a coating of the first
thermoplastic material including the blowing agent, and is coated
with a coating comprising a second thermoplastic material
comprising a second thermoplastic polymer and second blowing agent,
wherein second coating forms the outer layer of the yarn 110. In
this embodiment, the blowing agents or thermoplastic polymers or
both of the first thermoplastic material and the second
thermoplastic material may be the same or different, or may have
the same of different concentrations. Additionally, the first
thermoplastic material and the second thermoplastic material may
have the same or different additives.
[0050] In some embodiments the first thermoplastic material and
second thermoplastic material 500 may comprise the same blowing
agent and the same thermoplastic polymers but in differing amounts.
For instance, the first thermoplastic material may contain a
thermoplastic polyurethane with a thermally-activated chemical
blowing agent but such that the concentration of the thermally
activated chemical blowing agent in the first thermoplastic
material is at least twice the concentration of the
thermally-activated chemical blowing agent in the second material.
When processed, such a structure may create coaxially-aligned
regions of foam with different density and hardness
characteristics, or, under certain processing conditions, may yield
a yarn where a coaxial foam region has a density or hardness
gradient along the cross-sectional radius.
[0051] Similarly, by varying the concentration of various
additives, such as, but not limited to coloring agents,
cross-linking agents, stabilizers, emulsifiers, binders, or others,
in different coaxial coating layers before and after being foamed,
may have any number distinct coaxial regions with distinct
properties, or have a radial gradient of varying properties such as
color density, foam density, hardness, viscosity, melting
temperature, among other properties.
[0052] In other embodiments, the yarn 110 may comprise a first yarn
sub-strand comprising a thermoplastic material further comprising a
blowing agent and thermoplastic polymer, and may be combined with a
second yarn sub-strand. The second yarn sub-strand may or may not
comprise a thermoplastic material. The first yarn sub-strand and
second yarn sub-strand may be combined to form a multi strand yarn
620, either by twisting, twining, braiding, knotting, aligning,
fusing, softening the yarn materials, or other acceptable means. In
further embodiments, the yarn 110 may comprise a first yarn
sub-strand comprising core and a coating of a thermoplastic
material comprising a blowing agent and thermoplastic polymer.
[0053] The yarn 110 may have any of a variety of cross-sectional
shapes or sizes, dictated by the requirements for the final
application of the yarn 110. In some embodiments, further detailed
above, the yarn 110 comprises a core and a coating that is coaxial
to the core. At any given cross-section of the yarn 110, the core
has a cross-sectional area and the coating as a cross-sectional
area. The average coating cross-sectional area is equal to the
volume of the coating divided by the length of the yarn 110. For
any given cross-section of the yarn 110, the coating has an average
thickness being the average distance as measured from an inner
surface of the coating to an exterior surface of the coating, as
measured normal to the outer surface of the coating. In some
embodiments, the diameter of the core is smaller than the average
thickness of the coating. For example, the core may have a
cross-sectional diameter and the surrounding coating has an average
thickness such that the cross-sectional diameter of the core is at
least 1.5 times smaller, or at least 2 times smaller, or at least 3
times smaller than the average thickness of the coating prior to
foaming the yarn 110. In other embodiments, the diameter of the
core is greater than the average thickness of the coating. In such
an example, the core can have a cross-sectional diameter and the
surrounding coating has an average thickness such that the
cross-sectional diameter of the core is at least 2 times larger, or
at least 3 times larger, or at least 5 times larger than the
average thickness of the coating.
[0054] In some embodiments the coating has an average thickness
from about 0.3 mm to about 5.0 millimeters. In yet other
embodiments the coating has an average thickness less than about
0.3 millimeters. In yet other embodiments the coating has an
average thickness greater than about 5.0 mm. In still other
embodiments, the coating has a thickness from about 0.4 millimeters
to about 3.0 millimeters, or from about 0.5 millimeters to about 2
millimeters. In some embodiments the coating has a variable
thickness, and the variable thickness ranges from 0.1 millimeters
to about 6.0 millimeters.
[0055] In some embodiments, the yarn 110 includes a core yarn
comprising a core material with a layer of the first thermoplastic
material substantially surrounding the core layer and defining an
exterior surface of the yarn 110. In one such embodiment, the first
thermoplastic material of the yarn 110 comprises at least 30 weight
percent of a thermoplastic polymeric component, wherein the
thermoplastic polymeric component includes at least one
thermoplastic polyurethane, or at least one thermoplastic
polyolefin, or at least one thermoplastic polyamide, or any
combination thereof. The thermoplastic polymeric component of the
first thermoplastic material can comprise or consist essentially of
at least one thermoplastic polyurethane, such as a polyester
polyurethane copolymer. The thermoplastic polymeric component can
comprise or consist essentially of at least one polyolefin, such as
an ethylene-vinyl acetate copolymer. The thermoplastic polymeric
component can comprise or consist essentially of at least one
polyamide, such as a polyethylene polyamide block copolymer. In one
such embodiment, the first thermoplastic material further comprises
a thermally-activated chemical blowing agent, and a
thermally-activated crosslinking agent. In one such embodiment, the
core yarn is a multifilament yarn, such as an air-entangled
multifilament yarn, and has a breaking strength greater than 1.5
kilograms force per square centimeter. The core material of the
core yarn can comprise at least one thermoplastic polyester such as
a thermoplastic polyethylene terephthalate, or at least one
thermoplastic polyamide homopolymer. In one such embodiment, a
deformation temperature of the core material is at least 20 degrees
Celsius, or at least 40 degrees Celsius, or at least 60 degrees
Celsius greater than a melting temperature of the first
thermoplastic material, than an activation temperature of the
thermally-activated blowing agent, and then an activation
temperature of the thermally-activated crosslinking agent. In one
such embodiment, the yarn 110 including the unfoamed thermoplastic
material has a breaking strength greater than 1.5 kilograms force
per square centimeter, an elongation of less than 20 percent. In
one such embodiment, the thickness of the coating layer of the
first thermoplastic material ranges from about 0.4 millimeters to
about 3 millimeters, and expands in volume from about 2 times to
about 6 times when foamed.
[0056] II. Method of Processing a Textile
[0057] Described herein are methods of processing a foamable
textile 100 described above to form a foamed textile 200 comprising
any of the yarns described above, wherein the yarn 110 is a strand
comprising a least one thermoplastic material comprising at least
one thermoplastic polymer and a blowing agent.
[0058] The textile incorporating any of the yarns may be processed
to create one or more areas of a multicellular foam 210 in the
foamed textile 200. A multicellular foam is an expanded material
having a cellular structure, i.e. having a plurality of cavities
defined by the foamed material, resulting from introduction of gas
bubbles during manufacture. An open-cell foam is a multicellular
foam where the majority of cells are not fully encapsulated by the
foamed material. A closed-cell foam is a multicellular foam where
the majority of cells are fully encapsulated by the foamed
material. Once foamed, the multicellular foam areas 220 of the
foamed textile 200 have properties which differ from portions 230
of the textile without the multicellular foam 210, including
portions in which the yarn 110 has not been foamed. For example,
the foamed areas 220 can impart increased texturing, cushioning,
abrasion resistance, strength, lockout, or any combination of these
properties, to the textile.
[0059] In embodiments where the foamable yarn 110 comprises a
blowing agent, a first method of foaming an area of the foamable
textile 100 comprises the steps of softening the thermoplastic
material, activating the blowing agent of the thermoplastic
material of the yarn 110 to expand the softened thermoplastic
material into a multicellular foam 210, and solidifying the
multicellular foam 210, forming one or more areas of multicellular
foam 210 in the "foamed" textile 200. In some embodiments, the step
of activating the blowing agent comprises exposing a portion of the
foamable textile 100 containing the unprocessed yarn 110 to a heat
source, including, but not limited to, a heating solid surface, a
heating fluid, actinic radiation (such as microwave radiation,
radio wave radiation, electron beam radiation, gamma beam
radiation, infrared radiation, ultraviolet light, visible light),
or some combination thereof.
[0060] In embodiments where the foamable yarn 110 does not comprise
a blowing agent, the step of impregnating the foamable textile 200
with a blowing agent may take place before the step of foaming the
blowing agent. In some such embodiments, impregnating the foamable
textile 100 with the blowing agent can be accomplished through a
variety of means, including softening the thermoplastic material of
the foamable yarn 110 and introducing the blowing agent into the
foamable yarn. The step of softening the yarn may comprise raising
the temperature of the foamable yarn 110 above a softening
temperature of the thermoplastic material. Raising the temperature
of the thermoplastic yarn may be accomplished through a variety or
means including, but not limited to, exposing the yarn 110 to a
heating solid surface, a heating fluid, actinic radiation (such as
microwave radiation, radio wave radiation, electron beam radiation,
gamma beam radiation, infrared radiation, ultraviolet light,
visible light), or some combination thereof.
[0061] In some embodiments, the blowing agent to be infused in the
textile 100 is a physical blowing agent. In some embodiments, the
blowing agent comprises a physical blowing agent. In addition to
fluorocarbons, including fully or partially halogenated
fluorohydrocarbons such as fully or partially chlorinated
fluorohydrocarbons; hydrocarbons (e.g. isobutene and pentane); and
inert liquids, gases or supercritical fluids, such as carbon
dioxide or nitrogen or a combination thereof, can serve as physical
blowing agents. Inert liquids, gases and supercritical fluids offer
many advantages, including, low environmentally harmful outputs,
low gas consumption, increased foam volume per weight of blowing
agent used, high cost-effectiveness, non-flammable, non-toxic,
chemically inert, minimal or no residues left behind in the
polymeric foam after processing. Additionally, carbon dioxide has
the advantage of having a higher solubility in many thermoplastic
polymers than other inert compounds, such nitrogen. In some
embodiments, the physical blowing agent may comprise carbon dioxide
where carbon dioxide is present in an amount of about 1% to about
3% or about 1% to about 5% by weight based on upon a total weight
of thermoplastic material. Alternatively, the physical blowing
agent may comprise nitrogen, where nitrogen is present in an amount
of about 1% to about 3% or about 1% to about 5% by weight based
upon a total weight of thermoplastic material.
[0062] The step of impregnating a physical blowing agent into the
thermoplastic material may further comprise dissolving or
suspending the physical blowing agent in the thermoplastic
material. The impregnating may further comprise the steps of
softening the thermoplastic material of the yarn, impregnating the
softened thermoplastic material, and re-solidified the infused
thermoplastic material of the yarn 110 prior to the step of
softening the thermoplastic material and blowing the multicellular
foam 210. The impregnating may involve forming a single phase
solution of the physical blowing agent in the first thermoplastic
material, and solidifying the single phase solution under
conditions effective to maintain the physical blowing agent in
solution when solidified
[0063] The molecular structure, amount, and reaction temperature of
each ingredient determine the characteristics and subsequent use of
the foam. Therefore, each formulation can be designed with a
selection of ingredients to achieve multicellular foam having a
variety of properties. For instance, the concentration and type of
blowing agent and/or surfactant used can affect the cell size, rate
of expansion, hardness and/or density of the multicellular foam.
Similarly, the concentration and type of thermoplastic polymer(s)
included in the thermoplastic material can affect the hardness
and/or density of the multicellular foam. the multicellular
foam
[0064] The blowing agent used in the foaming step will, in part,
dictate temperature and pressure ranges for processing. Suitable
blowing agents may include chemical blowing agents, physical
blowing agents, or some combination thereof.
[0065] In some embodiments, the step of activating the chemical
blowing comprises raising the temperature of the thermoplastic
material to about or above the activation temperature of the
blowing agent. The step of raising the temperature may comprise
exposing the yarn 110 or textile 100 to a heating solid surface, a
heating fluid, a form of actinic radiation or a combination
thereof. When the blowing agent is activated, the generation of the
gas will cause the thermoplastic material to foam when the
thermoplastic material is at a temperature where it is soft and
deformable or fully melted. After the thermoplastic material is
expanded into a multicellular foam 210, the multicellular foam
multicellular foam is solidified.
[0066] In some embodiments, the step of activating the chemical
blowing comprises raising the temperature of the thermoplastic
material to about or above the activation temperature. When the
blowing agent is activated, the generation of the gas will cause
the thermoplastic composition to foam when the thermoplastic
composition is at a temperature where it is soft and deformable or
fully melted. After foaming the thermoplastic composition, some
embodiments of the method comprise solidifying the multicellular
foam 210.
[0067] In some embodiments, the blowing agent is present in the
first thermoplastic material in an amount effective to foam the
first thermoplastic material into a multicellular foam 210
structure when the yarn 110 is processed. The amount of blowing
agent may be measured as the concentration of blowing agent by
weight in the thermoplastic material. An amount of blowing agent is
considered effective when activating the blowing results in at
least a 10 percent increase in the volume of the thermoplastic
material. In one example, the thermoplastic material can comprise
from about 1 percent to about 10 percent by weight, or from about 1
percent to about 5 percent by weight, or from about 1 percent to
about 3 percent by weight of the blowing agent based on a total
weight of the thermoplastic material. In another example, the
thermoplastic material comprises a concentration of the blowing
agent sufficient to expand the thermoplastic material by at least
100 percent by volume, or by 100 percent to 900 percent by volume,
or by 200 percent to 500 percent by volume, or by 300 percent to
400 percent by volume, based on an initial volume of the
thermoplastic material prior to foaming.
[0068] In some embodiments of the method, the step of solidifying
the multicellular foam comprises decreasing the temperature of the
foamed thermoplastic material to a temperature below its
deformation temperature.
[0069] In other embodiments of the method, the step of solidifying
the multicellular foam comprises crosslinking the thermoplastic
material to the point that the composition becomes a thermoset
material. In embodiments where a crosslinking agent is used, the
crosslinking agent can be initiated during the processing
conditions used to process the textile. have an initiation
temperature within the processing conditions used for the textile.
For example, the cross-linking agent can be a thermally-activated
cross-linking agent having an initiation temperature of the
thermally-activated crosslinking agent can be near the initiation
temperature of the blowing agent, so that the foaming and
crosslinking occur simultaneously or nearly simultaneously. In this
way, the thermoplastic material may remain soft enough to form a
multicellular structure as the blowing agent is activated within
the thermoplastic material, but develops sufficient melt strength
to maintain the multicellular structure without collapsing on
itself, and cures into a solid multicellular foam having sufficient
hardness.
[0070] If the thermoplastic material comprises a blowing agent that
is thermally-activated, the blowing-agent activation temperature
should be at about or above the melting temperature of the
thermoplastic material before processing. As an example, if a
thermoplastic material has a melting temperature of about 90
degrees Celsius, and the blowing agent has an activation
temperature of about 120 degrees Celsius or higher, the
thermoplastic material would be in a molten state before the
blowing agent begins to evolve gas to create the multicellular form
structure. In such an instance, the textile or yarn may be
processed in a range of about 120 degrees Celsius or above,
including at about 145 degrees Celsius.
[0071] In other embodiments, the thermoplastic material further
comprises an additional additive. In addition to the blowing agent
and the optional cross-linking agent, other additives that may be
present in the thermoplastic material include a chain-extending
agent, a filler, a flame retardant, a coloring material (such as a
dye or pigment), an ultraviolet light absorber, an antioxidant, a
lubricant, a plasticizer, an emulsifier, a rheology modifier, an
odorant, a deodorant, a halogen scavenger, or any combination
thereof, depending on the application. Catalysts speed up the
reaction or, in some cases, reduce the reaction initiation
temperature. As discussed above, blowing agents that form gas
bubbles in the polymer or polymerizing mixture produce foam.
Surfactants may be added to control the size of bubbles. In one
example, the other additive is present in the thermoplastic
material at a concentration of from about 0.1 weight percent to
about 20 weight percent, or from about 0.2 weight percent to about
10 weight percent, or from about 0.5 weight percent to about 5
weight percent, based on a total weight of the thermoplastic
material.
[0072] As described above, if the thermoplastic material comprises
a blowing agent that is thermally-activated, the blowing-agent
activation temperature should be at about or above the melting
temperature of the thermoplastic material. As an example, if a
thermoplastic material has a melting temperature of about 90
degrees Celsius, and the blowing agent has an activation
temperature of about 120 degrees Celsius or higher, the
thermoplastic material would be in a molten state before the
blowing agent begins to evolve gas to create the multicellular form
structure. In such an instance, the textile or yarn may be
processed in at or above about 120 degrees Celsius or above,
including at or above about 145 degrees Celsius.
[0073] In some embodiments, the method of solidifying the
partially-processed thermoplastic material into a foamed textile
200 further comprises adhering the foamed textile 200 to a
surrounding portion of the textile. This step may comprise
decreasing the temperature of the foamed textile 200.
[0074] In some embodiments, during the foaming step, the material
110 may expand from about 10 percent to 2000 percent by volume, or
from about 100 percent to about 1000 percent. During the foaming,
the material 110 may expand from about 200 percent to about 700
percent by volume, or from about 300 percent to about 500 percent
by volume.
[0075] In other embodiments, the method of processing the foamable
textile 100 or yarn 110 further comprises the step of molding the
textile or yarn. The step of applying the mold 600 to the textile
100 can be conducted before, during or after the foaming of the
thermoplastic material. As exemplified in FIGS. 6A-7D, in some
embodiments, this step comprises applying a mold to the textile. In
some instances, the mold may be a compression mold 600, such as in
FIGS. 6A-7D, having a first mold surface 610 and a second mold
surface 620, or slump mold having only one molding surface.
Although the mold may be at an ambient temperature, in other
embodiments, the step of molding the textile or yarn may further
comprise heating the mold 600.
[0076] The step of heating may comprise exposing the mold 600 to a
heating solid surface, a heating fluid, electricity, actinic
radiation, or a combination thereof. The temperature of the mold
600 for processing the textile 100 or yarn 110 will vary depending
on the desired characteristics of the multicellular foam 210 as
well as the blowing agent, processing pressure, and thermoplastic
polymer. One possible range is between about 60 and 250 degrees
Celsius. By molding the foamable textile 100 at a temperature at
least 20 degrees Celsius above a temperature at which the foamed
textile 200 is used is one way to allow the textile to maintain a
molded shape during general use, wear, washing, drying, cleaning,
and storage. This additional step of heating the mold 600 may be
performed after the applying the foamble textile 100 or yarn 110 to
the mold 600 or before applying the foamable textile 100 or yarn
110 to the mold 600.
[0077] Additionally, for instances where the textile is applied to
a compression mold 600, the step of molding the textile may
comprise applying additional pressure to the mold, i.e., pressure
exceeding atmospheric pressure. Appling pressure to the mold can
shape and/or restrict the foaming of the material 110, portion of
the textile, creating a shaped foam and/or a denser foam. The
amount of pressure applied will vary depending on the desired
characteristics of the multicellular foam as well as the blowing
agent, processing temperature, and thermoplastic polymer.
[0078] In some embodiments the step of molding comprises applying
the mold 600 to the foamable textile 100, as seen in FIG. 6A,
activating the blowing agent, as seen in FIG. 6B to foam at least a
portion of the foamable textile 100. In some of these embodiments,
the step of molding further comprises removing the yarn 110 or
textile 200 from the mold, as depicted in FIG. 6C. In some such
embodiments, the step of decreasing the temperature of the first
thermoplastic material is performed before, after, or during
removing the foamed textile 200 from the mold 600.
[0079] In other embodiments, as exemplified by FIGS. 7A-7C, the
blowing agent in the foamable textile is activated to start foaming
the thermoplastic material, and then a mold 600 is applied to the
foamed textile while the thermoplastic material is thermo-moldable.
In some of these embodiments, the step of molding further comprises
removing the yarn 110 or textile from the mold, as depicted in FIG.
7D. In some such embodiments, the step of decreasing the
temperature of the first thermoplastic material is performed after
removing the foamed textile 200 from the mold.
[0080] In some embodiments, the step of applying the mold 600 to
the thermo-moldable foamed textile 200 or a foamable textile 100
results in at least one surface texture feature that sits proud of
the surface of the textile, i.e. projecting or protruding from the
textile, and/or adjacent foamed area. In other embodiments, the
step of applying the mold 600 to the thermo-moldable foamed textile
200 or a foamable textile 100 results in at least one foamed area
that sits flush with the surface of the textile. In still other
embodiments, the step of applying the mold 600 to the
thermo-moldable foamed textile 200 or a foamable textile 100
results in at least one foamed area wherein the multicellular foam
does not extend beyond the surface of the textile. In still other
embodiments, the step of applying the mold 600 to the
thermo-moldable foamed textile 200 or a foamable textile 100
results an area of increased rigidity 700 wherein the foamed
textile 200 maintains a non-planar morphology after solidifying. In
any such embodiments, the foamable yarn 110 may be enmeshed with at
least some of the multicellular foam 210.
[0081] III. A Processed Textile
[0082] Described herein is a foamed textile 200 comprising a
multicellular foam 210. The multicellular foam 210, can be
either-open celled or closed-cell, and can be the reaction product
of foaming at least a portion of a first yarn, wherein the first
yarn is a strand comprising at least one thermoplastic material
comprising at least one thermoplastic polymer and a blowing
agent.
[0083] A foamed textile incorporating yarn may exhibit some of the
advantageous properties of a fiber-based textiles, such as ease of
manufacture, minimal waste, flexibility of design, variation of
elasticity and thickness, ease of customization, and the like. A
foamed textile incorporating multicellular foam may exhibit some of
the advantageous properties of foams, such as increased hardness,
water resistance, moldablity, rigidity, cushioning, sound
dampening, mechanical dampening, among others. Additionally, a
foamed textile incorporating yarn may exhibit other advantageous
properties, such as maintaining fixed distance between textile
fibers, strands, and yarns, i.e. effectively locking the textile
into a specified morphology. This may be additionally advantageous
in instances where the spacing of textile fibers, strands, yarns,
or the like has an effect on the properties of the material such
as, but not limited to, electrical conductivity or resistance,
elasticity, strength, shear strength, tear resistance, or
resistance to fraying.
[0084] In some embodiments, the multicellular foam 210 is a
thermoplastic multicellular foam. For example, the thermoplastic
multicellular foam may comprise a thermoplastic material which is
the reaction product of a thermoplastic material comprising a
chemical blowing agent, wherein the reacted thermoplastic material
comprises reacted chemical blowing agent. In other embodiments, the
multicellular foam 210 may comprise a thermoset material which is
the crosslinked reaction product of a thermoplastic material
comprising a blowing agent and a cross-linking agent.
[0085] In some embodiments, the multicellular material may comprise
a thermoplastic material. In other embodiments, the multicellular
foam 210 may comprise a thermoset material. In yet other
embodiments, the multicellular foam 210 may comprise a
thermoformable material.
[0086] The foamed textile 200 further comprises a first surface
having a first surface texture, and a second surface, having a
second surface texture, and at least one intermeshing region 220
where foam 210 and un-foamed textile 120 are interconnected. The
first and second surface textures may or may not be similar. For
example, the first surface may include foamed areas in which the
foamed area has a greater height (i.e., sits proud of) the
surrounding textile, and the second surface may be substantially
flat. The intermeshing region 220 may have individual yarns 110 or
fibers running through, creating an internal structure in foam 210.
In some embodiments, the internal structure may act as a
substructure to the multicellular foam 210, imparting various
properties, such as tension or stretch resistance, stiffness, etc.
In some embodiments, this structure may be web-like. In other
embodiments, individual yarns 110 may be arranged substantially
parallel to each other. In still other embodiments, the yarns 110
may form a series of loops through the multicellular foam 210. In
any such embodiments, the yarns 110 running through the
multicellular foam 210 can impart specific qualities to the
multicellular foam including, but not limited to, elasticity,
durability, strength, hardness, abrasion resistance, electrical
conductivity, among others. Additionally, a foamed textile
incorporating yarn may exhibit other advantageous properties, such
as maintaining fixed distance between textile fibers, strands, and
yarns, i.e. effectively locking the textile into a specified
morphology. This may be additionally advantageous in instances
where the spacing of textile fibers, strands, yarns, or the like
has an effect on the properties of the material such as, but not
limited to, electrical conductivity or resistance, elasticity,
strength, shear strength, tear resistance, or resistance to
fraying.
[0087] In some embodiments, and as depicted in FIGS. 2B, 2C, and
2E, the first surface texture comprises an area of continuous foam
surface with little or no visible yarns 110 or un-foamed textile
120. As stated above, In FIGS. 1-8, element 120 is a genericized
representation of a portion of a textile. The portion of the
textile represented by 120 may be, but is not limited to, a knitted
textile, a woven textile, a crocheted textile, a braided textile, a
tatted textile, a wrapped textile, or some combination thereof.
This first surface may be bumpy, with smaller sub-areas where a
depth of the foam is relatively thicker and smaller sub-areas where
the foam is relatively thinner. These sub-areas of relatively
thicker and relatively thinner foam may be regularly spaced or
randomly distributed over the first surface. In other embodiments,
the thickness of the foam may be about uniform so that the first
surface texture is essentially smooth.
[0088] The smoothness of the surface may be measured by either
contact or non-contact methods. Contact methods involve dragging a
measurement stylus across the surface, for instance, with a
profilometer. Non-contact methods include: interferometry, confocal
microscopy, focus variation, structured light, electrical
capacitance, electron microscopy, atomic force microscopy and
photogrammetry.
[0089] In other embodiments, as exemplified in FIG. 5, the foamed
areas 220 may be discrete at the surface, creating a ridged or
dotted texture. In still other embodiments, such as the one
exemplified in FIG. 8, the foamed textile 200 may have a variety of
foamed areas 220 creating a variety of surface features. These may
include abstract designs, symbols, or other depictions, decorative
textures, or functional textures.
[0090] In other embodiments, as depicted in FIGS. 2A, 2D, and 2F,
the first surface texture comprises an area of discontinuous foam
surface where sub-areas of foam are distributed between sub-areas
of exposed un-foamed textile 120. These sub-areas may be regularly
spaced to create a pattern or randomly distributed over the first
surface.
[0091] In some embodiments, the multicellular foam 210 extends
beyond the surface of the unfoamed textile 120 through a gap or
aperture in the unfoamed textile. The gap or aperture may be a
space between a first knit stitch and a second knit stitch in an
embodiment where the unfoamed textile 120 is a knitted textile.
Alternatively, in instances where the unfoamed textile is a woven
textile, the gap or aperture may be the space between a first
strand and a second strand of the woven textile. In other
embodiments, the multicellular foam 210 extends beyond the surface
of the unfoamed textile 120 through a plurality of gaps or
apertures in the unfoamed textile.
[0092] In other embodiments, as depicted in FIGS. 2B, 2E and 2F,
the foamed textile 200 may comprise foamed regions 220 where the
multicellular foam 210 does not extend beyond the surface of the
unfoamed textile 120. In some embodiments, such foamed areas 220
may remain below the surface of the unfoamed textile 120. In other
embodiments, such foamed areas 220 may sit flush with the surface
of the foamed textile 120 either such that the unfoamed textile 120
is encapsulated in the multicellular foam 210 or such that the
unfoamed textile 120 is not fully encapsulated in the multicellular
foam 210.
[0093] In some embodiments, exemplified in FIGS. 3A-3C, the foamed
textile 200 may comprise a plurality of textile layers 300, 310,
320. Any one of the textile layers 300, 310, 320 may contain a
foamed area 220. The layers 300, 310, 320 may be layered or
interconnected to form a variety of foamed areas 220 and un-foamed
areas 230 creating a variety of surface textures, some of which are
described above, and inner layers of intermeshed foam 210 and
un-foamed textile 120. In some embodiments, of which FIG. 3B is a
representative, a first textile layer 300 may have a foamed area
220 comprising a first multicellular foam material 330 and a second
textile layer 310 may have a foamed area 220 comprising a second
multicellular foam material 340. In some embodiments, the first and
second foam materials 330, 340 may comprise the same thermoplastic
material. In some embodiments, the first and second foam materials
330, 340 may comprise different thermoplastic materials. In other
embodiments, the first and second foam materials 330, 340 may have
different densities or different multicellular structures. In still
other embodiments, a third textile layer 310 may include a third
multicellular foam material 350.
[0094] In some embodiments, the first and second foam materials may
form a gradient zone where the first foam material 330 transitions
into the second foam material 340. In other multilayer embodiments,
the first foam material may not be in physical contact with the
second foam material 340. In still other embodiments, the first
foam material 330 may abut the second foam material 340 without
forming a gradient zone.
[0095] In some embodiments, the multicellular foam 210 has a
hardness ranging from about 20 to 70 Asker C, or from about 30 to
about 60 Asker C, or from about 40 to about 50 Asker C. However,
depending on the desired properties of the multicellular foam 210,
the hardness may be greater than 70 Asker C, or less than 20 Asker
C. For example, if the foamed yarn is intended to provide
cushioning, a softer foam may be desirable. If the foamed yarn is
intended to provide abrasion resistance or act as a sacrificial
layer, a harder foam may be desirable.
[0096] IV. An Article Comprising the Textile
[0097] Described herein are articles incorporating the foamed
textile 200 or yarn 110 described above, comprising a multicellular
foam 210, wherein the multicellular foam 200 may be either-open
celled or closed-cell and may be the reaction product of foaming at
least a portion of a first yarn, wherein the yarn 110 is a strand
comprising a least one thermoplastic material comprising at least
one thermoplastic polymer and a blowing agent.
[0098] Such articles may include an article of footwear or a
portion of an article of such (such as an upper, a sole, a collar,
a tongue, a heel, or other), an article of apparel or a portion of
such, an article of sporting equipment or a portion of such. The
article may include the foamable textile 100 or the foamed textile
200 wherein the foamed textile 220 has un-foamed areas 230, foamed
areas 220, or some combination of the two. Additionally, such
articles may include or a grip element of the article, a cushioning
element of the article, a sound dampening element of the article, a
vibration dampening element of the article.
[0099] V. Methods of Manufacturing Articles
[0100] Described herein are methods of manufacturing articles
incorporating the foamed textile 200 or yarn described above,
comprising a multicellular foam 210.
[0101] A first method of manufacturing an article comprises the
steps of affixing a first component to a second component, wherein
the first component includes a textile 100 or 200 as described
above.
[0102] For the purposes of this disclosure, "consisting essentially
of" permits inclusion of components not enumerated, provided that
they do not materially affect the basic properties or
characteristics of the disclosure. For example, the basic
properties or characteristics can be determined using standard
tests, such as standard tests of physical properties, known to one
of ordinary skill in the art. Depending on the property, alteration
of the property by at least 1 percent or by at least 2 percent or
by at least 5 percent may be considered a material effect.
Alternatively or additionally, the presence of at least 1 weight
percent or at least 2 weight percent or at least 5 weight percent
of impurities or other materials may be considered to materially
alter a composition. These are examples and not to be considered as
a finite list of properties or methods where this terminology may
apply.
[0103] While various embodiments have been described, it will be
apparent to those of ordinary skill in the art that many more
embodiments and implementations are possible. Accordingly, the
embodiments described herein are examples, not the only possible
embodiments and implementations.
[0104] The subject matter of the disclosure may also relate to the
following aspects:
[0105] A first aspect relates to a textile comprising a first yarn,
the first yarn comprising: a first thermoplastic material
comprising a blowing agent and at least one at least one
thermoplastic polymer.
[0106] A second aspect relates to the textile of the first aspect,
wherein the blowing agent is a chemical blowing agent.
[0107] A third aspect relates to the textile of the first aspect,
wherein the blowing agent is a physical blowing agent.
[0108] A fourth aspect relates to the textile of the first through
third aspects, wherein the textile is chosen from a knitted
textile, a woven textile, a crocheted textile, a braided textile, a
tatted textile, or a non-woven textile.
[0109] A fifth aspect relates to the textile of the fourth aspect,
wherein the textile is a non-woven textile.
[0110] A sixth aspect relates to the textile of the fourth aspect,
wherein the textile further comprises a second yarn, and the first
yarn and the second yarn are in contact with each other.
[0111] A seventh aspect relates to the textile of the fourth
aspect, wherein the first yarn is inlaid in the textile.
[0112] An eighth aspect relates to the textile of the seventh
aspect, wherein the textile is a knitted textile, and the first
yarn is inlayed in the knitted textile.
[0113] A ninth aspect relates to the textile of the sixth aspect,
wherein the first yarn and the second yarn are interlooped.
[0114] A tenth aspect relates to the textile of the ninth aspect,
wherein the second yarn excludes the first thermoplastic
material.
[0115] An eleventh aspect relates to the textile of the tenth
aspect, wherein the second yarn is interlooped with at least one
loop of the first yarn, thereby forming a second knitted course
that is adjacent to the first knitted course.
[0116] A twelfth aspect relates to the textile of the eleventh
aspect, further comprising a third yarn inlaid between at least a
first loop and a second loop of the knitted component.
[0117] A thirteenth aspect relates to the textile of the ninth
aspect, wherein the first yarn forms a plurality of crocheted
stiches.
[0118] A fourteenth aspect relates to the textile of the thirteenth
aspect, wherein the second yarn is interconnected to the first
yarn, forming a second crocheted course.
[0119] A fifteenth aspect relates to the textile of the fourteenth
aspect, further comprising a third yarn inlaid between the first
and second courses.
[0120] A sixteenth aspect relates to the textile of any preceding
aspect, further comprising a first plurality of yarns oriented
along a first direction, forming a warp comprising a plurality of
warp yarns.
[0121] A seventeenth aspect relates to the textile of the sixteenth
aspect, further comprising a second plurality of yarns oriented
along a second direction unique from the first direction, forming a
weft comprising a plurality of weft yarns.
[0122] An eighteenth aspect relates to the textile of the
seventeenth aspect, wherein the warp and weft are interwoven.
[0123] A nineteenth aspect relates to the textile of the sixth
aspect, further comprising a third yarn, wherein the first, second,
and third yarns are braided.
[0124] A twentieth aspect relates to the textile of any preceding
aspect, wherein the thermoplastic material comprises thermoplastic
ethylene-vinyl acetate and a thermally-activated chemical blowing
agent, and a thermally activated cross-linking agent.
[0125] A twenty-first aspect relates to a textile comprising: a
multicellular foam, wherein the multicellular foam is the reaction
product of foaming at least a portion of a first yarn, the first
yarn comprising a first thermoplastic material, the first
thermoplastic material comprising one or more thermoplastic
polymers, optionally wherein the first thermoplastic material
comprises a blowing agent.
[0126] A twenty-second aspect relates to a textile comprising: a
first yarn comprising a core and a multicellular foam surrounding
the core.
[0127] A twenty-third aspect relates to the textile of the
twenty-second aspect, wherein the multicellular foam is attached to
the core.
[0128] A twenty-fourth aspect relates to the textile of the
twenty-third aspect, wherein the multicellular foam is
substantially surrounding the core.
[0129] A twenty-fifth aspect relates to the textile of the
twenty-third aspect, wherein the multicellular foam is partially
surrounding the core.
[0130] A twenty-sixth aspect relates to the textile of any of the
twenty-third through twenty-fifth aspects, comprising a second yarn
interconnected with the first yarn.
[0131] A twenty-seventh aspect relates to the textile of the
twenty-sixth aspect, wherein the second yarn is interloped with the
first yarn.
[0132] A twenty-eighth aspect relates to the textile of the
twenty-sixth or twenty-seventh aspect, wherein the second yarn is
not surrounded by foam.
[0133] A twenty-ninth aspect relates to the textile of the
twenty-eighth aspect, wherein the second yarn is exposed on a first
surface of the textile.
[0134] A thirtieth aspect relates to the textile of any of the
twentieth through the twenty-ninth aspects, wherein the first yarn
comprises a core, and the core comprises a core material at least
partially surrounded by a sheath material.
[0135] A thirty-first aspect relates to the textile of the
thirtieth aspect, wherein the sheath material comprises a
thermoplastic material further comprising a blowing agent.
[0136] A thirty-second aspect relates to the textile of the
thirty-first aspect, wherein the blowing agent is a physical
blowing agent.
[0137] A thirty-third aspect relates to the textile of the
thirty-first aspect, wherein the blowing agent is a chemical
blowing agent, wherein the multicellular foam comprises a second
material comprising a reacted form of the chemical blowing agent,
and the second material is a foamed product of the first
thermoplastic material comprising one or more polymers and the
chemical blowing agent, optionally wherein the chemical blowing
agent is a thermally-activated chemical blowing agent.
[0138] A thirty-fourth aspect relates to the thirty-first aspect,
wherein the thermoplastic material comprises thermoplastic
ethylene-vinyl acetate and a thermally-activated chemical blowing
agent, and a thermally activated cross-linking agent.
[0139] A thirty-fifth aspect relates to the textile of any one of
the twenty-first through the thirty-fourth aspects, wherein the
multicellular foam is an open-celled multicellular foam.
[0140] A thirty-sixth aspect relates to the textile of any one of
the twenty-first through the thirty-fifth aspects, wherein the
multicellular foam is a closed-cell multicellular foam.
[0141] A thirty-seventh aspect relates to the textile of any one of
the twenty-first through the thirty-sixth aspects, wherein the
second material is a thermoplastic material.
[0142] A thirty-eighth aspect relates to the textile of any one of
the twenty-first through the thirty-seventh aspects, wherein the
second material is a thermoset material.
[0143] A thirty-ninth aspect relates to the textile of any one of
the thirty-third through the thirty-eighth aspects, wherein the
second material is a cross-linked product of the first
thermoplastic material comprising the one or more polymers, and
wherein the first thermoplastic material comprises a cross-linking
agent, optionally wherein the cross-linking agent is a
thermally-activated cross-linking agent.
[0144] A fortieth aspect relates to the textile of any one of the
twenty-first through the thirty-ninth aspects, wherein the textile
is chosen from a knitted textile, a woven textile, a crocheted
textile, a braided textile, or a non-woven textile.
[0145] A forty-first aspect relates to the textile of any one of
the twenty-first through the fortieth aspects, wherein the
multicellular foam has a hardness from about 30 to about 60 as
measured on an Asker C durometer.
[0146] A forty-second aspect relates to the textile of any one of
the twenty-first through the forty-first aspects, wherein the
multicellular foam has a hardness from about 40 to about 50
measured on an Asker C durometer.
[0147] A forty-third aspect relates to the textile of any one of
the twenty-first through the forty-second aspects, wherein the
textile has a first surface having a first texture and a second
surface having a second texture.
[0148] A forty-fourth aspect relates to the textile of the
forty-third aspect, wherein the multicellular foam defines a foamed
area on the first surface of the textile.
[0149] A forty-fifth aspect relates to the textile of the
forty-fourth aspect, wherein the foamed area sits flush with the
first surface.
[0150] A forty-sixth aspect relates to the textile of the
forty-fourth aspect, wherein the foamed area sits proud of the
first surface.
[0151] A forty-seventh aspect relates to the textile of the
forty-first aspect, wherein the foamed area, having a maximum
height as measured as the maximum distance from the first surface
of the foamed area to the second surface, that is at least about 5
millimeters greater than a minimum height, as measured as the
minimum distance from the first surface to the second surface.
[0152] A forty-eighth aspect relates to the textile of any of the
forty-fifth through the forty-seventh aspects, wherein the textile
includes a plurality of the foamed areas.
[0153] A forty-ninth aspect relates to the textile of the
forty-eighth aspect, wherein at least three of the foamed areas are
regularly spaced or periodically arranged relative to each
other.
[0154] A fiftieth aspect relates to the textile of the forty-eighth
aspect, wherein at the plurality of foamed areas are randomly
dispersed across the first surface of the textile.
[0155] A fifty-first aspect relates to the textile of the
forty-fifth or forty-sixth aspect, wherein the foamed area has a
shape, and the shape is a representative shape.
[0156] A fifty-second aspect relates to the textile of any one of
the forty-third through the fifty-first aspects, wherein the
textile further comprises a first textile layer, comprising a first
front layer surface and a first back layer surface, and a second
textile layer, comprising a second front layer surface and a second
back layer surface.
[0157] A fifty-third aspect relates to the textile of the
fifty-second aspect, wherein the first back layer surface is in
contact with at least a portion of the second front layer surface,
defining an interior portion of the textile layers.
[0158] A fifty-fourth aspect relates to the textile of the
fifty-third aspect, wherein the first front layer surface comprises
the foamed area.
[0159] A fifty-fifth aspect relates to the textile of the
fifty-third or fifty-fourth aspect, wherein the first back layer
surface comprises the foamed area.
[0160] A fifty-sixth aspect relates to the textile of any one of
the fifty-third through the fifty-fifth aspects, wherein the second
front layer surface comprises the foamed area.
[0161] A fifty-seventh aspect relates to the textile of any one of
the fifty-third through the fifty-sixth aspects, wherein the first
back layer surface comprises the foamed area.
[0162] A fifty-eighth aspect relates to the textile of the
fifty-third aspect, wherein the first back layer comprises a first
foamed area comprising a first foamed material and the second front
layer comprises a second foamed area comprising a second foamed
material such that the first foamed material is in contact with the
second foamed material within the interior portion of the textile
layers.
[0163] A fifty-ninth aspect relates to the textile of the
fifty-eighth aspect, wherein the first foamed material and second
foamed material form a blended region where the first foamed
material is intermixed with the second foamed material.
[0164] A sixtieth aspect relates to the textile of the fifty-ninth
aspect, wherein the blended region is defined by a concentration
gradient of the first foamed material.
[0165] A sixty-first aspect relates to the textile of any one of
the fifty-third through the sixtieth aspects, wherein the textile
further comprises a third textile layer, comprises a third front
surface and a third back surface, such that the third front surface
is in contact with at least a portion of the second back
surface.
[0166] A sixty-second aspect relates to the textile of the
sixty-first aspect, wherein the third textile layer further
comprises the foamed area.
[0167] A sixty-third aspect relates to a method for processing a
textile, the method comprising the steps of: increasing a
temperature of a textile, the textile comprising a first yarn, the
first yarn comprising a first thermoplastic material, the first
thermoplastic material comprising a blowing agent and one or more
thermoplastic polymers, the first yarn optionally comprising a
core, wherein, increasing the temperature comprises increasing a
temperature of at least a portion of the yarn to a temperature at
or above a softening temperature of the first thermoplastic
material; activating the blowing agent, thereby foaming the at
least a portion the first thermoplastic material of the first yarn
into a multicellular foam; and solidifying the multicellular foam
to form a foamed area in the textile.
[0168] A sixty-fourth aspect relates to a method for processing a
textile, the method comprising the steps of: impregnating a first
thermoplastic material with a blowing agent, the first
thermoplastic material comprising one or more thermoplastic
polymers, the first thermoplastic material forming at least a
portion of a first yarn, the first yarn optionally comprising a
core formed of a core material; increasing a temperature of at
least a portion of a textile comprising the first yarn to a
temperature at or above a softening temperature of the first
thermoplastic material; activating the blowing agent, thereby
foaming at least a portion the first thermoplastic material of the
first yarn into a multicellular foam, and solidifying the
multicellular foam to form a foamed area in the textile.
[0169] A sixty-fifth aspect relates to the method of the
sixty-third aspect, wherein the blowing agent is a chemical blowing
agent, optionally wherein the chemical blowing agent is a
thermally-activated blowing agent.
[0170] A sixty-sixth aspect relates to the method of the
sixty-fifth aspect, wherein the chemical blowing agent is chosen
from sodium bicarbonate, ammonium carbonate, ammonium bicarbonate,
calcium azide, azodicarbonamide, hydrazocarbonamide,
benzenesulfonyl hydrazide, dinitrosopentamethylene tetramine,
toluenesulfonyl hydrazide, p,p'-oxybis(benzenesulfonylhydrazide),
azobisisobutyronitrile, barium azodicarboxylate, or any combination
thereof.
[0171] A sixty-seventh aspect relates to the method of the
sixty-third or sixty-fourth aspect, wherein the blowing agent is a
physical blowing agent.
[0172] A sixty-eighth aspect relates to the method of the
sixty-seventh aspect, wherein the physical blowing agent is chosen
from a fluorocarbon; a hydrocarbon; an inert gas; an inert liquid;
a supercritical fluid; or any combination thereof.
[0173] A sixty-ninth aspect relates to the method of the
sixty-eighth aspect, wherein the physical blowing agent is chosen
from, an inert liquid, an inert gas, or a supercritical fluid.
[0174] A seventieth aspect relates to the method of the sixty-ninth
aspect, wherein the inert liquid, the inert gas, or the
supercritical fluid comprises nitrogen.
[0175] A seventy-first aspect relates to the method of the
sixty-ninth aspect, wherein the inert liquid, the inert gas, or the
supercritical fluid comprises carbon dioxide.
[0176] A seventy-second aspect relates to the method of the
seventy-first aspect, wherein, prior to the foaming, the first
thermoplastic material comprises the physical blowing agent in an
amount of about 1 percent to about 5 percent, by weight based on
upon a total weight of thermoplastic material.
[0177] A seventy-third aspect relates to the yarn of the fiftieth
aspect, wherein, prior to the foaming, the first thermoplastic
material comprises the physical blowing agent in an amount of about
1 percent to about 3 percent by weight based on upon the total
weight of the thermoplastic material.
[0178] A seventy-fourth aspect relates to the method of the
sixty-fourth aspect, wherein the impregnating the first
thermoplastic material comprises infusing the first thermoplastic
material with the physical blowing agent.
[0179] A seventy-fifth aspect relates to the method of the
seventy-fourth aspect, wherein infusing the physical blowing agent
comprises dissolving the blowing agent in the first thermoplastic
material.
[0180] A seventy-sixth aspect relates to the method of the
seventy-fourth or seventy-fifth aspect, further comprising the step
of softening the first thermoplastic material prior to or during
the step of impregnating, and re-softening the first thermoplastic
material during the step of increasing the temperature.
[0181] A seventy-seventh aspect relates to the method of the
seventy-sixth aspect, wherein the infusing comprises adding the
physical blowing agent to a molten first thermoplastic material,
forming a single phase solution of the physical blowing agent in
the first at least one thermoplastic material, and solidifying the
single phase solution under conditions effective to maintain the
physical blowing agent in solution when solidified.
[0182] A seventy-eighth aspect relates to the method of the
seventy-fourth aspect, wherein the infusing comprises infusing a
solid first thermoplastic material with the physical blowing agent
to form infused solid first thermoplastic material.
[0183] A seventy-ninth aspect relates to the method of any one of
the sixty-third through the seventy-eighth aspects, wherein the
first yarn is present in at least a portion of a textile,
optionally wherein the textile comprises a second yarn.
[0184] An eightieth aspect relates to the method of any one of the
sixty-third through the seventy-ninth aspects, wherein the step of
solidifying further comprises adhering the multicellular foam to a
surrounding portion of the textile, forming the foamed area.
[0185] An eighty-first aspect relates to the method of any one of
the sixty-third through the eightieth aspects, wherein the step of
solidifying the multicellular foam comprises decreasing the
temperature of the multicellular foam.
[0186] An eighty-second aspect relates to the method of the
eighty-first aspect, wherein decreasing the temperature comprises
cooling the multicellular foam at ambient temperature.
[0187] An eighty-third aspect relates to the method of the
eighty-first aspect, wherein the step of decreasing the temperature
further comprises quenching the multicellular foam with a
liquid.
[0188] An eighty-fourth aspect relates to the method of the
eighty-third aspect, wherein quenching the multicellular foam
comprises spraying the textile with the liquid.
[0189] An eighty-fifth aspect relates to the method of the
eighty-third aspect, wherein quenching the multicellular foam
comprises placing the textile in contact with the liquid in a
bath.
[0190] An eighty-sixth aspect relates to the method of the
eighty-third aspect, wherein quenching the multicellular foam
comprises pouring the liquid on the textile.
[0191] An eighty-seventh aspect relates to the method of the
eighty-first aspect, wherein the step of decreasing the temperature
further comprises exposing the multicellular foam to a gas.
[0192] An eighty-eighth aspect relates to the method of the
eighty-first aspect, wherein the step of decreasing the temperature
further comprises placing at least the portion of the textile
comprising the multicellular foam in contact with a surface.
[0193] An eighty-ninth aspect relates to the method of any one of
the sixty-third through the eighty-eighth aspects, wherein the step
of increasing the temperature of the first yarn comprises exposing
the textile to a heat source.
[0194] A ninetieth aspect relates to the method of the eighty-ninth
aspect, wherein the heat source is a convection heat source.
[0195] A ninety-first aspect relates to the method of the
eighty-ninth aspect, wherein the heat source is a direct heat
source.
[0196] A ninety-second aspect relates to the method of the
eighty-ninth aspect, wherein the heat source is an indirect heat
source.
[0197] A ninety-third aspect relates to the method of the
eighty-ninth aspect, wherein the heat source is an oven.
[0198] A ninety-fourth aspect relates to the method of the
ninety-first aspect, wherein the direct heat source is a liquid,
optionally wherein the direct heat source is a liquid bath.
[0199] A ninety-fifth aspect relates to the method of the
ninety-first aspect, wherein the direct heat source is a
surface.
[0200] A ninety-sixth aspect relates to the method of the
ninety-first aspect, wherein the direct heat source is a
surface.
[0201] A ninety-seventh aspect relates to the method of the any one
of the sixty-third through the ninety-sixth aspects, wherein the
step of foaming the first thermoplastic material comprises exposing
the first yarn to actinic radiation.
[0202] A ninety-eighth aspect relates to the method of the
ninety-seventh aspect, wherein the actinic radiation is chosen from
microwave radiation, radio wave radiation, electron beam radiation,
gamma beam radiation, infrared radiation, ultraviolet light,
visible light, or a combination thereof.
[0203] A ninety-ninth aspect relates to the method of any one of
the sixty-third through ninety-eighth aspects, further comprising
the step of molding the textile.
[0204] A one-hundredth aspect relates to the method of the
ninety-ninth aspect, wherein molding the textile comprises applying
a mold to the textile.
[0205] A one hundred and first aspect relates to the method of the
one hundredth aspect, wherein the mold is a slump mold.
[0206] A one hundred and second aspect relates to the method of the
one hundredth aspect, wherein the mold is a compression mold.
[0207] A one hundred and third aspect relates to the method of the
one hundredth through the one hundred and second aspect, further
comprising the step of increasing a temperature of the mold.
[0208] A one hundred and fourth aspect relates to the method of the
one hundred and third aspect, wherein the step of increasing a
temperature of the mold is performed after applying the mold to the
textile.
[0209] A one hundred and fifth aspect relates to the method of the
one hundred and third aspect, wherein the step of increasing a
temperature of the mold is performed before applying the mold to
the textile.
[0210] A one hundred and sixth aspect relates to the method of the
one hundredth through the one hundred and fifth aspects, further
comprising the step of removing the textile from the mold following
the step of solidifying the multicellular foam.
[0211] A one hundred and seventh aspect relates to the method of
the one hundred and sixth aspect, wherein the step of decreasing
the temperature of the first thermoplastic material is performed
before or during the step of removing the textile from the
mold.
[0212] A one hundred and eighth aspect relates to the method of the
one hundred and sixth aspect, wherein the step of decreasing the
temperature of the first thermoplastic material is performed after
removing the textile from the mold.
[0213] A one hundred and ninth aspect relates to the method of any
one of the sixty-third through the one hundred and eighth aspects,
further comprising the step of infusing a physical blowing agent
into the first thermoplastic material, wherein the infusing is
conducted prior to the steps of softening the first thermoplastic
material, foaming the first thermoplastic material, and solidifying
the multicellular foam.
[0214] A one hundred and tenth aspect relates to a textile made by
the method of any one of the sixty-third through the hundred and
ninth aspects.
[0215] A one hundred and eleventh aspect relates to an article
comprising: a textile comprising a first yarn, the first yarn
comprising a first thermoplastic material, the first thermoplastic
material comprising a blowing agent and one or more thermoplastic
polymers, optionally wherein the first yarn comprises a core, the
core comprising a core material.
[0216] A one hundred and twelfth aspect relates to an article
comprising: a first yarn, the first yarn comprising a first
thermoplastic material, the first thermoplastic material comprising
a blowing agent and one or more thermoplastic polymers.
[0217] A one hundred and thirteenth aspect relates to an article
comprising: a textile comprising a multicellular foam, wherein the
multicellular foam is the reaction product of foaming at least a
portion of a first yarn, the first yarn comprising a first
thermoplastic material, the first thermoplastic material comprising
a blowing agent and one or more thermoplastic polymers, optionally
wherein the first yarn comprises a core, the core comprising a core
material.
[0218] A one hundred and fourteenth aspect relates to the article
of the one hundred and thirteenth aspect, wherein the textile is a
textile according to any one of the first through the sixty-first
aspects.
[0219] A one hundred and fifteenth aspect relates to the article of
the one hundred and fourteenth aspect, wherein the multicellular
foam has a hardness from about 30 to about 60 as measured on an
Asker C durometer.
[0220] A one hundred and sixteenth aspect relates to the article of
the one hundred and fourteenth aspect, wherein the multicellular
foam has a hardness from about 40 to about 50 measured on an Asker
C durometer.
[0221] A one hundred and seventeenth aspect relates to the article
of any one of the one hundred and eleventh through the one hundred
and sixteenth aspects, wherein the article is an article of
footwear.
[0222] A one hundred and eighteenth aspect relates to the article
of any one of the one hundred and eleventh through the one hundred
and sixteenth aspects, wherein the article is an article of
apparel.
[0223] A one hundred and nineteenth aspect relates to the article
of any one of the one hundred and eleventh through the one hundred
and sixteenth aspects, wherein the article is an article of
sporting equipment.
[0224] A one hundred and twentieth aspect relates to the article of
any one of the one hundred and eleventh through the one hundred and
sixteenth aspects, wherein the textile is a grip element of the
article.
[0225] A one hundred and twenty-first aspect relates to the article
of any one of the one hundred and eleventh through the one hundred
and sixteenth aspects, wherein the textile is a cushioning element
of the article.
[0226] A one hundred and twenty-second aspect relates to the
article of any one of the one hundred and eleventh through the one
hundred and sixteenth aspects, wherein the textile is sound
dampening element of the article.
[0227] A one hundred and twenty-third aspect relates to the article
of any one of the one hundred and eleventh through the one hundred
and sixteenth aspects, wherein the textile is a vibration dampening
element of the article.
[0228] A one hundred and twenty-fourth aspect relates to a method
of manufacturing an article, the method comprising: affixing a
first component to a second component, wherein the first component
includes a textile according to any one of the sixty-third through
the eighty-second aspects.
[0229] A one hundred and twenty-fifth aspect relates to the method
of the one hundred and twenty-fourth aspect, wherein the first
component is an upper for an article of footwear, and the second
component is a sole structure for an article of footwear.
[0230] A one hundred and twenty-sixth aspect relates to an upper
for an article of footwear comprising: a textile including a first
yarn, the first yarn comprising a core yarn and a first
thermoplastic material forming an unfoamed coating at least
partially surrounding the core yarn; wherein the core yarn
comprises a plurality of fibers or filaments, each of the plurality
of fibers or filaments comprising a core material; and wherein the
first thermoplastic material comprises at least one first
thermoplastic polymer chosen from a thermoplastic polyurethane, a
thermoplastic polyolefin, a thermoplastic polyester, a
thermoplastic polyether, a thermoplastic polyamide, or any
combination thereof; and a chemical blowing agent, wherein the
chemical blowing agent is present in the first thermoplastic
material in an amount effective to foam the unfoamed coating of the
first thermoplastic material into a multicellular foam.
[0231] A one hundred and twenty-seventh aspect relates to the upper
for an article of footwear of the one hundred and twenty-sixth
aspect, wherein the textile is a knitted textile, and the knitted
textile further comprises a second yarn.
[0232] A one hundred and twenty-eighth aspect relates to the upper
of the one hundred and twenty-seventh aspect, wherein the first
yarn is inlayed in the knitted textile between courses of the
second yarn.
[0233] A one hundred and twenty-ninth aspect relates to the upper
of the twenty-seventh aspect, wherein the second yarn is
interlooped with at least one loop of the first yarn.
[0234] A one hundred and thirtieth aspect relates to the upper of
any one of the one hundred and twenty-sixth through the one hundred
and twenty-ninth aspects, wherein the first thermoplastic material
comprises the thermoplastic polyolefin and the thermoplastic
polyolefin includes a thermoplastic ethylene-vinyl acetate
copolymer, wherein the chemical blowing agent is a
thermally-activated chemical blowing agent, wherein the first
thermoplastic material further comprises a thermally-activated
cross-linking agent, and wherein the core material comprises a
thermoplastic polyester.
[0235] A one hundred and thirty-first aspect relates to an upper
for an article of footwear comprising: a textile comprising a
multicellular foam at least partially surrounding and attached to a
core yarn; wherein the core yarn comprises a plurality of fibers or
filaments, each of the plurality of fibers or filaments comprising
a core material; and wherein the multicellular foam is the product
of processing an unfoamed coating at least partially surrounding
the core yarn to expand the unfoamed coating into the multicellular
foam; wherein the multicellular foam comprises a first polymeric
material including at least one first polymer chosen from a
polyurethane, a polyolefin, a polyether, a polyamide, or any
combination thereof; and the degradation product of a chemical
blowing agent.
[0236] A one hundred and thirty-second aspect relates to the upper
of the one hundred and thirty-first aspect, wherein the unfoamed
coating comprises a first thermoplastic material including at least
one first thermoplastic polymer chosen from a thermoplastic
polyurethane, a thermoplastic polyolefin, a thermoplastic
polyester, a thermoplastic polyether, a thermoplastic polyamide, or
any combination thereof; and a chemical blowing agent, wherein the
chemical blowing agent is present in the first thermoplastic
material in an amount effective to foam the unfoamed coating of the
first thermoplastic material into the multicellular foam.
[0237] A one hundred and thirty-third aspect relates to the upper
of the one hundred and thirty-second aspect, wherein the first
polymeric material is a cross-linked polymeric material.
[0238] A one hundred and thirty-fourth aspect relates to the upper
of the one hundred and thirty-third aspect, wherein the unfoamed
coating comprises a first thermoplastic material including at least
one first thermoplastic polymer chosen from a thermoplastic
polyurethane, a thermoplastic polyolefin, a thermoplastic
polyester, a thermoplastic polyether, a thermoplastic polyamide, or
any combination thereof; a cross-linking agent; and a chemical
blowing agent, wherein the chemical blowing agent is present in the
first thermoplastic material in an amount effective to foam the
unfoamed coating of the first thermoplastic material into the
multicellular foam.
[0239] A one hundred and thirty-fifth aspect relates to the upper
of any one of one hundred and thirty-second through the one hundred
and thirty-fourth aspects, wherein the multicellular foam has a
hardness from about 30 to about 60 as measured by an Asker C
durometer.
[0240] A one hundred and thirty-sixth aspect relates to the upper
of any one of one hundred and thirty-second through the one hundred
and thirty-fifth aspects, wherein the textile further comprises a
second yarn, and the second yarn is exposed on a first surface of
the textile.
[0241] A one hundred and thirty-seventh aspect relates to the upper
of any one of one hundred and thirty-second through the one hundred
and thirty-sixth aspects, wherein the multicellular foam defines a
foamed area on the first surface of the textile.
[0242] A one hundred and thirty-eighth aspect relates to the upper
of the one hundred and thirty-seventh aspect, wherein the textile
includes a plurality of the foamed areas, and at least three of the
plurality of foamed areas are regularly spaced or periodically
arranged relative to each other.
[0243] A one hundred and thirty-ninth aspect relates to the upper
of the one hundred and thirty-seventh aspect, wherein the textile
includes a plurality of the foamed areas, and the plurality of
foamed areas are randomly dispersed across the first surface of the
textile.
[0244] A one hundred and fortieth aspect relates to the upper of
the one hundred and thirty-seventh aspect, wherein the foamed area
has a shape, and the shape is a representative shape.
[0245] A one hundred and forty-first aspect relates to a method for
processing an upper for an article of footwear, the method
comprising the steps of: forming a foamed area in a textile portion
of the upper by expanding at least a portion of an unfoamed coating
of a yarn present in the textile into a multicellular foam by
increasing a temperature of the yarn to a first processing
temperature; after expanding the unfoamed coating into the
multicellular foam, decreasing a temperature of the multicellular
foam to a second processing temperature at which the multicellular
foam adheres to the core yarn, adheres to a surrounding portion of
the textile, and solidifies while retaining its multicellular
structure, thereby forming the foamed area in the textile portion;
wherein the yarn comprises a core yarn and a first thermoplastic
material forming the unfoamed coating, the first thermoplastic
material at least partially surrounds the core yarn, the core yarn
comprises a plurality of fibers or filaments, and each of the
plurality of fibers or filaments comprising a core material;
wherein the first thermoplastic material comprises at least one
first thermoplastic polymer chosen from a thermoplastic
polyurethane, a thermoplastic polyolefin, a thermoplastic
polyester, a thermoplastic polyether, a thermoplastic polyamide, or
any combination thereof, the first thermoplastic material further
comprises a blowing agent, and the blowing agent is present in the
first thermoplastic material in an amount effective to expand the
unfoamed coating of the first thermoplastic material into a
multicellular foam; and wherein the first processing temperature is
a temperature at or above a softening temperature of the first
thermoplastic material.
[0246] A one hundred and forty-second aspect relates to the method
of the one hundred and forty-first aspect, wherein the
multicellular foam is a cross-linked foam, and the first
thermoplastic material further comprises a cross-linking agent.
[0247] A one hundred and forty-third aspect relates to the method
of the one hundred and forty-first or one hundred and forty-second
aspect, wherein the core material is a second thermoplastic
material, and the first processing temperature is a temperature at
least 20 degrees Celsius below a softening temperature of the
second thermoplastic material.
[0248] A one hundred and forty-fourth aspect relates to the method
of any one of the one hundred and forty-first through the one
hundred and forty-third aspects, wherein the blowing agent is a
thermally-activated blowing agent, and the first processing
temperature is a temperature at or above the activation temperature
of the thermally-activated blowing agent, and optionally, when the
multicellular foam is a cross-linked foam and the first
thermoplastic material further comprises a thermally-activated
cross-linking agent, the first processing temperature is a
temperature at or above the activation temperature of the
thermally-activated cross-linking agent.
[0249] A one hundred and forty-fifth aspect relates to an upper for
an article of footwear made by the method of any one of the one
hundred and forty-first through the one hundred and forty-fourth
aspects.
* * * * *