U.S. patent application number 17/369037 was filed with the patent office on 2021-12-30 for method of making laminate panel with auxetic layer.
The applicant listed for this patent is Under Armour, Inc.. Invention is credited to Alan Toronjo.
Application Number | 20210401118 17/369037 |
Document ID | / |
Family ID | 1000005839837 |
Filed Date | 2021-12-30 |
United States Patent
Application |
20210401118 |
Kind Code |
A1 |
Toronjo; Alan |
December 30, 2021 |
Method of Making Laminate Panel with Auxetic Layer
Abstract
A method for making an article of apparel includes applying an
auxetic structure to a first layer such that the auxetic structure
penetrates the first layer. The auxetic structure includes a
plurality of interconnected members forming an array of cell units.
Each of the plurality of interconnected members form cell walls
with interior recesses defined within the cell walls. The method
further comprises coupling a second layer to the first layer via
the auxetic structure.
Inventors: |
Toronjo; Alan; (Portland,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Under Armour, Inc. |
Baltimore |
MD |
US |
|
|
Family ID: |
1000005839837 |
Appl. No.: |
17/369037 |
Filed: |
July 7, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15980263 |
May 15, 2018 |
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17369037 |
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62506127 |
May 15, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 23/0265 20130101;
A43B 23/0235 20130101; A43B 1/04 20130101; A43B 23/024 20130101;
A43B 23/0255 20130101; A43B 1/02 20130101; A43B 23/026
20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02; A43B 1/02 20060101 A43B001/02; A43B 1/04 20060101
A43B001/04 |
Claims
1. A method of manufacturing a panel for an article of apparel, the
method comprising: printing an auxetic structure on a first side of
a first layer, the auxetic structure defining a repeating pattern
of perimeter walls and interior recesses; allowing the auxetic
structure to penetrate into the first layer; applying a second
layer to the first side of the first layer to form the panel; and
finish treating the panel such that the second layer is secured to
the first layer.
2. The method of claim 1 further comprising at least partially
curing the auxetic structure before applying the second layer to
the first side of the first layer.
3. The method of claim 2 further comprising cutting the panel after
curing the panel.
4. The method of claim 1 wherein the auxetic structure is screen
printed on the first side of the first layer.
5. The method of claim 1 wherein the first layer is a textile and
the second layer is a synthetic leather material.
6. A method of making a textile laminate for an article of apparel,
the method comprising: printing a bonding layer on an interior
layer, the interior layer possessing an interior layer Poisson's
value, the bonding layer forming an auxetic structure defining a
repeating pattern of perimeter walls and interior recesses; waiting
a period of time to allow the bonding layer to penetrate into the
interior layer such that it is at least partially embedded in the
interior layer; applying an exterior layer to the bonding layer,
the exterior layer possessing an exterior layer Poisson's value;
allowing the bonding layer to penetrate into the exterior layer
such that it is at least partially embedded in the exterior layer;
and finish curing the bonding layer to form the textile laminate,
wherein the textile laminate possesses a laminate Poisson's value
that is less than at least one of the interior layer Poisson's
value and the exterior layer Poisson's value.
7. The method of claim 6 wherein at least one of the interior layer
and the exterior layer is a textile layer.
8. The method of claim 7 wherein the interior layer is a resilient
textile provided by a four way stretch material possessing stretch
and recovery properties.
9. The method of claim 6 wherein the bonding layer is an adhesive
material.
10. The method of claim 6 wherein each of the interior layer
Poisson's value and the exterior layer Poisson's value is a
positive value.
11. The method of claim 6 further comprising incorporating the
textile layer into the article of apparel.
12. The method of claim 11 wherein the article of apparel is an
article of footwear.
13. The method of claim 12 wherein the interior layer is a
resilient textile and wherein the exterior layer is a synthetic
leather material.
14. The method of claim 6 wherein the perimeter walls of the
auxetic structure comprise a plurality of interconnected wall
segments that form a repeating pattern of reentrant polygonal
shapes.
15. The method of claim 6 wherein the auxetic structure has a
Poisson's ratio of near zero or less than zero.
16. The method of claim 6 wherein the exterior layer is a sheer
material and the bonding layer is visible through the sheer
material.
17. A method of making a textile laminate for an article of
footwear comprising: providing a first layer defining a first
surface, wherein the first layer is a four-way stretch material;
applying an auxetic structure to the first layer such that the
auxetic structure penetrates the first surface of the first layer,
the auxetic structure including a plurality of interconnected
members forming an array of cell units, each of the plurality of
interconnected members forming cell walls with interior recesses
defined within the cell walls; coupling a second layer to the first
layer via the auxetic structure such that the auxetic structure
penetrates the second layer, wherein the second layer is a
synthetic leather material, and wherein the first layer, auxetic
structure and the second layer form the textile laminate; and
incorporating the textile laminate into the article of
footwear.
18. The method of claim 17 wherein applying the auxetic structure
to the first layer comprises printing the auxetic structure on the
first surface of the first layer.
19. The method of claim 18 wherein the auxetic structure is
provided by an adhesive material.
20. The method of claim 17 wherein wherein the textile laminate
possesses a Poisson's value that is different than that of each of
the interior layer and the exterior layer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 15/980,263, filed May 15, 2018, which claims priority from
U.S. Provisional Patent Application No. 62/506,127, filed May 15,
2017, the disclosures of which are incorporated herein by reference
in their entirety.
FIELD
[0002] This document relates to the field of apparel, including
footwear, and structures for incorporation into the articles of
apparel.
BACKGROUND
[0003] When forming articles of apparel such as shirts, pants, and
shoes, apparel manufacturers consider the fit of the apparel. Many
garments and other articles of apparel are designed to fit closely
to the human body. When designing an article of apparel for a close
fit to the human body, different body shapes and sizes must be
considered. Different individuals within a particular garment size
will have different body shapes and sizes. For example, two
individuals wearing the same shoe size may have very differently
shaped feet, including very different heel, midfoot and forefoot
dimensions. These variable measurements between similarly sized
individuals makes proper design of closely fitting garments
difficult.
[0004] In view of the foregoing, it would be desirable to provide a
shoe or other article of apparel capable of conforming to various
foot or body shapes within a given size range. It would also be
desirable to provide a shoe or other article of apparel that is
capable of conforming to various double curvatures on the human
body and generally providing a good fit. Furthermore, it would be
advantageous if such a shoe or other article of apparel could be
designed to offer good performance characteristics for multiple
uses, such as a cross-training shoe that offers good performance
characteristics when the shoe is used for any of a number of
different athletic training purposes. In addition, it would be
desirable for such a garment or article of apparel to be relatively
inexpensive and easy to manufacture.
SUMMARY
[0005] A method is disclosed herein for making an article of
footwear including an upper with at least one laminate panel. The
laminate panel includes a bonding layer positioned between a first
layer and a second layer. The first layer is a textile having an
expansion pattern. The bonding layer provides an auxetic structure
that at least partially penetrates the first layer. The laminate
panel is configured such that, under load, the bonding layer
influences the expansion pattern of the textile layer to control
expansion of the first layer.
[0006] In accordance with one exemplary embodiment of the
disclosure, there is provided a method of making article of apparel
comprising an interior layer, an exterior layer, and a bonding
layer positioned between the interior layer and the exterior layer.
The bonding layer forms an auxetic structure defining a repeating
pattern of perimeter walls and interior recesses.
[0007] In accordance with another exemplary embodiment of the
disclosure, there is provided a method of making an article of
apparel comprising a first layer and a second layer. The method
comprises applying an auxetic structure to the first layer such
that the auxetic structure penetrates the first layer. The auxetic
structure includes a plurality of interconnected members forming an
array of cell units. Each of the plurality of interconnected
members form cell walls with interior recesses defined within the
cell walls. The method further comprises coupling the second layer
to the first layer via the auxetic structure.
[0008] In accordance with yet another exemplary embodiment of the
disclosure, there is provided a method of manufacturing a panel for
an article of apparel. The method includes printing an auxetic
structure on a first side of a first layer, the auxetic structure
defining a repeating pattern of perimeter walls and interior
recesses. The method further includes allowing the auxetic
structure to penetrate into the first layer. Thereafter, the second
layer is applied to the first side of the first layer to form the
panel. The panel is finish treated with pressure and/or heat such
that the second layer is secured to the first layer.
[0009] The above described features and advantages, as well as
others, will become more readily apparent to those of ordinary
skill in the art by reference to the following detailed description
and accompanying drawings. While it would be desirable to provide
an article of apparel that provides one or more of these or other
advantageous features, the teachings disclosed herein extend to
those embodiments which fall within the scope of the appended
claims, regardless of whether they accomplish one or more of the
above-mentioned advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of an article of footwear in
accordance with an embodiment of the present disclosure;
[0011] FIG. 2A shows an enlarged plan view of a laminate panel
including an outer layer partially cut away to expose an inner
layer and an auxetic layer;
[0012] FIG. 2B shows a cross-sectional view of the laminate panel
of FIG. 2A along line B-B of FIG. 2A;
[0013] FIG. 3A shows an alternative embodiment of the laminate
panel of FIG. 2A with an out layer partially cut away to expose an
inner layer and an auxetic layer;
[0014] FIG. 3B shows an enlarged, schematic view of the auxetic
layer of the laminate panel of FIG. 3A, showing exemplary
dimensions of the interconnected segments of the auxetic layer;
[0015] FIG. 3C shows a cross-sectional view of the laminate panel
of FIG. 3A;
[0016] FIG. 4A shows a plan view of an auxetic layer of the
laminate panel of FIG. 3A in a contracted position;
[0017] FIG. 4B shows a plan view of the auxetic layer of FIG. 4A in
an expanded position;
[0018] FIG. 5A shows a plan view of an alternative embodiment of
the auxetic layer of FIG. 4A,
[0019] FIG. 5B shows another alternative embodiment of the auxetic
layer of FIG. 4A;
[0020] FIG. 5C shows yet another alternative embodiment of the
auxetic layer of FIG. 4A;
[0021] FIG. 5D shows another alternative embodiment of the auxetic
layer of FIG. 4A;
[0022] FIG. 6 shows a perspective view of how the laminate panels
of FIGS. 2A and 3A are configured to expand when a strain is
applied to the laminate panel; and
[0023] FIG. 7 shows a method of making a panel for an article of
apparel including the laminate panels of FIGS. 2A and 3A.
[0024] Like reference numerals have been used to identify like
elements throughout this disclosure.
DESCRIPTION
[0025] In the following detailed description, reference is made to
the accompanying figures which form a part hereof wherein like
numerals designate like parts throughout, and in which is shown, by
way of illustration, embodiments that may be practiced. It is to be
understood that other embodiments may be utilized, and structural
or logical changes may be made without departing from the scope of
the present disclosure. Therefore, the following detailed
description is not to be taken in a limiting sense, and the scope
of embodiments is defined by the appended claims and their
equivalents.
[0026] Aspects of the disclosure are disclosed in the accompanying
description. Alternate embodiments of the present disclosure and
their equivalents may be devised without parting from the spirit or
scope of the present disclosure. It should be noted that any
discussion herein regarding "one embodiment", "an embodiment", "an
exemplary embodiment", and the like indicate that the embodiment
described may include a particular feature, structure, or
characteristic, and that such particular feature, structure, or
characteristic may not necessarily be included in every embodiment.
In addition, references to the foregoing do not necessarily
comprise a reference to the same embodiment. Finally, irrespective
of whether it is explicitly described, one of ordinary skill in the
art would readily appreciate that each of the particular features,
structures, or characteristics of the given embodiments may be
utilized in connection or combination with those of any other
embodiment discussed herein.
[0027] Various operations may be described as multiple discrete
actions or operations in turn, in a manner that is most helpful in
understanding the claimed subject matter. However, the order of
description should not be construed as to imply that these
operations are necessarily order dependent. In particular, these
operations may not be performed in the order of presentation.
Operations described may be performed in a different order than the
described embodiment. Various additional operations may be
performed and/or described operations may be omitted in additional
embodiments.
[0028] For the purposes of the present disclosure, the phrase "A
and/or B" means (A), (B), or (A and B). For the purposes of the
present disclosure, the phrase "A, B, and/or C" means (A), (B),
(C), (A and B), (A and C), (B and C), or (A, B and C).
[0029] The terms "comprising," "including," "having," and the like,
as used with respect to embodiments of the present disclosure, are
synonymous.
[0030] With reference now to FIG. 1, an article of apparel is shown
in the form of an article of footwear 10. The article of footwear
10 is an athletic shoe (e.g., a cross-training shoe) including an
upper 100 coupled to a sole assembly 105 (e.g., connected via an
adhesive, stitching, etc.). As described in further detail herein,
the upper 100 includes a laminate panel 118 formed by a first layer
and a second layer with a bonding layer coupling the first layer to
the second layer. The bonding layer is printed or otherwise
disposed on the first layer as an auxetic layer providing auxetic
structure.
[0031] The article of footwear 10 defines a forefoot region 110A, a
midfoot region 110B, and a hindfoot region 110C, as well as a
medial side and a lateral side. The forefoot region 110A is
configured to align generally with (be positioned proximate to) the
ball and toes of the foot, the midfoot region 110B is configured to
align generally with the arch and instep areas of the foot, and the
hindfoot region 110C is configured to align generally with the heel
and ankle areas of the foot. Additionally, the medial side is
oriented along the medial (big toe) side of the foot, while the
lateral side is oriented along the lateral (little toe) side of the
foot.
[0032] The upper 100 includes a plurality of sections that
cooperate to define a foot cavity. Specifically, a heel section 121
includes heel cup configured to align with and cover the calcaneus
area of a human foot. A medial quarter section 130, disposed
forward the heel section 121, is oriented on the medial shoe side.
Similarly, a lateral quarter section (not shown), disposed forward
the heel section 121, is oriented on the lateral shoe side. A vamp
section 136 is disposed forward the quarter sections 130 and a toe
cage section 141 is disposed forward the vamp section. The upper
100 may further include tongue 132 disposed within a tongue slot
131 configured to align with and span the instep area of the
foot.
[0033] The sole assembly 105 typically includes an insole (not
shown), a midsole 106, and an outsole 108, which together cushion
and protect the user's foot while the user makes contact with the
ground. The sole assembly may be a conventional sole assembly, or,
as illustrated, may include a mechanical cushioning system as
disclosed in U.S. application Ser. No. 15/149,661, the disclosure
of which is incorporated herein by reference in its entirety.
[0034] With this configuration, the heel 121, lateral quarter and
medial quarter 130, vamp 136, toe cage 141, and tongue 132
cooperate with the sole assembly 105 to define a foot cavity into
which a human foot is inserted by way of an access opening 155
bounded by a collar 157. The foot may be secured within the cavity
utilizing a fastening device 159 such as a lacing system, a cable
system, a hook and loop fastener, etc.
[0035] Laminate Panel
[0036] All or part of the upper is formed from a laminate panel
having a predetermined expansion pattern. As shown in FIGS. 2A-2B,
the laminate panel includes an inner layer or lining122 and an
outer layer or face 142 coupled together by a bonding or coupling
layer 120. In FIGS. 2A and 2B, the outer layer 142 is partially
removed to expose the inner layer 122 and the bonding layer
120.
[0037] The inner layer 122 is a sheet of material that may be
provided in any of various forms that may be appropriate for an
article of apparel, such as a shoe or other article of footwear. In
the embodiment of FIGS. 2A and 2B, the inner layer is provided by a
textile. Accordingly, the inner layer 122 may also be referred to
herein as a "textile layer." The textile layer includes a plurality
of strands interconnected via weaving, kitting, braiding, or via a
nonwoven process. The strands forming the textile may be any
natural or synthetic strands suitable for their described purpose.
The term "strand" includes one or more filaments organized into a
fiber and/or an ordered assemblage of textile fibers having a high
ratio of length to diameter and normally used as a unit (e.g.,
slivers, roving, single yarns, plies yarns, cords, braids, ropes,
etc.). In at least one embodiment, a strand is a yarn, i.e.,
textile fibers or filaments intertwined in a form suitable for
knitting, weaving, or otherwise intertwining to form a textile
fabric. A yarn may include a number of fibers twisted together
(spun yarn); a number of filaments laid together without twist (a
zero-twist yarn); a number of filaments laid together with a degree
of twist; and a single filament with or without twist (a
monofilament).
[0038] The strands, furthermore, may include elastic strands and/or
an inelastic strands. An elastic strand is formed of elastomeric
material; accordingly, it possesses the ability to stretch and
recover by virtue of its composition. A specific example of an
elastomeric material suitable for forming an elastic strand is an
elastomeric polyester-polyurethane copolymer such as elastane,
which is a manufactured fiber in which the fiber-forming substance
is a long chain synthetic polymer composed of at least 85% of
segmented polyurethane. In contrast, an inelastic is formed of a
non-elastomeric material. Accordingly, by virtue of its
composition, inelastic strands possess no inherent stretch and/or
recovery properties. Hard yarns are examples of inelastic strands.
Hard yarns include natural and/or synthetic spun staple yarns,
natural and/or synthetic continuous filament yarns, and/or
combinations thereof. By way of specific example, natural fibers
include cellulosic fibers (e.g., cotton, bamboo) and protein fibers
(e.g., wool, silk, and soybean). Synthetic fibers include polyester
fibers (poly(ethylene terephthalate) fibers and poly(trimethylene
terephthalate) fibers), polycaprolactam fibers, poly(hexamethylene
adipamide) fibers, acrylic fibers, acetate fibers, rayon fibers,
nylon fibers and combinations thereof.
[0039] It should be noted that an inelastic strand may be modified
to possess a topology that enables the strand to provide mechanical
stretch and recovery within the textile structure. For example, a
hard yarn may be texturized (e.g., crimped) to generate stretch
within the yarn.
[0040] Preferably, the textile layer is a resilient layer
possessing stretch and recovery properties. That is, the textile
structure possesses the ability to expand from its original
shape/dimensions (stretch), as well as to contract, returning to
its original shape/dimensions (recover). Accordingly, the textile
layer expands when a tension is placed on the textile (e.g., along
the machine direction and/or along the non-machine direction). In
an embodiment, the stretch possessed by the lining is at least 5%
and/or in a range of from about 5% to about 20%. The stretch of the
textile, moreover, may be directional. For example, the textile may
possess four-way or two-way stretch capabilities. A textile with
"four way" stretch capabilities stretches in a first direction and
a second, directly-opposing direction, as well as in a third
direction that is perpendicular to the first direction and a fourth
direction that is directly opposite the third direction. In other
words, a sheet of four-way stretch material stretches in both
crosswise and lengthwise. A material with "two way" stretch
capabilities, in contrast, stretches to some substantial degree in
the first direction and the second, directly opposing direction,
but will not stretch in the third and fourth directions, or will
only stretch to some limited degree in the third and fourth
directions relative to the first and second directions (i.e., the
fabric will stretch substantially less in the third and fourth
directions than in the first direction and second directions). In
other words, a sheet of two-way stretch material stretches either
crosswise or lengthwise.
[0041] Regardless of the direction of the stretch, during
expansion, the textile will possess an expansion pattern.
Specifically, textiles generally exhibit a strongly positive
Poisson ratio. Thus, when a load or tension is applied to textile
(along an axis), the normal stretch pattern causes the textile to
constrict along the axis that is perpendicular to the load axis.
Stated another way, the expansion pattern of the textile layer is
anticlastic, contracting in the directions transverse to the
direction of stretching. Upon release of the tension/load, the
recovery power of textile returns the fabric to its original
shape/dimensions.
[0042] With continued reference to FIGS. 2A and 2B, the outer layer
142 is coupled to the inner layer 122 via the bonding layer 120.
The outer layer 142 is a sheet of material that may be provided in
any of various forms that may be appropriate for an article of
apparel, such as a shoe or other article of footwear. For example,
the outer layer may be provided by a textile (similar to the inner
layer 122), a leather, a synthetic leather (e.g., polyurethane on a
fibrous polyester base layer), or any of various polymers or other
materials. In embodiments wherein the outer layer 142 is a leather
or synthetic leather layer, the outer layer provides relatively
limited stretch and expansion properties in comparison to more
resilient layers, such as an inner layer comprised of elastic
strands. Accordingly, it will be recognized that the outer layer
142 may be provided by a same or similar material to that of the
inner layer 122, or may be provided by a completely different
material. While the outer layer 142 is shown as having a similar
thickness as the inner layer 122 in FIG. 2B, it will be recognized
that in at least some embodiments the outer layer 142 is
significantly thicker or thinner than the inner layer 122.
[0043] During expansion, the material providing the outer layer 142
will possess an expansion pattern. Specifically, leathers and
synthetic leathers generally exhibit a significantly positive
Poisson ratio. Thus, when a load or tension is applied to the
material (along an axis), the normal stretch pattern causes the
leather or synthetic leather to constrict along the axis that is
perpendicular to the load axis. Upon release of the tension/load,
some recovery may occur that allows the material to return closer
to its original shape/dimensions. Because the recovery properties
of leather and synthetic leathers are limited, and the materials
tend to lose their original shape over time.
[0044] With continued reference to FIGS. 2A and 2B, the bonding
layer 120 is a resilient framework capable of altering the
expansion pattern of the face 142 and/or the lining 122. In an
embodiment, the bonding layer 120 is formed of a flexible polymer
material capable of bonding the inner layer 122 to the outer layer
142 of the panel 118. The bonding layer 120 may be formed by any of
various adhesive materials available in any of various forms.
Examples of adhesive materials include structural adhesives,
pressure sensitive adhesives, and thermosetting structural
adhesives, including materials such as epoxies, cements, and
elastomer adhesives. The adhesives may be provided in various forms
including resins, pastes, liquids, gels, films and supported films.
Advantageously, because of the adhesive quality of the bonding
layer 120, the inner layer 122 may be connected to the outer layer
142 via the bonding layer alone, without the need for sewing or
additional fasteners in order to secure the two layers 122, 142
together. The bonding layer 120 should provide an adhesion strength
capable of bonding to and controlling the face and lining. In an
embodiment, the bonding layer possesses a dry adhesive strength of
about 0.15 kg/cm.sup.2 (e.g., at least 0.15 kg/cm.sup.2) and a wet
adhesive strength of about 0.10 kg/cm.sup.2 (e.g., at least 0.12
kg/cm.sup.2). By way of example, the bonding layer 120 is a curable
polyurethane adhesive applied at a thickness of less than one
millimeter (e.g., 0.10-0.20 mm).
[0045] The bonding layer 120 is applied to the inner layer 122 and
outer layer 142 such that any movement of the bonding layer
generates movement in the textile layer, and vice versa. The
bonding layer may be directly applied to a textile layer in a
liquid or gelatinous state such that the polymer of the bonding
layer infiltrates the textile, flowing between the strands. By way
of example, the bonding layer 120 may be applied via flow molding.
By way of further example, the polymer that forms the bonding layer
120 may be applied via screen printing (e.g., three dimensional
screen printing) or an additive manufacturing process (3D printing
techniques). In other embodiments, the polymer that forms the
bonding layer 120 may be applied in non-solid form and cured. In
still other embodiments, the bonding layer 120 is formed separately
(e.g., via selective laser sintering/ablation) and is adhered to
the base layer via, e.g., an adhesive, welding, etc.
[0046] The bonding layer includes a plurality of cells or
substructures arranged in an array. The cells are polygons
including one or more internal angles that are reflexive
(possessing a value between 180.degree.-360.degree.. In other
words, the cells are reentrant polygons. The cell array is a
structure of interconnected cells, with a cell sharing common
borders with adjacent cells. Specifically, the plurality of cells
forming the array is organized in a series of columns. In some
embodiments (e.g., see FIG. 2A), the cells of adjacent columns are
oriented in opposite directions. In other embodiments (e.g., see
FIG. 3A), the cells of adjacent columns are oriented along the same
direction, but are longitudinally offset such that cells of a first
column are staggered relative to the cells of a second, adjacent
column. By way of example, the upper end of one cell is oriented
proximate the longitudinal center (equator) of its adjacent cell.
With either configuration, the cell array is configured such that
movement of one cell generates movement in an adjacent cell.
[0047] The expansion pattern of the bonding layer differs from the
expansion pattern of the textile of the inner layer 122 and the
outer layer 142. For example, while the normal stretch pattern of
the textile layer is to constrict along the axis that is
perpendicular to the load axis, the bonding layer (or portions
thereof) may either resist constriction or expand along the axis
perpendicular to the load axis. For example, the bonding layer may
be synclastic or auxetic, exhibiting a negative Poisson's
ratio.
[0048] The bonding layer 120 is sandwiched between the inner layer
122 and the outer layer 142 and couples the inner layer 122 to the
outer layer 142. The bonding layer 120 may be coupled to (e.g.,
mounted on or embedded in) the inner layer 122 or the outer layer
142, and the other layer may be applied to the bonding layer 120 to
form the textile laminate, with the inner layer 122, the outer
layer 142, and the bonding layer being generally coextensive across
the laminate. The bonding layer 120 is configured to influence the
textile layer during expansion, altering the expansion pattern of
the inner and/or outer layers of the laminate panel. That is,
during expansion of the laminate panel, the expansion pattern of
the bonding layer 120 has an effect on the expansion pattern of the
inner layer 122 and/or outer layer 142. Accordingly, the bonding
layer drives the expansion of the laminate panel in a predetermined
pattern that differs from the native expansion pattern of the inner
and outer layers and is closer to that of the bonding layer.
[0049] Accordingly, when coupled to the inner layer 122 and outer
layer 142, the bonding layer 120 (the cell array) may work to
resist deformation and shrinkage in the inner layer 122 and the
outer layer 142. Specifically, the bonding layer is configured to
lower the Poisson ratio of the fabric or leather, making the ratio
of the laminate panel 118 (i.e., the combined structure textile
layer/polymer layer structure) less positive. In some embodiments,
the Poisson ratio of the resulting laminate panel is less strongly
positive. In other embodiments, it is zero; in others, it the
Poisson ratio is negative. For example, the laminate panel 118 (or
portions thereof) may possess a negative Poisson's ratio,
generating a synclastic or auxetic expansion pattern in which the
function laminate expands along the axis perpendicular to the load
axis (expands in directions transverse to the direction of
stretching). The inner and outer layers 122, 142, however, may
possess greater recovery power than the bonding layer 120.
Accordingly, upon removal of the load along the load axis, the
inner and outer layers 122, 142 may draw the bonding layer 120 back
to its contracted configuration. In this manner, each layer plays a
role in the combined structure, driving expansion or contraction
behavior of the laminate panel.
EXAMPLES
[0050] Referring again to the embodiment of FIGS. 2A and 2B, an
enlarged view of the laminate panel 118 is shown with the outer
layer 142 partially removed to show the inner layer 122 (which may
also be referred to herein as the "base layer") and the bonding
layer 120 (which may also be referred to herein as the "auxetic
layer" or an "auxetic bonding layer"). The auxetic layer 120
includes a first portion 120a that penetrates the base layer 122
(as noted by the dotted lines in the base layer 122 in FIG. 2B),
and a second portion 120b that is above or outwardly from the base
layer 122. The first portion 120a of the auxetic layer 120
penetrates through at least a first surface 122a of the base layer
122, and in some embodiments, the first portion 120a may penetrate
completely through the base layer 122 to a second surface 122b of
the base layer 122. As a result, the auxetic layer 120 is at least
partially embedded in the base layer 122 and may not be removed or
peeled away from the base layer 122 without destruction of either
the auxetic layer 120 or the base layer 122.
[0051] When the panel 118 is implemented in an article of footwear,
the first surface 122a of the base layer 122 is an inner surface
that faces inwardly toward the foot cavity, and the second surface
122b is a middle surface that faces the outer layer 142. For
clarity in FIG. 2A, the base layer 122 is shown as the
cross-hatched portion under the auxetic layer 120 which does not
include any cross-hatching. Therefore, it will be recognized that
the cross-hatching in FIG. 2A is for purposes of contrast only, and
does not indicate any cross-section or particular material.
[0052] As indicated above, the auxetic layer 120 includes an
auxetic structure provided by a plurality of interconnected
segments 126 arranged in a manner to provide a repeating pattern of
reentrant shapes (i.e., concave polygons). In the embodiment of
FIG. 2A, the repeating pattern of reentrant shapes is an array of
reentrant shapes which may be considered to exist in rows and
columns of the auxetic structure. The interconnected segments 126
form the reentrant shapes in the auxetic structure, and an interior
recess 128 is defined within each reentrant shape. In the
embodiment of FIGS. 2A-2B, the auxetic layer 120 separates the base
layer 122 from the outer layer 142 (as shown on the left side of
FIG. 2B). Thus, in this embodiment, portions of the interior recess
128 are void of material between the base layer 122 and the outer
layer 142. However because the first portion 120a of the bonding
layer penetrates the base layer 122, portions of the base layer 122
fill the interior recesses at the first portion 120a of the bonding
layer 120. Similarly, because the second portion 120b of the
bonding layer penetrates the outer layer 142, portions of the outer
layer 142 fill the interior recesses at the second portion 120b of
the bonding layer 120.
[0053] The reentrant shapes formed by the interconnected segments
126 may be any of various shapes capable of providing an auxetic
structure. In the embodiment of FIGS. 2A-2B, the reentrant shapes
formed by the interconnected segments are arrowhead shapes (which
may also be referred to herein as "chevron" shapes). Segments
125A-125D in FIG. 2A illustrate a group of interconnected segments
that form an arrowhead shape. Segments 125A and 125B are connected
at a leading vertex 127a and form a first acute interior angle for
the reentrant shape. Segments 125A and 125C are connected at a
first trailing vertex 127b and form a second acute interior angle.
Segments 125B and 125D are connected at a second trailing vertex
127c and form a third acute interior angle. Segments 125C and 125D
are connected at a concave portion of the reentrant shape and form
a reflexive interior angle.
[0054] Together, each set of interconnected segments 126 forming a
reentrant shape and the associated interior recess 128 forms a cell
unit 124. For example, in FIG. 2A, segments 125A-d and interior
recess 128a forms cell unit 124a. While each cell unit has a unique
interior recess 128, cell units may share the same segment 126. In
other words, each segment 126 may border more than one interior
recess 128. For example, in FIG. 2A, segment 126x borders interior
recess 128y and 128z. Accordingly, it will be recognized that each
segment 126 may be considered to be a part of multiple cells and,
therefore, each segment 126 may be considered to a portion of two
different reentrant shapes. Because the segments 126 surround an
interior recess 128 in the auxetic structure, the segments 126 may
also be referred to herein as "perimeter walls," "cell walls," or
"interconnected members." In the embodiment of FIG. 2A, the auxetic
structure includes an array of cell units which may be considered
to exist in rows and columns of the auxetic structure. However,
because each interconnected segment 126 may be shared by two
different cell units 124, the areas covered by the individual rows
and columns overlap within the auxetic structure.
[0055] In at least one embodiment, the auxetic layer 120 is a
continuous structure, with each cell unit 124 sharing segments 126
with at least one adjacent cell unit or partial cell unit.
Accordingly, the material forming the segments 126 is continuous
and uninterrupted across the auxetic structure. However, as noted
above, the first portion 120a of the auxetic layer 120 is embedded
in the base layer 122 and therefore fibers of the base layer are
present within the auxetic layer. The auxetic structure may be
formed using any of various processes such as screen printing
and/or three-dimensional printing, examples of which are discussed
in further detail below.
[0056] In the embodiment of FIG. 2A-2B, the segments 126 are
generally uniform in width (i.e., the distance across the segment
parallel to the base layer 122), but are staggered in height. For
example, as shown in FIG. 2A, each segment 126 has a width, w,
which is generally uniform. In at least one embodiment, this width
w is between 1 mm and 5 mm, and particularly about 2 mm.
[0057] As shown in FIG. 2B, each segment 126 has a height, h,
defined between the top surface and the bottom surface of the
segment 126. In at least one embodiment, the height h is between
0.5 mm and 4 mm, and particularly about 2 mm.
[0058] The interconnected segments 126 of the auxetic layer 120 may
be provided by any of various materials suitable for the desired
purposes of the auxetic layer. In at least one embodiment, the wall
material forming the interconnected segments 126 comprises a
resilient polymer material such as ethylene-vinyl acetate (EVA), a
thermoplastic such as nylon, or a thermoplastic elastomer such as
polyurethane. Each of these materials may mixed with other
materials to provide adhesive properties for the auxetic layer 120.
The auxetic layer 120 may be provide in a liquid or gelatinous
state when applied to the base layer 122 and then fully or
partially cured before the outer layer 142 is applied, as discussed
in further detail below.
[0059] As noted previously, the bottom surface of the auxetic layer
120 is embedded in the base layer 122, while the top surface of the
auxetic layer is exposed to the outer layer 142. The auxetic layer
120 may be embedded in the base layer 122 using any of various
methods, including seeping of printed liquid and subsequent curing,
heat fusing, or any of various other methods as will be recognized
by those of ordinary skill in the art. In at least one embodiment,
the auxetic layer 120 is printed directly on to the base layer 122
in a liquid or gelatinous form using a screen printing process.
After the auxetic layer is printed, the liquid or gelatinous
material slowly seeps into the base layer 122 and subsequently
cures. In at least one alternative embodiment, the auxetic layer
120 is brought into contact with the base layer 122 while the
auxetic layer 120 is in a solid state, and then heat is applied to
bring the auxetic layer 120 to a liquid or semi-liquid (partially
melted) state. With the auxetic layer in a liquid or semi-liquid
state, the material of the auxetic layer 120 that is in contact
with the base layer 122 infiltrates the base layer fabric.
Alternatively, the auxetic layer 120 may be applied to the base
layer 122 in a molten or semi-molten state (e.g., during an inkjet
printing process). In each of these embodiments, once cooled or
otherwise cured, the auxetic layer 120 is securely fixed
(permanently connected) to the fibers of the base layer 122 such
that any movement of the base layer is transferred to the auxetic
layer, and vice versa.
[0060] The outer layer 142 of the laminate panel 118 is connected
to the base layer 122 via the auxetic layer 120. In at least one
embodiment, the outer layer 142 is provided by a stretch fabric
(e.g., a four-way stretch material) such that the inner layer 122
and the outer layer 142 are similarly influenced by the auxetic
layer 120. In another embodiment, the outer layer 142 is a
relatively inelastic material (e.g., a leather material) that
limits the overall auxetic properties of the laminate panel 118.
The outer layer 142 may be connected to the auxetic layer 120 via
any of various means, including adhesives inherent in the auxetic
layer 120, molding, welding, sintering, stitching or any of various
other means. In at least one embodiment, the outer layer 142 is
brought into contact with the auxetic layer 120 and then heat is
applied to place the material forming the auxetic layer in a
semi-liquid (partially melted) state. The material forming the
auxetic layer then infiltrates the outer layer fabric such that the
auxetic layer 120 is at least partially embedded in the outer layer
142. Alternatively, the outer layer 142 may be applied to the
auxetic layer 120 with the auxetic layer in a molten or semi-molten
state. In either application, once cooled or otherwise cured, the
auxetic layer 120 is securely fixed (permanently connected) to the
fibers of the outer layer 142 such that any movement of the outer
142 layer is transferred to the auxetic layer 120, and vice
versa.
[0061] The structure of the laminate panel 118, including the
auxetic layer 120, the base layer 122, and the outer layer 142,
provides improved contouring properties around a three-dimensional
object compared to a structure including only the base layer and/or
the outer layer. For example, when incorporated into an article of
footwear 10, the vamp easily and smoothly conforms to the various
shapes and curvatures present on the foot. The laminate panel 118
is capable of double curvature forming synclastic and/or
anticlastic forms when stretched. Double curvatures are prevalent
along the length of the human foot. Accordingly, the laminate panel
118 providing the vamp 136 will follow the curvatures of the foot
with little to no wrinkling or folding visible to the wearer.
Furthermore, the inherent features and characteristics of the
laminate panel 118 allow the vamp 136 to be provided as a single
panel that extends across a wide region of the article of footwear
10.
[0062] While FIGS. 2A and 2B show one embodiment of an laminate
panel 118 that may be used on the article of footwear 10, it will
be recognized that the laminate panel 118 may take a number of
different forms. For example, in lieu of the auxetic layer 120 of
FIGS. 2A-2B wherein the reentrant shapes are provided in the form
of arrowhead shapes, the auxetic structure of FIGS. 3A-3C may be
used, wherein the reentrant shapes are hourglass or bow-tie shapes
(which may also be referred to as "auxetic hexagons"). Although the
shapes formed by the interconnected segments 126 are different in
FIG. 3A from the shapes formed in FIG. 2A, it will be recognized
that both embodiments share a number of similarities. For example,
the laminate panel 118 in FIGS. 3A-3C also includes an auxetic
layer 120, a base layer 122, and an outer layer 142. The auxetic
layer 120 includes a plurality of interconnected segments 126 that
form cells units 124 oriented in an array, each cell unit being
positioned in horizontal rows and vertical columns. The
interconnected segments 126 may have different widths, as noted in
FIG. 3B by widths "w" and "x". An interior recess 128 is formed
within each cell unit 124, with the interior recess 128 bordered by
the surrounding interconnected segments 126. The width "y" across
on of the interior recesses 128 is generally greater than the width
"w" or "x" across one of the interconnected segments 126. As shown
in FIG. 3C, the interconnected segments 126 penetrate the base
layer 122 and the outer layer 142. While the recesses 128 are shown
in FIG. 3C as including voids positioned between the base layer 122
and the outer layer 142, in at least one embodiment the outer layer
142 is in contact with the base layer 122, and the recesses 128 are
substantially filled with material from either the base layer 122
or the outer layer 142.
[0063] FIGS. 4A and 4B illustrate the operation of one auxetic
structure that may be used as the auxetic layer. In particular FIG.
4A shows the auxetic layer 120 of FIG. 3A separated from the base
layer 122 and the outer layer 142 in its normal, unstretched state.
The thickness (or width) of the auxetic layer 120 in the
unstretched state is indicated as d1. FIG. 4B shows the auxetic
layer 120 stretched in the direction of arrows 12. The thickness of
the auxetic layer in the stretched state is indicated by d2. As can
be seen in FIG. 4B, when tension is applied along a first direction
(indicated by arrows 12), the auxetic structure is stretched,
expanding (i.e., becoming thicker) in a second direction (indicated
by arrows 13) that is perpendicular to the first direction such
that in the stretched state d2>d1. This is the result of the
pivoting/rotation that occurs along the vertices of the reentrant
shape (i.e., where the ends of the interconnected segments form
corners of the polygons in the reentrant shape). It will be
appreciated that the auxetic layer 120 of FIG. 2A is also
configured to expand in a similar manner to the auxetic layer of
FIG. 4A.
[0064] The term "auxetic structure" as used herein generally refers
to a structure provided in a configuration that, depending on an
appropriately flexible material being used, will have a near zero
or negative Poisson's ratio. In other words, when stretched,
auxetic structures tend to become thicker (as opposed to thinner)
or expand in a direction perpendicular to the applied force, or at
least do not contract to a significant extent in a direction
perpendicular to the applied force. This generally occurs due to
inherent hinge-like components between the interconnected segments
which flex when stretched. In contrast, materials with a positive
Poisson's ratio that is not near zero contract to a significant
extent in a direction perpendicular to the applied outward force
(i.e., perpendicular to the direction of stretch). As used herein,
an auxetic structure having a "near zero" Poisson's ratio is a
structure exhibiting a Poisson's ratio of approximately zero and,
in particular, less than +0.15.
[0065] The term "auxetic" as used herein is not limited to
structures that actually have a near zero or negative Poisson's
ratio in operation or implementation. The reason for this is that
an entire auxetic structure, or portions thereof, may be
practically locked in place and substantially prohibited from
expansion or contraction in either direction. For example, a
structure comprised of glass may still be considered an "auxetic
structure" if it is provided with the appropriate array of
reentrant shapes, although forces attempting to stretch the
structure will typically result in the structure breaking rather
than expanding. Also, components or materials adjacent to, within,
or surrounding the auxetic structure may prevent the auxetic
structure from exhibiting a near zero or negative Poisson's ratio
when stretched. An example of an auxetic structure that may not
exhibit a zero or negative Poisson's ratio when stretched may be
realized in association with the laminate panel 118 of FIGS. 2A and
2B when either the inner layer 122 or the outer layer 142 is a
relatively inelastic material, such as leather.
[0066] In addition to the foregoing, it will be recognized that
whether a structure has a negative Poisson's ratio, may depend upon
the degree to which the structure is stretched. Structures may
exhibit a negative Poisson's ratio up to a certain stretch
threshold, but when stretched past the threshold may have a
positive Poisson's ratio. For example, it is possible that when the
auxetic layer 120 in FIG. 4A is stretched in the direction of
arrows 12 past a threshold expansion position (e.g., past the state
shown in FIG. 4B), the cells and segments of the auxetic structure
may be stretched to an extent that the auxetic structure becomes
slightly thinner (in the direction perpendicular to arrows 12)
before the structure is torn apart or otherwise damaged.
[0067] In the embodiments disclosed herein, auxetic structures are
formed from a plurality of interconnected segments 126 forming an
array of cell units 124, and each cell unit has a "reentrant
shape". As used herein, the term "reentrant shape" may also be used
to refer to a "concave", or "non-convex" polygon or shape, which
provides shape having an interior angle with a measure that is
greater than 180.degree.. The angle a shown in each of FIGS. 2A and
3A is an angle in a reentrant shape having a measurement of greater
than 180.degree.. The auxetic layers 120 in FIGS. 2A and 3A are two
examples of such an auxetic structure defining a reentrant shape.
It will be appreciated that numerous other auxetic structures are
possible. Examples of other auxetic structures are shown in FIGS.
5A-5D.
[0068] FIG. 5A shows an auxetic structure 150a in the form of a
wave hourglass configuration. In this embodiment of the auxetic
structure, the segments 125A positioned along one axis (i.e., the
vertical axis in FIG. 5A) are curved or sinusoidal, and the
segments 125B along another axis (i.e., the horizontal axis in FIG.
5A) are straight or relatively linear. The auxetic structure 150a
of FIG. 5A has the advantage of being form fitting and strongly
tunable.
[0069] FIG. 5B shows another auxetic structure 150b in the form of
a double wave configuration. In this embodiment of the auxetic
structure, the segments 125A positioned along one axis (i.e., the
vertical axis in FIG. 5B) are curved or sinusoidal in shape, and
the segments 125B along another axis (i.e., the horizontal axis in
FIG. 5B) are also curved or sinusoidal in shape. Similar to the
auxetic structure 150a of FIG. 5A, the auxetic structure 150b of
FIG. 5B has the advantage of being form fitting, strong, and easily
tunable.
[0070] FIG. 5C shows another auxetic structure 150c in the form of
a hinged hourglass configuration. In this embodiment of the auxetic
structure, the segments 125A positioned along one axis (i.e., the
vertical axis in FIG. 5C) are a combination of square and
triangular in shape, and the segments 125B along another axis
(i.e., the horizontal axis in FIG. 5C) are also straight or
relatively linear. Similar to the auxetic structure 150a and 150b
of FIGS. 5A and 5B, the auxetic structure 150c of FIG. 5C has the
advantage of being form fitting, strong, and very tunable.
[0071] FIG. 5D shows another auxetic structure 150d in the form of
a tessellating planes configuration. In this embodiment of the
auxetic structure, the segments 126 are generally square or
rectangular in shape, and recesses 128 are generally diamond
shaped, with an edge of each square or rectangular segment defined
along one of the edges of the diamond shaped recesses. While the
auxetic structure 150d of FIG. 5D is less form fitting and tunable
than the auxetic structures 150a, 150b, and 150c of FIGS. 5A-5C,
the auxetic structure has the advantage of being very strong.
[0072] As noted previously, the laminate panel 118, including an
inner layer 122, bonding layer 120 providing an auxetic structure,
and outer layer 142, is incorporated into an article of apparel.
For example, the laminate panel 118 may be provided on an article
of footwear. FIG. 1 shows the article of footwear 10 as a shoe that
includes an upper 100 made from the laminate panel 118. The article
of footwear 10 includes an upper 100 and a sole assembly 105
including a midsole 106 and an outsole 108.
[0073] FIG. 6 illustrates one benefit to providing the laminate
panel 118 on the upper of an article of footwear 10. In particular,
when a user cuts, pivots, or otherwise moves with the article of
footwear 10 on his or her feet, the user's foot will apply a
straining force on the laminate panel 118 of the upper. When the
upper 100 with the laminate panel 118 is subjected to strain in one
direction (e.g., the direction indicated by the arrow 160 in the
illustration of FIG. 6), the auxetic structure of the bonding layer
120 influences the panel 118 to expand in the direction
perpendicular to the applied force (i.e., the direction indicated
by arrows 162). This expansion in the perpendicular direction is
different from prior art panels that contract in the direction
perpendicular to the applied force (i.e., in the direction
indicated by arrows 164). Accordingly, the laminate panel 118
provides the benefit of spreading a load that is concentrated on a
relatively small surface area across a significantly greater
surface area of the upper. Additionally, the laminate panel 118
provides improved contouring properties around a three-dimensional
object compared to a structure including only the base layer and/or
the outer layer. For example, when incorporated into an article of
footwear 10, the vamp easily and smoothly conforms to the various
shapes and curvatures present on the foot.
[0074] Method of Making an Article of Apparel
[0075] With reference now to FIG. 7, a method 700 of making an
article of apparel is shown. The method 700 begins in step 710 with
the auxetic bonding layer 120 being applied to the base layer 122.
The auxetic bonding layer 120 may be applied to the bonding layer
122 with the material providing the bonding layer in a liquid,
semi-liquid, paste, or gelatinous form. Any of various means may be
used to apply the auxetic bonding layer 120 to the base layer, such
as screen printing, inkjet printing, 3D printing, or any of various
other means.
[0076] After the auxetic bonding layer 120 is applied to the base
layer 122, the material of the auxetic bonding layer 120 penetrates
the base layer 122 by seeping through a first surface of the base
layer 122 and into the body of the base layer. This results in the
auxetic bonding layer 120 being embedded in the base layer 122.
Thereafter, the auxetic bonding layer 120 is apt least partially
cured as shown in step 720. Curing of the auxetic bonding layer 120
may occur using any of various means appropriate for the material
used for the auxetic bonding layer. For example, depending on the
material used for the auxetic bonding layer, heat, pressure,
cooling, UV light, time-setting, or any of various other
appropriate means may be used to completely or partially cure the
auxetic bonding layer 120. Once cured or partially cured, the
auxetic bonding layer 120 is hardened to some extent and connected
to the base layer 122, the auxetic bonding layer 120 being embedded
in the base layer 122 in a manner such that the auxetic bonding
layer 120 cannot be removed from the base layer 122 without
destruction of either the auxetic bonding layer 120 or the base
layer 122.
[0077] After the auxetic bonding layer 120 is at least partially
cured in step 720, the method continues to step 730 and the outer
layer 142 is attached to the base layer 122 by applying the outer
layer 142 to the exposed side of the auxetic bonding layer 120. As
a result, the auxetic bonding layer 120 is sandwiched between the
base layer 122 and the outer layer 142, and this three-layered
arrangement forms the laminate panel 118. If the auxetic bonding
layer 120 was only partially cured in step 720, the auxetic bonding
layer 120 may remain somewhat soft, as a paste, semi-liquid, or
gelatinous material. This material may then seep into the fibers of
the outer layer 142 before the auxetic bonding layer 120 is fully
cured. Alternatively, if the auxetic bonding layer 120 was fully
cured in step 720, the outer layer 142 may rest on top of the
exposed surface of the auxetic bonding layer 120.
[0078] Thereafter, in step 740 of FIG. 7, the laminate panel 118 is
finish treated to further secure the three layers of the laminate
panel 118 together. In at least one embodiment, the laminate panel
118 is finish treated by applying heat and/or pressure to the
laminate panel 118. For example, the laminate panel 118 may be
placed in a heat press and a heated plate may be forcibly applied
to the outer surface of the outer layer 142 (i.e., the surface
opposite the auxetic bonding layer 120). The heat and pressure
applied in this finishing process causes the auxetic bonding layer
120 to more completely mix with the fibers of the outer layer 142
and the base layer 122. In at least one embodiment, the finish
treatment may be designed to further cure the auxetic bonding layer
120 using any of various means such as application of heat,
cooling, application of UV light, time, or any of various other
curing processes.
[0079] Alternatively, or in addition to one or more of the
foregoing processes, the finish treating the laminate panel 118 in
step 740 may include additional processes. One example of such an
additional process is embossing the laminate panel 118 in order to
emphasize the auxetic structure provided by the bonding layer 120.
Any of various embossing processes may be used, such as cold
molding, heat embossing, registration, etc. As another example, the
laminate panel may be pressed or stretched to enhance the visual
effects of the auxetic bonding layer 120 of the laminate panel 118.
The visual effect of the auxetic layer tends to be more prominent
on a thinner textile layer. Therefore, if the outer layer 142 is a
leather or synthetic leather, and the inner layer 122 is a four-way
stretch material (or other relatively thin textile), the visual
effect of the auxetic bonding layer 120 will not be prominent on
the exterior of the article of footwear or other article of
apparel. However, if the outer layer 142 is a four-way stretch
material, the visual effect of the auxetic bonding layer may be
very prominent, similar to that shown in FIG. 1. In at least one
embodiment, the visual effect of the auxetic bonding layer is made
more prominent by the auxetic bonding layer 120 having a relatively
dark or bright color (e.g., black, blue, red, etc.), and the outer
layer 142 being a light colored sheer material (e.g., a white 4-way
stretch material). In these embodiments, the auxetic bonding layer
120 is visible through the sheer outer layer 142 and provides and
interesting visual effect for the article of apparel, similar to
that shown in FIG. 1.
[0080] Referring again to the method of FIG. 7, after the laminate
panel 118 is finish treated, the method 700 continues to step 750,
and the laminate panel 118 is cut to a desired shape and
incorporated into the article of apparel. Advantageously, the
auxetic properties of the laminate panel 118 are such that a single
piece of the laminate panel 118 may be used to extend across a wide
region of the article of apparel. For example, when incorporated
into an article of footwear 10 such as that of FIG. 1, the vamp
easily and smoothly conforms to the various shapes and curvatures
present on the foot.
[0081] While the invention has been described in detail and with
reference to specific embodiments thereof, it will be apparent to
one skilled in the art that various changes and modifications can
be made therein without departing from the spirit and scope
thereof. For example, while the embodiments disclosed herein show
an article of apparel in the form of an article of footwear, and
particularly a shoe, it will be recognized that the term "article
of apparel" as used herein refers to any garment, article of
footwear or accessory configured to be worn on or carried by a
person (whether human or otherwise). Examples of articles of
apparel include helmets, hats, caps, shirts, pants, shorts,
sleeves, knee pads, elbow pads, shoes, boots, backpacks, duffel
bags, cinch sacks, and straps, as well as numerous other products
configured to be worn or carried by a person. Examples of other
articles of footwear include socks, boots, cleats, or any of
numerous other products configured to be worn in association with
the foot of a person.
[0082] While the figures disclosed herein reference various regions
of the article of footwear 10, including the forefoot region 110A,
midfoot region 110B, and heel region 110C, it will be recognized
that each of these regions generally corresponds to a region of a
human foot associated with such region in the article of footwear
10. Furthermore, it will be recognized that overlap may occur
between regions or that a transition region may be defined between
each of these regions. Accordingly, when various portions of the
upper 100 or sole assembly 105 are described herein as extending to
different "regions", it will be recognized that these regions may
be generally defined with reference to a human foot positioned
within the associated article of footwear.
[0083] The components of the upper 100 may be presented in any of
various configurations and thereby provide different forms of the
footwear. For example, the upper 100 of FIG. 1 may be configured as
a low-cut running shoe, a high-top basketball shoe, or any of
various other forms of athletic shoes. The upper 100 may also be
configured with various tightening mechanisms to secure the article
of footwear 10 to the foot of the wearer. For example, the upper
100 may be configured such that the article of footwear is a
lace-up shoe, a slip-on shoe, or a strap-tightened boot.
[0084] With the above-described construction, a laminate is
provided that possesses a lower Poisson ratio than the laminate
would have without the bonding layer. In particular, it is possible
to form a laminate that, while not including any individual textile
(facing or lining) layer possessing auxetic (or near auxetic)
properties, functions as an auxetic or near auxetic once coupled to
the bonding layer.
[0085] The described process further reduces the cost of forming
auxetic structures. Forming auxetic textiles is expensive,
involving the manipulation of strands and their location in
specific locations within a textile structure. Accordingly, the
described process enables formation of auxetic textiles at a lower
price point via a simplified process.
[0086] The foregoing detailed description of one or more exemplary
embodiments of the articles of apparel including auxetic materials
has been presented herein by way of example only and not
limitation. It will be recognized that there are advantages to
certain individual features and functions described herein that may
be obtained without incorporating other features and functions
described herein. Moreover, it will be recognized that various
alternatives, modifications, variations, or improvements of the
above-disclosed exemplary embodiments and other features and
functions, or alternatives thereof, may be desirably combined into
many other different embodiments, systems or applications.
Presently unforeseen or unanticipated alternatives, modifications,
variations, or improvements therein may be subsequently made by
those skilled in the art which are also intended to be encompassed
by the appended claims. Therefore, the spirit and scope of any
appended claims should not be limited to the description of the
exemplary embodiments contained herein.
* * * * *