Thermoplastic non-woven textile elements

• US 10,174,447 B2
• Filed: 03/21/2012
• Issued: 01/08/2019
• Est. Priority Date: 02/06/2009
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Hawkinson, Karen A.
• Primary Examiner(s): Trieu, Timothy K
• Application Number:
  US13/426,323
• Publication Number:
  US 20130067768A1
• Time in Patent Office: 2,484 Days
• Field of Search: 36 45, 36 47- 48, 36 501, 36 56, 36 49, 156166, 12142 R, 12146 R
• CPC Class Codes: A41B 1/08 Details
• CPC Class Codes: A41D 1/06 Trousers
• CPC Class Codes: A41D 2500/30 Non-woven
• CPC Class Codes: A43B 1/00 Footwear characterised by the material
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 1/14 made of plastics A43B1/028 takes precedence
• CPC Class Codes: A43B 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 23/027 with a part of the upper particularly flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 23/24 Ornamental buckles; Other ornaments for shoes without fastening function
• CPC Class Codes: A43B 3/0078 provided with logos, letters, signatures or the like decoration A43B23/24 takes precedence
• CPC Class Codes: A43B 9/16 Footwear with soles moulded on to uppers or welded on to uppers without adhesive
• CPC Class Codes: B29C 65/022 Particular heating or welding methods not otherwise provided for
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 66/003 Protecting areas of the parts to be joined from overheating B29C66/348, B29C66/8744 take precedence
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/1282 comprising at least one overlap joint-segment
• CPC Class Codes: B29C 66/12841 comprising at least two butt joint-segments
• CPC Class Codes: B29C 66/133 Fin-type joints, the parts to be joined being flexible the parts to be joined being rigid B29C66/1312
• CPC Class Codes: B29C 66/14 the joint having the same thickness as the thickness of the parts to be joined B29C66/1142 takes precedence
• CPC Class Codes: B29C 66/244 : said joint lines being non-straight, e.g. forming non-closed contours
• CPC Class Codes: B29C 66/303 : the joint involving an anchoring effect B29C66/341, B29C65/56 and subgroups take precedence
• CPC Class Codes: B29C 66/30326 : in the form of porosity
• CPC Class Codes: B29C 66/43 : Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/431 : Joining the articles to themselves B29C66/4322 and B29C66/4332 take precedence
• CPC Class Codes: B29C 66/433 : Casing-in, i.e. enclosing an element between two sheets by an outlined seam for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261
• CPC Class Codes: B29C 66/45 : Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/472 : said single elements being substantially flat
• CPC Class Codes: B29C 66/4722 : Fixing strips to surfaces other than edge faces fixing strips to edge faces B29C63/0026
• CPC Class Codes: B29C 66/4724 : said single elements being appliques, e.g. in the form of a text or drawing
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/723 : being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/727 : being porous, e.g. foam
• CPC Class Codes: B29C 66/729 : Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/7294 : Non woven mats, e.g. felt
• CPC Class Codes: B29C 66/7392 : characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/7394 : characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/81422 : being convex
• CPC Class Codes: B29C 66/81423 : being concave
• CPC Class Codes: B29C 66/81435 : comprising several parallel ridges, e.g. for crimping comprising a single ridge B29C66/81427
• CPC Class Codes: B29C 66/8226 : Cam mechanisms; Wedges; Eccentric mechanisms
• CPC Class Codes: B29C 66/83221 : cooperating reciprocating tools, each tool reciprocating along one axis
• CPC Class Codes: B29C 66/8362 : Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
• CPC Class Codes: B29D 35/00 : Producing footwear
• CPC Class Codes: B29K 2023/00 : Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/0633 : LDPE, i.e. low density polyethylene
• CPC Class Codes: B29K 2023/0683 : UHMWPE, i.e. ultra high molecular weight polyethylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2033/08 : Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/10 : Aromatic polyamides [polyaramides] or derivatives thereof
• CPC Class Codes: B29L 2031/4842 : Outerwear
• CPC Class Codes: B29L 2031/4857 : Trousers
• CPC Class Codes: B29L 2031/50 : Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B32B 2262/02 : Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/0253 : Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0261 : Polyamide fibres
• CPC Class Codes: B32B 2262/0269 : Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/0292 : Polyurethane fibres
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/12 : Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2262/14 : Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2266/02 : Organic
• CPC Class Codes: B32B 2266/0214 : Materials belonging to B32B27/00
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2437/00 : Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 3/263 : characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/04 : characterised by a layer being specifically extensible by reason of its structure or arrangement , e.g. by reason of the chemical nature of the fibres or filaments
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/142 : Variation across the area of the layer
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/24 : one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D04H 1/52 : by applying or inserting filamentary binding elements
• CPC Class Codes: D04H 1/558 : in combination with mechanical or physical treatments other than embossing
• CPC Class Codes: D04H 13/00 : Other non-woven fabrics
• CPC Class Codes: D04H 3/14 : with bonds between thermoplastic yarns or filaments produced by welding
• CPC Class Codes: D04H 3/153 : Mixed yarns or filaments
• CPC Class Codes: D04H 5/08 : characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns
• CPC Class Codes: D06H 5/00 : Seaming textile materials splicing webs B65H21/00; seaming felts in paper-making machines D21F7/10
• CPC Class Codes: D10B 2331/10 : polyurethanes
• CPC Class Codes: D10B 2403/033 : Three dimensional fabric, e.g. forming or comprising cavities in or protrusions from the basic planar configuration, or deviations from the cylindrical shape as generally imposed by the fabric forming process
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined
• CPC Class Codes: Y10T 428/2481 : including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24826 : Spot bonds connect components
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/652 : Nonwoven fabric is coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/69 : Autogenously bonded nonwoven fabric

Abstract

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

Claims

1. An article of footwear comprising a composite element including an upper, a sole structure, and a heatbond that joins a lower area of the upper directly to the sole structure,

wherein at least a portion of the upper includes a non-woven textile comprising a plurality of filaments that include a thermoplastic polymer material,

wherein the non-woven textile has a first region and a second region, the first region including a fused region having a continuous area of at least one square centimeter and comprising the thermoplastic polymer material in non-filamentous form, wherein the heatbond comprises the thermoplastic polymer material of the non-woven textile in non-filamentous form extending from the lower area of the upper and infiltrating the sole structure,

wherein the fused region extends from an area that is proximal to a lace receiving area of the upper to an area that is proximal to the sole structure, to increase the stretch resistance of the upper.

2. The article of footwear recited in claim 1, wherein the first region is located in a forefoot area of the article of footwear.

3. The article of footwear recited in claim 1, wherein the first region extends around the lace receiving area of the upper.

4. The article of footwear recited in claim 1, wherein the first region extends from a heel area of the article of footwear to a forefoot area of the article of footwear.

5. The article of footwear recited in claim 1, wherein the first region is proximal to an ankle opening of the upper.

6. The article of footwear recited in claim 1, wherein at least eighty percent of a combined mass of the composite element comprises the thermoplastic polymer material.

7. The article of footwear recited in claim 1, wherein the sole structure includes at least one of (a) a foam material comprising the thermoplastic polymer material and (b) a fluid-filled chamber comprising the thermoplastic polymer material.

8. The article of footwear recited in claim 1, wherein adhesive is absent from an area between the upper and the sole structure.

9. An article of footwear comprising:

a composite element including an upper, a sole structure and a heatbond that joins a lower area of the upper directly to the sole structure, wherein at least a portion of the upper includes a non-woven textile comprising a plurality of filaments that include a thermoplastic polymer material,

wherein the non-woven textile has a first region having a first permeability and a second region having a second permeability, each of the first region and the second region having a continuous area of at least one square centimeter, and the filaments of the first region being fused to a greater degree than the filaments of the second region, the first permeability being less than the second permeability;

the heatbond comprises the thermoplastic polymer material of the non-woven textile in non-filamentous form extending from the lower area of the upper and infiltrating the sole structure, wherein the filaments of the first region that are fused extend from an area that is proximal to a lace receiving area of the upper to an area that is proximal to the sole structure, to increase the stretch resistance of the upper.

10. The article of footwear recited in claim 9, wherein stitching is absent from an area between the non-woven textile of the upper and the sole structure.

11. The article of footwear recited in claim 9, wherein a portion of an interior surface of the upper is at least partially formed from the thermoplastic polymer material.

12. The article of footwear recited in claim 11, wherein the heatbond joins the upper to a polymer foam material or a fluid-filled chamber of the sole structure.

13. A composite article including an upper for an article of footwear, a sole structure secured to the upper, a first heatbond, and a second heatbond, the composite article comprising:

the upper, wherein the upper comprises a non-woven textile formed from a plurality of filaments that include a thermoplastic polymer material, the non-woven textile having a first surface and an opposite second surface, wherein the non-woven textile has a first region and a second region, each of the first region and the second region having a continuous area of at least one square centimeter, and the thermoplastic polymer material of the plurality of filaments of the first region being fused to form a non-filamentous portion of the non-woven textile; and

one or more strands at least partially recessed under the first surface and extending in a direction that is substantially parallel to the first surface for a distance of at least five centimeters, wherein the at least a portion of the one or more strands extend substantially parallel to the first surface through the substantially uniform thickness of a single layer of the first region;

wherein the first heatbond secures at least a portion of the one or more strands to the upper; and

wherein the second heatbond joins a lower area of the upper to the sole structure, the second heatbond comprising the thermoplastic polymer material of the non-woven textile in non-filamentous form extending from the lower area of the upper and infiltrating the sole structure;

wherein the one or more strands extend from either an area that is proximal to a lace receiving area of the upper to an area that is proximal to the sole structure or a heel area of the composite article to a forefoot area of the composite article;

wherein the first surface is positioned to form an exterior surface of the upper.

14. The composite article recited in claim 13, wherein the first heatbond secures at least a portion of the one or more strands to the lower area of the upper.

15. The composite article recited in claim 13, wherein the first heatbond or the second heatbond further secures the one or more strands to at least a portion of the sole structure.