Yarns, Threads, And Textiles Incorporating A Thermoplastic Polymer Material

• US 20130260104A1
• Filed: 04/03/2012
• Published: 10/03/2013
• Est. Priority Date: 04/03/2012
• Status: Abandoned Application

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Davis, Carrie L.
• Application Number:
  US13/438,520
• Publication Number:
  US 20130260104A1
• Time in Patent Office: Days
• US Class Current: 428/175
• CPC Class Codes: A41D 2500/52 in sheet form
• CPC Class Codes: A41D 27/245 made by welding or gluing joining of plastics by welding or gluing B29C65/00; sewing machines for concurrently making thread and welded seams D05B17/00; thermal or chemical fixing of seams and hems D06M
• 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 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/122 characterised by the outsole or external layer
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/187 Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• CPC Class Codes: A43B 13/223 Profiled soles
• CPC Class Codes: A43B 23/0215 Plastics or artificial leather
• CPC Class Codes: A43B 23/025 assembled by stitching
• CPC Class Codes: A43B 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 9/02 Footwear stitched or nailed through
• CPC Class Codes: A43B 9/12 Stuck or cemented footwear
• CPC Class Codes: A43C 1/04 with rings or loops
• CPC Class Codes: A43C 9/00 Laces; Laces in general for garments made of textiles, leather, or plastics
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/62 Stitching
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• 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 66/135 : Single hemmed joints, i.e. one of the parts to be joined being hemmed in the joint area
• 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 66/223 : being in the form of a triangle wave or of a sawtooth wave, e.g. zigzagged
• CPC Class Codes: B29C 66/244 : said joint lines being non-straight, e.g. forming non-closed contours
• 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 66/45 : 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 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 : 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 66/73116 : of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
• CPC Class Codes: B29C 66/73118 : of different glass transition temperature, i.e. the glass transition temperature of one of the parts to be joined being different from the glass transition temperature of the other part
• 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 66/81422 : 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 66/83221 : cooperating reciprocating tools, each tool reciprocating along one axis
• CPC Class Codes: B29C 66/91411 : of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
• CPC Class Codes: B29C 66/91443 : following a temperature-time profile B29C65/38 takes precedence
• CPC Class Codes: B29C 66/91933 : higher than said fusion temperature
• CPC Class Codes: B29C 66/91935 : lower than said fusion temperature
• CPC Class Codes: B29C 66/91943 : higher than said glass transition temperature
• CPC Class Codes: B29C 66/91951 : in explicit relation to time, e.g. temperature-time diagrams
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/4842 : Outerwear
• CPC Class Codes: B29L 2031/50 : Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B32B 15/14 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/10 : Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2250/02 : 2 layers
• CPC Class Codes: B32B 2250/20 : All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/0292 : Polyurethane fibres
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/08 : Animal fibres, e.g. hair, wool, silk
• CPC Class Codes: B32B 2262/12 : Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2266/0214 : Materials belonging to B32B27/00
• CPC Class Codes: B32B 2305/18 : Fabrics, textiles
• CPC Class Codes: B32B 2437/00 : Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 27/02 : in the form of fibres or filaments not used
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• 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 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/028 : Net structure, e.g. spaced apart filaments bonded at the crossing points
• 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 5/18 : characterised by features of a layer of foamed material
• 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: D02G 3/402 : the adhesive being one component of the yarn, i.e. thermoplastic yarn
• CPC Class Codes: D03D 15/283 : synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/587 : adhesive; fusible
• CPC Class Codes: D04B 1/16 : synthetic threads
• CPC Class Codes: D10B 2331/10 : polyurethanes
• CPC Class Codes: D10B 2401/041 : thermoplastic; thermosetting
• CPC Class Codes: D10B 2501/04 : Outerwear; Protective garments
• CPC Class Codes: D10B 2501/043 : Footwear
• CPC Class Codes: D10B 2503/06 : Bed linen
• CPC Class Codes: D10B 2505/08 : Upholstery, mattresses
• CPC Class Codes: D10B 2505/10 : Packaging, e.g. bags
• CPC Class Codes: D10B 2507/04 : Sails
• CPC Class Codes: D10B 2507/06 : Parachutes
• CPC Class Codes: Y10T 428/24636 : Embodying mechanically interengaged strand[s], strand-portion[s] or strand-like strip[s] [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 428/2481 : including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24818 : Knitted, with particular or differential bond sites or intersections
• CPC Class Codes: Y10T 442/3065 : Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/425 : Including strand which is of specific structural definition

Abstract

A yarn or thread may include a plurality of substantially aligned filaments, with at least ninety-five percent of a material of the filaments being a thermoplastic polymer material. Various woven textiles and knitted textiles may be formed from the yarn or thread. The woven textiles or knitted textiles may be thermal bonded to other elements to form seams. A strand that is at least partially formed from a thermoplastic polymer material may extend through the seam, and the strand may be thermal bonded at the seam. The woven textiles or knitted textiles may be shaped or molded, incorporated into products, and recycled to form other products.

Claims

1. A yarn comprising a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments being a thermoplastic polymer material.

2. The yarn recited in claim 1, wherein the thermoplastic polymer material is a thermoplastic polyurethane material.

3. The yarn recited in claim 1, wherein the yarn exhibits twist.

4. The yarn recited in claim 1, wherein at least ninety-nine percent of the material of the filaments is the thermoplastic polymer material.

5. The yarn recited in claim 1, wherein the yarn and at least one substantially identical yarn are twisted together to form a thread.

6. A thread comprising:

a first yarn including a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments being a thermoplastic polymer material; and

a second yarn twisted with the first yarn.

7. The thread recited in claim 6, wherein the second yarn includes a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments of the second yarn being the thermoplastic polymer material.

8. The thread recited in claim 6, wherein the thermoplastic polymer material is a thermoplastic polyurethane material.

9. The thread recited in claim 6, wherein the first yarn exhibits twist.

10. The thread recited in claim 6, wherein at least ninety-nine percent of the material of the filaments is the thermoplastic polymer material.

11. A woven textile comprising:

a warp strand extending in a first direction and including a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments being a thermoplastic polymer material; and

a weft strand extending in a second direction that is substantially perpendicular to the first direction.

12. The woven textile recited in claim 11, wherein the warp strand is one of a yarn and a thread.

13. The woven textile recited in claim 11, wherein the warp strand and the weft strand are thermal bonded to each other.

14. The woven textile recited in claim 11, wherein the weft strand includes a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments of the weft strand being the thermoplastic polymer material.

15. The woven textile recited in claim 11, wherein the woven textile has a fused region and an unfused region, the warp strand and the weft strand being thermal bonded to each other in the fused region, and the warp strand and the weft strand being unbonded to each other in the unfused region.

16. The woven textile recited in claim 11, wherein the thermoplastic polymer material is a thermoplastic polyurethane material.

17. The woven textile recited in claim 11, wherein at least ninety-nine percent of the material of the filaments is the thermoplastic polymer material.

18. A knitted textile comprising at least one strand that forms a plurality of interlocked loops arranged in courses and wales, the strand including a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments being a thermoplastic polymer material.

19. The knitted textile recited in claim 18, wherein the strand is one of a yarn and a thread.

20. The knitted textile recited in claim 18, wherein one of the loops is thermal bonded to another of the loops.

21. The knitted textile recited in claim 18, wherein the knitted textile includes a fused region and an unfused region, a section of the strand being thermal bonded to a different section of the strand in the fused region.

22. The knitted textile recited in claim 18, wherein the thermoplastic polymer material is a thermoplastic polyurethane material.

23. The knitted textile recited in claim 18, wherein at least ninety-nine percent of the material of the filaments is the thermoplastic polymer material.

24. A textile at least partially formed from a thermoplastic polymer material, the textile having one of a woven or knitted structure, and the textile being molded to have a non-planar configuration.

25. The textile recited in claim 24, wherein the textile includes at least one strand incorporating a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments being the thermoplastic polymer material.

26. The textile recited in claim 25, wherein the strand is one of a yarn and a thread.

27. The textile recited in claim 25, wherein at least ninety-nine percent of the material of the filaments is the thermoplastic polymer material.

28. The textile recited in claim 24, wherein the thermoplastic polymer material is a thermoplastic polyurethane material.

29. A method of shaping a textile element formed from a thermoplastic polymer material and having one of a woven or knitted structure, the method comprising:

locating a planar configuration of the textile element within a press having non-planar surfaces;

heating to the textile element to at least a glass transition temperature of the thermoplastic polymer material; and

cooling the textile element to impart a non-planar configuration to the textile element.

30. The method recited in claim 29, further including a step of selecting the textile element to include at least one strand incorporating a plurality of substantially aligned filaments, at least ninety-five percent of a material of the filaments being the thermoplastic polymer material.