MULTILAYERED TEXTILE MATERIAL FOR FORMING THREE DIMENSIONAL OBJECTS

• US 20150210034A1
• Filed: 01/27/2014
• Published: 07/30/2015
• Est. Priority Date: 01/27/2014
• Status: Abandoned Application

• Current Assignee: Adidas AG
• Original Assignee: Adidas AG
• Inventors: Tarrier, James, Leimer, Robert, Holmes, Chris, Henderson, Mark
• Application Number:
  US14/165,468
• Publication Number:
  US 20150210034A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A43B 23/0225 Composite materials, e.g. material with a matrix
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/026 Laminated layers
• 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 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/108 Rockwool fibres
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2274/00 Thermoplastic elastomer material thermoplastic elastomer fibres B32B2262/0215, thermoplastic elastomer particles B32B2264/0221, thermoplastic elastomer foam B32B2266/0292
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/516 mono-axially
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/738 Thermoformability
• CPC Class Codes: B32B 2307/75 Printability
• 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 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• 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 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• 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: Y10T 428/24124 : Fibers

Abstract

Described are multilayered materials for forming three dimensional objects. The multilayered materials include at least three nonwoven fiber layers with unidirectionally oriented fibers and a matrix material. The multilayered materials have elastic properties that allow the multilayered material to deform by stretching the multilayered material over a three dimensional mold to form a three dimensional object.

Claims

1. A multilayered material for forming three dimensional footwear objects comprising:

(a) at least three nonwoven fiber layers, each fiber layer comprising a plurality of unidirectionally oriented fibers, wherein the fibers in a first one of the at least three nonwoven fiber layers form an angle in the range of −

25°

to −

65°

with respect to the fibers in another one of the at least three nonwoven fiber layers, and the fibers in a second one of the at least three nonwoven fiber layers form an angle in the range of +25°

to +65°

with respect to the fibers in another one of the at least three nonwoven fiber layers; and

(b) a matrix material comprising at least one outer layer adhered to a side of one of the at least three nonwoven fiber layers;

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform by stretching the multilayered material over a three dimensional mold to form a three dimensional footwear object.

2. The multilayered material of claim 1, wherein the matrix material further comprises a second outer layer adhered to a side of another one of the at least three nonwoven fiber layers.

3. The multilayered material of claim 1, wherein the matrix material is formed of materials selected from the group consisting of thermoplastic polyurethane, other polyurethanes, silicone, ethylene propylene diene, polyvinyl chloride, thermoplastic elastomer, polylactic acid, polyamide, and polyethylene.

4. The multilayered material of claim 2, wherein at least one of the outer layers is formed of thermoplastic polyurethane and comprises screen printing.

5. The multilayered material of claim 1, wherein the fibers in the first one of the at least three nonwoven fiber layers form an angle in the range of −

30°

to −

60°

with respect to the fibers in another one of the at least three nonwoven fiber layers, and the fibers in the second one of the at least three nonwoven fiber layers form an angle in the range of +30°

to +60°

with respect to the fibers in another one of the at least three nonwoven fiber layers.

6. The multilayered material of claim 1, wherein the fibers in the first one of the at least three nonwoven fiber layers form an angle in the range of −

40°

to −

50°

with respect to the fibers in another one of the at least three nonwoven fiber layers, and the fibers in the second one of the at least three nonwoven fiber layers form an angle in the range of +40°

to +50°

with respect to the fibers in another one of the at least three nonwoven fiber layers.

7. The multilayered material of claim 1, wherein the fibers are formed of materials selected from the group consisting of ultra high molecular weight polyethylene, other polyethylenes, polyester, nylon, Basalt, aramid, carbon, polymer/carbon composites, liquid crystal polymers, and high performance films.

8. The multilayered material of claim 1, further comprising a woven layer.

9. The multilayered material of claim 8, wherein the woven layer is printed.

10. The multilayered material of claim 9, wherein the woven layer is colored.

11. The multilayered material of claim 1, wherein the at least three nonwoven fiber layers are punctured to improve breathability of the multilayered material.

12. The multilayered material of claim 1, further comprising a wicking lining to transport moisture away from the multilayered material.

13. The multilayered material of claim 1, further comprising a hydrophilic layer to pull moisture away from the multilayered material.

14. A multilayered material for forming three dimensional footwear objects comprising:

(a) at least three nonwoven fiber layers, each nonwoven fiber layer comprising a plurality of unidirectionally oriented fibers, wherein the fibers in a first one of the at least three nonwoven fiber layers form an angle in the range of −

25°

to −

65°

with respect to the fibers in another one of the at least three nonwoven fiber layers, and the fibers in a second one of the at least three nonwoven fiber layers form an angle in the range of +25°

to +65°

with respect to the fibers in another one of the at least three nonwoven fiber layers; and

(b) at least one thermoplastic polyurethane outer layer adhered to a side of one of the the at least three nonwoven fiber layers;

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform by stretching the multilayered material over a three dimensional mold to form a three dimensional footwear object.

15. The multilayered material of claim 14, further comprising a second thermoplastic polyurethane outer layer adhered to a side of another one of the at least three nonwoven fiber layers.

16. The multilayered material of claim 15, wherein at least one of the thermoplastic polyurethane outer layers comprises screen printing.

17. The multilayered material of claim 14, wherein the fibers in the first one of the at least three nonwoven fiber layers form an angle in the range of −

30°

to −

60°

with respect to the fibers in another one of the at least three nonwoven fiber layers, and the fibers in the second one of the at least three nonwoven fiber layers form an angle in the range of +30°

to +60°

with respect to the fibers in another one of the at least three nonwoven fiber layers.

18. The multilayered material of claim 14, wherein the fibers in the first one of the at least three nonwoven fiber layers form an angle in the range of −

40°

to −

50°

with respect to the fibers in another one of the at least three nonwoven fiber layers, and the fibers in the second one of the at least three nonwoven fiber layers form an angle in the range of +40°

to +50°

with respect to the fibers in another one of the at least three nonwoven fiber layers.

19. The multilayered material of claim 14, wherein the fibers are formed of materials selected from the group consisting of ultra high molecular weight polyethylene, other polyethylenes, polyester, nylon, Basalt, aramid, carbon, polymer/carbon composites, liquid crystal polymers, and high performance films.

20. The multilayered material of claim 14, further comprising a woven layer.

21. The multilayered material of claim 20, wherein the woven layer is printed.

22. The multilayered material of claim 21, wherein the woven layer is colored.

23. The multilayered material of claim 14, wherein the at least three nonwoven fiber layers are punctured to improve breathability of the multilayered material.

24. The multilayered material of claim 14, further comprising a wicking lining to transport moisture away from the multilayered material.

25. The multilayered material of claim 14, further comprising a hydrophilic layer to pull moisture away from the multilayered material.

26. A multilayered material for forming three dimensional footwear objects comprising:

(a) three nonwoven fiber layers, each nonwoven fiber layer comprising a plurality of unidirectionally oriented ultra high molecular weight polyethylene fibers, wherein the fibers in a first one of the three nonwoven fiber layers form an angle in the range of −

25°

to −

65°

with respect to the fibers in another one of the three nonwoven fiber layers, and the fibers in a second one of the the three nonwoven fiber layers form an angle in the range of +25°

to +65°

with respect to the fibers in another one of the three nonwoven fiber layers; and

(b) at least one thermoplastic polyurethane outer layer adhered to a side of one of the three nonwoven fiber layers; and

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform by stretching the multilayered material over a three dimensional mold to form a three dimensional footwear object.

27. The multilayered material of claim 26, further comprising a second thermoplastic polyurethane outer layer adhered to a side of another one of the three nonwoven fiber layers.