TEXTILE INCLUDING BULKING YARN

• US 20170370027A1
• Filed: 06/23/2017
• Published: 12/28/2017
• Est. Priority Date: 06/27/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: da Costa Pereira Machado, Fabricio, Orme, Kristen
• Granted Patent: US 11,492,730 B2
• Time in Patent Office: Days
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/025 assembled by stitching
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 23/22 Supports for the shank or arch of the uppers
• CPC Class Codes: A43B 7/142 situated under the medial arch, i.e. under the navicular or cuneiform bones
• CPC Class Codes: D02G 3/24 Bulked yarns or threads, e.g. formed from staple fibre components with different relaxation characteristics
• CPC Class Codes: D02G 3/32 Elastic yarns or threads ; Production of plied or cored yarns, one of which is elastic
• CPC Class Codes: D02G 3/44 Yarns or threads characterised by the purpose for which they are designed protective gloves A41D19/00; protective clothing A62B17/00; ropes D07B1/02
• CPC Class Codes: D04B 1/12 characterised by thread material
• CPC Class Codes: D10B 2403/0241 enhancing mechanical properties
• CPC Class Codes: D10B 2403/032 Flat fabric of variable width, e.g. including one or more fashioned panels
• CPC Class Codes: D10B 2501/043 Footwear

Abstract

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

Claims

1. An article of footwear comprising a textile component arch support, the arch support comprising:

a) a first section formed from a fusible yarn and disposed adjacent to the external surface of the article of footwear;

b) a second section formed from a bulking yarn and disposed adjacent to the first section; and

c) a third section formed from a nonfusible yarn, the third section disposed adjacent to the internal surface of the article of footwear and opposite the first section.

2. The article of footwear of claim 1, wherein the textile component is a knitted component.

3. The article of footwear of claim 1, wherein the arch support reduces the rate of pronation of the foot.

4. The article of footwear of claim 1, wherein the arch support further comprises a monofilament yarn disposed between the first section and the second section.

5. The article of footwear of claim 1, wherein the bulking yarn has a first state and a second state, the second state having an increased loft relative to the first state, wherein the bulking yarn transitions from a first state to a second state on heating.

6. The article of footwear of claim 1, wherein the fusible yarn melts upon heating to form a more rigid material, as compared to the fusible yarn before heating.

7. The article of footwear of claim 1, wherein the arch support is divided into compartments.

8. The article of footwear of claim 1, wherein the arch support comprises flex lines that flex in response to motion of the article of footwear.

9. An article comprising a textile component, the textile component comprising:

a) a first section comprising a first material;

b) a second section comprising a bulking yarn and disposed adjacent to the first section; and

c) a third section comprising a second material,

wherein the first material is relatively rigid, as compared to the second material, and

wherein the second section is disposed between the first section and the third section.

10. The article of claim 9, wherein the textile component is a knitted component.

11. The article of claim 9, wherein the first section is disposed adjacent to the external surface of the article and the third section is disposed adjacent to the internal surface of the article.

12. The article of claim 9, wherein the first material comprises a fusible yarn that melts upon heating, or a stiffened plate.

13. The article of claim 9, wherein the third material comprises a nonfusible yarn.

14. The article of claim 12, wherein the knitted component comprises a support structure for an article of footwear.

15. The article of claim 14, wherein the support structure comprises an arch support or heel counter.

16. A method of forming a knitted component support structure for an article of footwear, the method comprising:

a) forming a first section comprising a fusible yarn;

b) forming a second section comprising a bulking yarn adjacent to the first section;

c) forming a third section comprising a nonfusible yarn adjacent to the second section and opposite to the first section; and

d) heating the first section, second section, and third section of the knitted component to form a knitted component support structure.

17. The method according to claim 16, wherein forming comprises knitting a first section, second section, and third section.

18. The method of claim 16, wherein heating comprises free steaming without pressing.

19. The method according to claim 16, wherein the first section at least partially melts upon heating to form a rigid material.

20. The method according to claim 16, wherein heating increases the volume of the bulking yarn.