Composite element with a polymer connecting layer
First Claim
1. An article of footwear having an upper and a sole structure secured to the upper, at least a portion of the upper comprising:
- a textile layer with a first surface and an opposite second surface, the textile layer stretching at least thirty percent prior to tensile failure;
a thermoplastic polymer material separate from the textile layer and extending into and infiltrating the textile layer, the polymer material being at least partially located at the first surface of the textile layer;
a thread having a section lying adjacent to the first surface of the textile layer and substantially parallel to the first surface of the textile layer throughout a distance of at least five centimeters, the thread being bonded to the textile layer with the polymer material; and
a cover layer forming at least a portion of an exterior surface of the upper, the cover layer being located adjacent to the first surface of the textile layer and bonded to the textile layer with the polymer material, the section of the thread being located between the cover layer and the textile layer.
1 Assignment
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Accused Products
Abstract
A composite element includes a base layer, a thermoplastic polymer material, a thread, and a cover layer. The base layer has a first surface and an opposite second surface. The polymer material is separate from the base layer, extends into the base layer, and is at least partially located at the first surface. The thread has a section lying adjacent to the first surface layer and substantially parallel to the first surface throughout a distance of at least five centimeters, and the thread is bonded to the base layer with the polymer material. The cover layer is located adjacent to the first surface and bonded to the base layer with the polymer material, and the section of the thread is located between the cover layer and the base layer.
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Citations
18 Claims
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1. An article of footwear having an upper and a sole structure secured to the upper, at least a portion of the upper comprising:
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a textile layer with a first surface and an opposite second surface, the textile layer stretching at least thirty percent prior to tensile failure; a thermoplastic polymer material separate from the textile layer and extending into and infiltrating the textile layer, the polymer material being at least partially located at the first surface of the textile layer; a thread having a section lying adjacent to the first surface of the textile layer and substantially parallel to the first surface of the textile layer throughout a distance of at least five centimeters, the thread being bonded to the textile layer with the polymer material; and a cover layer forming at least a portion of an exterior surface of the upper, the cover layer being located adjacent to the first surface of the textile layer and bonded to the textile layer with the polymer material, the section of the thread being located between the cover layer and the textile layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of manufacturing a composite element, the method comprising:
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incorporating a polymer material into a textile layer, the polymer material extending into and infiltrating the textile layer, the polymer material being located at a first surface and an opposite second surface of the textile layer; embroidering the textile layer with a thread such that a section of the thread lies adjacent to the textile layer and substantially parallel to the textile layer throughout a distance of at least five centimeters; locating a cover layer adjacent to the first surface of the textile layer such that the section of the thread is located between the textile layer and the cover layer; and heating the polymer material to bond the section of the thread and the cover layer to the textile layer. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18)
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Specification