Thermoplastic non-woven textile elements

• US 9,227,363 B2
• Filed: 03/21/2012
• Issued: 01/05/2016
• 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): GOFF II, JOHN L
• Application Number:
  US13/426,349
• Publication Number:
  US 20130068378A1
• Time in Patent Office: 1,385 Days
• Field of Search: 156/213, 156/308.2, 156/308.4, 156/297, 156/299, 156/300, 156/309.6, 121/46.C
• US Class Current: 1/1
• 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. A method of manufacturing a composite element incorporated in an article of apparel, the method comprising:

locating a component adjacent to a surface of a non-woven textile formed from a plurality of filaments that include a thermoplastic polymer material, wherein the component is in contact with at least a portion of the plurality of filaments, wherein the component includes a woven textile that is formed of a plurality of yarns, the plurality of yarns being mechanically manipulated to exhibit a one-directional stretch which allows the woven textile to stretch in a first direction but limits stretch of the woven textile in a direction perpendicular to the first direction;

melting at least a first portion of the plurality of filaments of the non-woven textile such that the at least first portion of the plurality of filaments exhibits a non-filamentous configuration, wherein the non-filamentous configuration has no permeability to gaseous and liquid fluids;

heating and compressing the component and the non-woven textile to bond the component to the non-woven textile, wherein the component includes a thickness that is comparable to the thickness of the non-woven textile thereby

securing the component to the non-woven textile by a heatbonding process;

forming a composite element, wherein the at least first portion of the plurality of filaments is in contact with the component, wherein the non-filamentous configuration of the at least first portion of the plurality of filaments increases the stretch-resistance of the composite element; and

incorporating the component and the non-woven textile into the article of apparel.

2. The method recited in claim 1, further including a step of providing one or more fused regions along at least one surface of the non-woven textile, wherein the fused regions are at least partially adjacent to the component, and wherein the fused regions have a higher stretch-resistance than regions that remain unfused in the composite element.

3. The method recited in claim 1, further including a step of bonding the component directly to the non-woven textile.

4. The method recited in claim 1, wherein the plurality of yarns comprise thermoset polymer materials, and the thermoplastic polymer material of the non-woven textile extends around and bonds with the yarns of the woven textile to secure the non-woven textile and woven textile together.

5. The method recited in claim 1, wherein the step of heating and compressing includes placing the component and the non-woven textile between platens of a press.

6. The method recited in claim 3, further including a step of securing the component to the non-woven textile by heatbonding, wherein heatbonding involves at least partial infiltration of at least a portion of the thermoplastic polymer filaments to secure the non-woven textile to the component by at least one of softening the thermoplastic polymer filaments and melting the thermoplastic polymer filaments.

7. The method recited in claim 1, further including a step of incorporating the component and the non-woven textile into an upper of an article of footwear.

18. The method of claim 1, wherein the step of melting the at least first portion of the plurality of filaments occurs prior to securing the component to the non-woven textile.

19. The method of claim 1, wherein the step of melting the at least first portion of the plurality of filaments occurs after securing the component to the non-woven textile.

8. A method of manufacturing a composite element incorporated in an article of apparel, the method comprising:

locating two layers of a non-woven textile on opposite sides of an intermediate element, the layers being formed from a plurality of filaments that include a thermoplastic polymer material, the intermediate element including a solid sheet of polymer material;

forming at least a first fused region in at least one layer of the non-woven textile, wherein the at least first fused region exhibits a non-filamentous configuration, wherein the non-filamentous configuration has no permeability to gaseous and liquid fluids;

heating and compressing the layers and the intermediate element to heatbond the layers to the opposite sides of the intermediate element, wherein at least a portion of the plurality of filaments of the layers that exhibit the non-filamentous configuration are in contact with the intermediate element, wherein the at least first fused region increases the stretch-resistance of the composite element;

heatbonding the two layers directly to each other around at least a portion of a perimeter of the intermediate element;

securing the intermediate element to the layers, wherein the thermoplastic polymer material of the layers is used to directly secure the layers to the intermediate element without the use of additional adhesives; and

incorporating the intermediate element and the non-woven textile into the article of apparel.

9. The method recited in claim 8, further including a step of selecting the thermoplastic polymer material to include another thermoplastic polymer material.

10. The method recited in claim 8, wherein the step of heating and compressing includes placing the intermediate element and the layers between platens of a press.

11. The method recited in claim 8, wherein the step of heatbonding the two layers to each other further comprises heatbonding the two layers around the entire perimeter of the intermediate element.

12. The method recited in claim 8, further including a step of incorporating the intermediate element and the layers into an article of footwear, wherein the composite element comprising the intermediate element and the layers are configured to reduce the amount of stretch in a direction extending between a forefoot area and a heel area in the article of footwear.

20. The method of claim 8, wherein the step of forming the at least first fused region occurs prior to securing the intermediate element to the layers.

13. A method of manufacturing a composite element incorporated in an article of apparel, the method comprising:

locating a series of substantially parallel strips adjacent to a surface of a non-woven textile formed from a plurality of filaments that include a permeable thermoplastic polymer material, the strips including solid sheets of polymer material;

melting at least a portion of the plurality of filaments of the non-woven textile to form at least one fused region, the at least one fused region exhibiting a non-filamentous configuration, wherein the non-filamentous configuration has no permeability to gaseous and liquid fluids, wherein the non-filamentous configuration of the at least one fused region increases the stretch-resistance of the non-woven textile;

disposing the strips along the surface of the non-woven textile such that adjacent strips are spaced apart from one another;

heating and compressing the strips and the non-woven textile to heatbond the strips to the non-woven textile, wherein at least a portion of the plurality of filaments of the non-woven textile that exhibit the non-filamentous configuration are in contact with the strips, such that the at least one fused region increases the stretch-resistance of the composite element;

securing the strips to the non-woven textile, wherein the thermoplastic polymer material of the non-woven is used to directly secure the first textile element to the strips without the use of additional adhesives;

forming regions of no permeability in the composite element associated with the areas where the non-woven textile is bonded to the strips, while the interstitial spaces remain relatively permeable; and

incorporating the strips and the non-woven textile into the article of apparel.

14. The method recited in claim 13, further including a step of disposing the series of substantially parallel strips so they extend longitudinally across the surface of the non-woven textile.

15. The method recited in claim 13, further including a step of securing the non-woven textile to the strips wherein the non-woven textile at least partially intermingles with the polymer material of the strips.

16. The method recited in claim 13, wherein the step of disposing the strips along the surface of the non-woven textile such that they are spaced apart from one another further includes providing a substantially uniform spacing between adjacent strips.

17. The method of claim 14, further including the step of including the composite element in an upper for an article of footwear, wherein the strips extend longitudinally from a heel area to a forefoot area of the article of footwear.

21. The method of claim 13, wherein the step of melting the at least a portion of the plurality of filaments occurs prior to securing the strips to the non-woven textile.