Thread structure composition and method of making

• US 9,410,270 B2
• Filed: 08/22/2014
• Issued: 08/09/2016
• Est. Priority Date: 08/22/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Sterman, Yoav, Waatti, Todd A.
• Primary Examiner(s): Izaguirre, Ismael
• Application Number:
  US14/466,319
• Publication Number:
  US 20160053410A1
• Time in Patent Office: 718 Days
• US Class Current: 1/1
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/266 Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
• CPC Class Codes: B29C 48/2886 of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
• CPC Class Codes: B29C 48/2888 in band or in strip form, e.g. rubber strips
• CPC Class Codes: D02G 3/04 Blended or other yarns or threads containing components made from different materials
• CPC Class Codes: D02G 3/045 all components being made from artificial or synthetic material
• CPC Class Codes: D02G 3/402 the adhesive being one component of the yarn, i.e. thermoplastic yarn
• 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: D03D 25/00 Woven fabrics not otherwise provided for

Abstract

A system, method, and thread structure composition are disclosed. The thread structure composition includes a first thread and a second thread. The second thread includes a heat moldable material that is moldable above a predetermined temperature. The first thread remains in a solid form at temperatures substantially above the predetermined temperature. The second thread is twisted around the first thread.

Claims

1. A system comprising:

a thread structure composition comprising;

a first thread comprising a first material, the first material having a first melting temperature;

a second thread comprising a second material, the second material having a second melting temperature; and

wherein the second thread is twisted around the first thread;

a heat source configured to heat the thread structure composition to a temperature;

wherein the temperature is less than the first melting temperature;

wherein the temperature is greater than the second melting temperature;

an extruder configured to extrude the heated thread structure composition; and

a fabric for receiving the extruded thread structure composition,

wherein the fabric has a length, a width, and a thickness;

wherein a first direction extends along the length;

wherein a second direction extends along the width;

wherein a third direction extends along the thickness; and

wherein the extruder is further configured to move in the first direction, the second direction, and the third direction.

2. The system according to claim 1, wherein the second material is configured to permeate into the fabric.

3. The system according to claim 1, wherein the second material is configured to bond directly onto an outer surface of the first thread.

4. The system according to claim 1, wherein the second material is configured to permeate through an outer surface of the first thread.

5. The system according to claim 1, wherein the second material is thermoplastic.

6. The system according to claim 1, wherein the temperature is approximately 250 degrees Celsius.

7. The system according to claim 1, wherein the first thread has a first diameter substantially equal to a second diameter of the second thread.

8. The system according to claim 1, wherein the second thread includes a core layer and an outer layer, the outer layer being formed of the second material;

and

wherein the core layer is formed of the first material.

9. The system according to claim 1, wherein the first thread includes a core layer and an outer layer, the outer layer being formed of the second material;

and

wherein the core layer is formed of the first material.

10. A method of using a printable thread structure composition, the method comprising:

providing a printable thread structure composition comprising

a first thread comprising a first material, wherein the first material has a first melting temperature;

a second thread comprising a second material, wherein the second material has a second melting temperature;

heating the printable thread structure composition to a temperature, wherein the temperature is less than the first melting temperature and greater than the second melting temperature;

extruding the heated printable thread structure composition onto a fabric with an extruder,

wherein the fabric has a length, a width, and a thickness;

wherein a first direction extends along the length;

wherein a second direction extends along the width;

wherein a third direction extends along the thickness; and

wherein the step of extruding includes moving the extruder in the first direction, the second direction, and the third direction.

11. The method according to claim 10, wherein the extruder is a component of a freeform printer.

12. The method according to claim 11, wherein the step of heating the printable thread structure composition includes using a heater, wherein the heater is a second component of the freeform printer.

13. The method according to claim 10, wherein the step of providing a printable thread composition includes

providing a first thread comprising a first material;

providing a second thread comprising a second material that is different from the first material;

wherein the second material is moldable above the temperature;

wherein the first material is in a solid state above the temperature; and

twisting the second thread around the first thread to form the thread structure composition.

14. The method according claim 13, wherein the step of twisting the second thread around the first thread helically twists the second thread around the first thread.

15. The method according claim 13, wherein the twisting the second thread around the first thread twists the first thread around the second thread.

16. The method according to claim 10, wherein the first thread is provided with a core layer formed of the first material;

and

wherein the first thread is provided with an outer layer formed of the second material.

17. The method according to claim 10, wherein the second thread is provided with a core layer and an outer layer, the outer layer being formed of the second material;

and

wherein the core layer is formed of the first material.

18. The method according to claim 10, wherein the temperature is approximately 250 degrees Celsius.

19. The method according to claim 10 further comprising the step of applying a downward force to the heated printable thread structure composition after the step of extruding to push a portion of the heated printable thread structure composition into the fabric.

20. The method according to claim 10, wherein the material of the second thread permeates the fabric after the step of extruding.