Multilayered textile material in shoes

• US 9,655,407 B2
• Filed: 01/27/2014
• Issued: 05/23/2017
• Est. Priority Date: 01/27/2014
• Status: Active Grant

• Current Assignee: Adidas AG
• Original Assignee: Adidas AG
• Inventors: Reinhardt, Stuart David, Chapdelaine, Matthew, Schlarb, Heiko, Tarrier, James, Leimer, Robert, Henderson, Mark, Holmes, Chris
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US14/165,499
• Publication Number:
  US 20150208762A1
• Time in Patent Office: 1,212 Days
• Field of Search: 36 45
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 23/0205 characterised by the material material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08
• 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 23/024 Different layers of the same material
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 23/0265 having different properties in different directions
• CPC Class Codes: A43B 23/027 with a part of the upper particularly flexible, e.g. permitting articulation or torsion
• 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 2307/51 Elastic
• 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

Abstract

Described are shoe uppers in which at least a portion thereof is formed of a multilayered material. The multilayered material includes at least one nonwoven fiber layer with unidirectionally oriented fibers and a matrix material, wherein the multilayered material has elastic properties that allow the multilayered material to deform when stretched over a three dimensional mold.

Claims

1. A shoe upper comprising at least a portion formed of a multilayered material comprising:

(a) a collection of an odd number of nonwoven fiber layers, wherein the collection comprises a base layer and at least one set of paired layers, each nonwoven fiber layer comprising a plurality of unidirectionally oriented fibers, wherein the fibers in a first layer of the at least one set of paired layers form an angle in the range of −

25°

to 65°

with respect to the fibers in the base layer, and the fibers in a second layer of the at least one set of paired layers form an angle in the range of +25°

to +65°

with respect to the fibers in the base layer; and

(b) a matrix material;

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform into a smooth three dimensional shape when the multilayered material is stretched over a three dimensional mold, wherein the multilayered material is not cut or sewn to eliminate wrinkles in the smooth three dimensional shape.

2. The shoe upper of claim 1, wherein the matrix material comprises a first outer layer adhered to a side of one of the nonwoven fiber layers, and a second outer layer adhered to a side of another one of the nonwoven fiber layers.

3. The shoe upper of claim 2, wherein the first outer layer and the second outer layer are 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 shoe upper of claim 2, wherein at least one of the first outer layer and the second outer layer is formed of thermoplastic polyurethane and comprises screen printing.

5. The shoe upper of claim 1, wherein the fibers in the first layer of the at least one set of paired layers form an angle in the range of −

30°

to 60°

with respect to the fibers in the base layer, and the fibers in the second layer of the at least one set of paired layers form an angle in the range of +30°

to +60°

with respect to the fibers in the base layer.

6. The shoe upper of claim 1, wherein the fibers in the first layer of the at least one set of paired layers form an angle of −

40°

or −

50°

with respect to the fibers in the base layer, and the fibers in the second layer of the at least one set of paired layers form an angle of +40°

or +50°

with respect to the fibers in the base layer.

7. The shoe upper 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 shoe upper of claim 1, wherein substantially all of the shoe upper is formed of the multilayered material.

9. The shoe upper of claim 8, wherein the nonwoven fiber layers are punctured to improve breathability of the multilayered material.

10. The shoe upper of claim 8, further comprising a wicking lining to transport moisture away from the multilayered material.

11. The shoe upper of claim 8, wherein the multilayered material further comprises a hydrophilic layer to pull moisture away from the multilayered material.

12. The shoe upper of claim 1, wherein at least one of a heel area, a midfoot area, and a toe area comprise additional layers of the multilayered material.

13. The shoe upper of claim 1, wherein the fibers in at least one of the nonwoven fiber layers are aligned with a direction of high durability or stretch restriction.

14. A shoe upper comprising:

(a) a first portion formed of a breathable material;

(b) a second portion formed of a multilayered material comprising;

(i) a collection of an odd number of nonwoven fiber layers, wherein the collection comprises a base layer and at least one set of paired layers, each nonwoven fiber layer comprising a plurality of unidirectionally oriented fibers, wherein the fibers in a first layer of the at least one set of paired layers form an angle in the range of −

25°

to 65°

with respect to the fibers in the base layer, and the fibers in a second layer of the at least one set of paired layers form an angle in the range of +25°

to +65°

with respect to the fibers in the base layer; and

(ii) a matrix material;

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform into a smooth three dimensional shape when the multilayered material is stretched over a three dimensional mold, wherein the multilayered material is not cut or sewn to eliminate wrinkles in the smooth three dimensional shape.

15. The shoe upper of claim 14, wherein the matrix material comprises a first outer layer adhered to a side of one of the nonwoven fiber layers, and a second outer layer adhered to a side of another one of the nonwoven fiber layers.

16. The shoe upper of claim 15, wherein the first outer layer and the second outer layer are 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.

17. The shoe upper of claim 15, wherein at least one of the first outer layer and the second outer layer is formed of thermoplastic polyurethane and comprises screen printing.

18. The shoe upper of claim 14, wherein the fibers in the first layer of the at least one set of paired layers form an angle in the range of −

30°

to −

60°

with respect to the fibers in the base layer, and the fibers in the second layer of the at least one set of paired layers form an angle in the range of +30°

to +60°

with respect to the fibers in the base layer.

19. The shoe upper of claim 14, wherein the fibers in the first layer of the at least one set of paired layers form an angle of −

40°

or −

50°

with respect to the fibers in the base layer, and the fibers in the second layer of the at least one set of paired layers form an angle of +40°

or +50°

with respect to the fibers in the base layer.

20. The shoe upper 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.

21. The shoe upper of claim 14, wherein at least one of a heel area, a midfoot area, and a toe area comprise additional layers of the multilayered material.

22. The shoe upper of claim 14, wherein the fibers in at least one of the nonwoven fiber layers are aligned with a direction of high durability or stretch restriction.

23. A shoe comprising:

(a) an upper; and

(b) a sole coupled to the upper;

wherein a portion of at least one of the upper and the sole comprises a multilayered material comprising;

(i) a collection of an odd number of nonwoven fiber layers, wherein the collection comprises a base layer and at least one set of paired layers, each fiber layer comprising a plurality of unidirectionally oriented fibers; and

(ii) a matrix material;

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform into a smooth three dimensional shape when the multilayered material is stretched over a three dimensional mold, wherein the multilayered material is not cut or sewn to eliminate wrinkles in the smooth three dimensional shape.

24. A shoe comprising:

(a) an upper; and

(b) a sole coupled to the upper;

wherein a portion of at least one of the upper and the sole comprises a multilayered material comprising;

(i) a collection of an odd number of nonwoven fiber layers, wherein the collection comprises a base layer and at least one set of paired layers, each nonwoven fiber layer comprising a plurality of unidirectionally oriented fibers, wherein the fibers in a first layer of the at least one set of paired layers form an angle in the range of −

25°

to 65°

with respect to the fibers in the base layer, and the fibers in a second layer of the at least one set of paired layers form an angle in the range of +25°

to +60°

with respect to the fibers in the base layer; and

(ii) a matrix material;

wherein the multilayered material comprises elastic properties that allow the multilayered material to deform into a smooth three dimensional shape when the multilayered material is stretched over a three dimensional mold, wherein the multilayered material is not cut or sewn to eliminate wrinkles in the smooth three dimensional shape.

25. The shoe of claim 24, wherein the matrix material comprises a first outer layer adhered to a side of one of the nonwoven fiber layers, and a second outer layer adhered to a side of another one of the nonwoven fiber layers.

26. The shoe of claim 25, wherein the first outer layer and the second outer layer are 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.

27. The shoe of claim 25, wherein at least one of the first outer layer and the second outer layer is formed of thermoplastic polyurethane and comprises screen printing.

28. The shoe of claim 24, wherein the fibers in one of the nonwoven fiber layers form an angle in the range of −

30°

to −

60°

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

29. The shoe of claim 24, wherein the fibers in one of the nonwoven fiber layers form an angle of −

40°

or −

50°

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

30. The shoe of claim 24, 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.

31. The shoe of claim 24, wherein substantially all of the upper is formed of the multilayered material.

32. The shoe of claim 24, wherein at least one of a heel area, a midfoot area, and a toe area comprise additional layers of the multilayered material.

33. The shoe of claim 24, wherein the fibers in at least one of the nonwoven fiber layers are aligned with a direction of high durability or stretch restriction.

34. The shoe of claim 24, wherein the multilayered material forms a bottom plate in the sole.