Textiles and articles and processes for making textiles and articles

Abstract

The present application relates to a textile and an article and a process for making the textile and the article. A wearable article having one or more textiles and a method for making the wearable article are disclosed, wherein the textile comprises a low processing temperature polymer composition and a high processing temperature polymer composition. The low processing temperature polymer composition and the high processing temperature polymer composition can be selectively incorporated into the textile to provide the article with one or more structural properties and / or other advantageous properties. The textile can be thermoformed to impart such structural properties and / or other advantageous properties to the wearable article. This abstract is intended as a browsing tool for search purposes in a particular field and is not intended to limit the present disclosure.

Description

[0001] This application is a divisional application of an application filed on November 9, 2017, with application number 201780082865.9 and invention name “Textiles and articles and processes for making textiles and articles”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Application Nos. 62 / 419,824; 62 / 419,832; 62 / 419,841; and 62 / 419,851, each filed on November 9, 2016, each of which is incorporated herein by reference in its entirety. Technical Field

[0004] The present disclosure relates to articles, such as articles of clothing, articles of footwear, and articles of athletic equipment. More specifically, the present disclosure relates to articles comprising one or more materials, wherein the one or more materials include a low processing temperature polymer composition and a high processing temperature polymer composition. The present disclosure also relates to methods of making articles using materials including the low processing temperature polymer composition and the high processing temperature polymer composition. background

[0005] Traditionally, certain articles of wear, such as footwear, are manufactured by cutting and joining together individual pieces of material. The individual pieces may be joined together by sewing and / or using adhesives. However, cutting and joining multiple pieces of material is a wasteful, labor-intensive, and error-prone process, wherein such errors result in increased waste material and increased manufacturing time and energy. BRIEF DESCRIPTION OF THE DRAWINGS

[0006]

[0011] Further aspects of the present disclosure will be readily understood upon review of the detailed description described below when taken in conjunction with the accompanying drawings.

[0007] Figure 1A are top and side perspective views of an article of footwear according to aspects of the present invention, primarily illustrating the locations of three distinct textile zones.

[0008] Figure 1B According to aspects of the present invention Figure 1A Bottom and side perspective views of an article of footwear.

[0009] Figure 1C According to aspects of the present invention Figure 1A Top and side perspective views of alternative aspects of an article of footwear primarily illustrating the locations of three different textile zones.

[0010] Figure 2Ais a side view of an article of apparel according to aspects of the present invention, primarily illustrating an elbow patch;

[0011] Figure 2B According to aspects of the present invention Figure 2A Close-up view of the elbow patch on an item of clothing, illustrating the three distinct textile areas.

[0012] Figure 3 is a schematically depicted plan view of a textile having three types of textile regions according to aspects of the present invention.

[0013] Figures 4A-4E Describes aspects of the present invention Figure 3 Exemplary cross-sections of various types of textile areas of textiles.

[0014] Figures 5A-5J Describes the aspects of the present invention that may exist in Figures 4A-4E An exemplary knitted structure in each segment of the exemplary cross-section depicted in FIG.

[0015] Figure 6 is a schematic representation of two interconnected courses of loops having different types of yarn and depicting an interlaced interface according to aspects of the present invention.

[0016] Figure 7A is a schematic representation of three interconnected courses of stitches, wherein the middle course of stitches is formed from a different yarn than the outer courses of stitches, in accordance with aspects of the present invention.

[0017] Figure 7B is according to aspects of the present invention after exposure to a thermoforming process Figure 7A Schematic representation of interconnected rows of loops and showing that the middle row of loops is converted into a molten yarn component after thermoforming, but the two outer rows of loops are not converted into molten yarn components.

[0018] Figure 8 According to aspects of the present invention Figure 7B Schematic representation of a cross section of a melted yarn component and showing a portion of the yarn of one of the courses from the outside stitches being encapsulated within the melted yarn component.

[0019] Figure 9A According to aspects of the present invention Figure 7A Schematic representation of a cross section of a portion of interconnected rows showing one coil in the middle row of coils and one coil in the upper row of coils.

[0020] Figure 9BAccording to aspects of the present invention Figure 7A The interconnected rows have been exposed to a thermoforming process after Figure 9A Schematic representation of a cross section showing how the yarn loops in the middle course are deformed but still maintain the general yarn structure.

[0021] Figure 10A is a schematic representation of three interconnected courses of yarn of one type according to aspects of the present invention, with anchor yarns in float stitch and tuck stitch.

[0022] Figure 10B According to aspects of the present invention Figure 10A and showing that after thermoforming one type of yarn forming the interconnected courses has been transformed into a melted yarn component, wherein the anchor yarns are still present as yarns.

[0023] Figure 10C According to aspects of the present invention Figure 10B Schematic representation of a cross-section of a melted yarn component showing that the anchor yarn is encapsulated within the melted yarn component.

[0024] Figure 11A According to aspects of the present invention Figure 3 Schematic representation of a portion of one of the textile areas of a textile and showing areas of different types of fibers.

[0025] Figure 11B is according to aspects of the present invention after exposure to a thermoforming process Figure 11A and shows how fibers of one type among multiple types of fibers have been transformed into a non-fibrous material with fibers of another material embedded within the non-fibrous material.

[0026] Figure 11C According to aspects of the present invention Figure 11B A cross-section of a non-fibrous material showing two other fibers encapsulated within the non-fibrous material.

[0027] Figure 12 is a side elevational view of a schematic representation of an article of footwear comprising textile material according to aspects of the present invention and showing a chassis, heel counter, and sock liner for incorporation into the article of footwear.

[0028] Figure 13 According to aspects of the present invention Figure 12A cross-section of an article of footwear having a sole plate, a heel counter, and a sockliner positioned in an interior of the article of footwear.

[0029] Figure 14 is a side view of a schematic representation of an article of footwear including textile material, showing the addition of ground-engaging cleats to a ground-facing outsole area of ​​the article of footwear according to aspects of the present invention.

[0030] Figure 15 are top and side perspective views showing an upper for an article of footwear placed on a last, according to aspects of the present invention.

[0031] Figure 16 According to aspects of the present invention, the shoe last is Figure 15 Top and side perspective views of a shoe upper showing the shoe upper surrounding at least a bottom portion of a last.

[0032] Figure 17 According to aspects of the present invention, Figure 16 A cross-section of an upper on a last showing the last in contact with the inner surface of the upper.

[0033] Figure 18 According to aspects of the present invention, Figure 16 Top and side perspective views of the upper on the last, showing the protective sheath surrounding the upper.

[0034] Figure 19 According to aspects of the present invention, Figure 18 A cross-section of a shoe upper covered by a protective cover showing the protective cover contacting the outer surface of the shoe upper.

[0035] Figure 20A According to aspects of the present invention, Figure 16 Side view of a shoe upper on a last showing the vacuum bag with the upper placed inside.

[0036] Figure 20B According to aspects of the present invention Figure 20A A side view of the shoe upper inside the vacuum bag, showing the vacuum bag compressing the outer surface of the shoe upper.

[0037] Figure 21 is a schematic representation of a thermoforming system having heating and cooling zones according to aspects of the present invention.

[0038] Figure 22 is a flow chart of an exemplary process for manufacturing an upper for a shoe according to aspects of the present invention.

[0039] Figure 23 is a flow chart of another exemplary process for manufacturing an upper for a shoe according to aspects of the present invention.

[0040] Figure 24 is a flow chart of an exemplary process for manufacturing a knitted upper for an article of footwear according to aspects of the present invention.

[0041] Figure 25 is a flow chart of an exemplary process for forming a knitted article according to aspects of the present invention.

[0042] Figure 26 is a flow chart of an exemplary process for manufacturing an upper for an article of footwear according to aspects of the present invention.

[0043] Figure 27 is a flow chart of an exemplary process for manufacturing an outsole for an article of footwear according to aspects of the present invention. Detailed description

[0044] The present disclosure relates to a textile or a combination of a textile and other materials (e.g., a forming part, a film, a second textile, a yarn or a fiber), wherein one or more of the textile or other materials comprises a low processing temperature polymer composition and one or more of the textile or other materials comprises a high processing temperature polymer composition. In some aspects, a single textile comprises both a low processing temperature polymer composition and a high processing temperature polymer composition. The present disclosure also relates to a method of thermoforming a textile alone or in combination with one or more other materials on a molding surface to reshape the textile, to attach one or more other materials to the textile using a reflown polymeric material, or to perform both operations. The thermoforming process involves placing at least a portion of the textile on a molding surface and, while the textile remains in contact with the molding surface, raising the temperature of the entire textile to a first temperature and then lowering the temperature of the entire textile to a second temperature. The first temperature is a temperature above the melting point of the low processing temperature polymer composition, but below at least one of the following of the high processing temperature polymer composition: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs. Thus, using the disclosed process, portions of the textile and / or one or more materials comprising the low processing temperature polymer composition will melt, reflow, and then resolidify into a new shape or configuration, while the portion formed from the high processing temperature polymer composition will retain its original shape or configuration. Forming a first fiber and / or a first yarn from the low processing temperature polymer composition and using these fibers and / or yarns to construct textiles, such as woven textiles, knitted textiles, non-woven textiles, braided textiles, etc., is a particularly efficient and effective way to incorporate low processing temperature polymer compositions in these thermoforming processes. For example, the use of the disclosed textiles and processes makes it possible to use only a single textile to produce thermoformed articles comprising an integrally formed area using only a single thermoforming process, the thermoformed articles having properties ranging from conventional textiles to solid molded polymer materials. It was found that producing yarns and / or fibers that function well in the disclosed process while also producing a final article with desirable properties required the use of a low processing temperature polymer composition having a balance of the properties disclosed herein. Also disclosed are embodiments of polymers that can provide this balance of properties in a low processing temperature polymer composition.In certain embodiments, also disclosed are low processing temperature polymer compositions for making yarn suitable for use on commercial braiding or knitting equipment.

[0045] In various aspects, the present disclosure relates to a textile comprising: a first yarn or a first fiber comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers; and a second yarn or a second fiber comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr .

[0046] In one aspect, the present disclosure relates to a textile comprising: a first yarn or a first fiber comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers; and a second yarn or a second fiber comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Heat deformation temperature T hd .

[0047] In one aspect, the present disclosure relates to a textile comprising: a first yarn or a first fiber comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers; and a second yarn or a second fiber comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Vicat softening temperature T vs .

[0048] In one aspect, the present disclosure relates to a textile comprising: a first yarn or a first fiber comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers, wherein the low processing temperature polymer composition exhibits a melting temperature T of 135°C or less. m and a second yarn or second fiber comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs .

[0049] In one aspect, the present disclosure is directed to a process for making an article, the process comprising: providing the disclosed textile; and combining the textile with one or more additional components to form an article of footwear, an article of apparel, or an article of athletic equipment.

[0050] In one aspect, the present disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming part, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and resolidified product of a first element selected from a first forming part, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr .

[0051] In one aspect, the present disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming part, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and resolidified product of a first element selected from a first forming part, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Heat deformation temperature T hd .

[0052] In one aspect, the present disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming part, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and resolidified product of a first element selected from a first forming part, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Vicat softening temperature T vs .

[0053] In one aspect, the present disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming part, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and resolidified product of a first element selected from a first forming part, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature Tvs .

[0054] In various aspects, the melted and resolidified product is a melted and resolidified element selected from a first formed component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof, the melted and resolidified element being a component of a second element.

[0055] In one aspect, the present disclosure is directed to a process for making an article, the process comprising: providing a disclosed article; and combining the article with one or more additional materials to form an article of footwear, an article of apparel, or an article of athletic equipment.

[0056] In one aspect, the present disclosure relates to a process for making an article, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber; receiving a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers, wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs placing at least a portion of the first element and at least a portion of the second element on a molding surface; while at least a portion of the first element and at least a portion of the second element are on the molding surface, raising the temperature of the entire article to a temperature above the melting temperature T of the low processing temperature polymer composition m and below 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs and after raising the temperature of the entire article, while at least a portion of the article is maintained on the molding surface, lowering the temperature of the entire article to below the melting temperature T of the low processing temperature polymer composition m temperature, thereby forming an article.

[0057] In one aspect, the present disclosure relates to a combination upper and outsole for an article of footwear, the combination upper and outsole comprising: a first reflow material; and a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and resolidified product of a first element selected from a first forming component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymer composition exhibits a melting temperature T greater than the low processing temperature polymer composition m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs and wherein the combined upper and outsole includes a medial midsole area, a lateral midsole area, a ground-facing outsole area, and at least a portion of the first reflow material is present on the ground-facing outsole area.

[0058] In one aspect, the present disclosure relates to a process for making a combined upper and outsole for an article of footwear, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber; receiving a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers, wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs placing at least a portion of the first element and at least a portion of the second element on a molding surface; while at least a portion of the first element and at least a portion of the second element are on the molding surface, raising the temperature of the entire first element and the entire second element to a temperature above the melting temperature T of the low processing temperature polymer composition m and below 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature Tvs and after raising the temperature of the entire first article and the entire second article, while at least a portion of the first article and at least a portion of the second article are maintained on the molding surface, lowering the temperature of the entire first element and the entire second element to below the melting temperature T of the low processing temperature polymer composition. m temperature, thereby forming an article.

[0059] The present disclosure relates to materials and processes for making textiles, sports equipment articles and wearable articles (including footwear articles and clothing articles). It should be understood that the present disclosure contemplates a variety of sports equipment articles, including backpacks, equipment bags, hats, protective gear (protective gear) and the like. It should be understood that the present disclosure contemplates a variety of wearable articles, including knitted articles. A non-limiting list of wearable articles contemplated by the present disclosure includes footwear, shirts, pants, socks, jackets or other coats, protective equipment (protective equipment), hats and underwear such as bras. In some aspects, the wearable article is a footwear article. "Footwear article" is used to refer to articles intended for wearing on human feet, for example, in some aspects, footwear articles can be shoes. In some aspects, the disclosed materials and processes can be used to manufacture parts used in wearable articles such as footwear articles. Exemplary parts of wearable articles include, but are not limited to, uppers for footwear articles.

[0060] Exemplary articles of footwear are athletic footwear or sports footwear, including, but not limited to, running shoes, basketball shoes, soccer shoes, baseball shoes, American football shoes, tennis shoes, rugby shoes, cross-training shoes, walking shoes, hiking boots, golf shoes, sneakers, and the like. Alternatively, articles of footwear may be non-athletic footwear, including, but not limited to, dress shoes, loafers, casual shoes, sandals, and boots, including work boots. The shoe may or may not enclose the entire foot of the wearer. For example, the shoe may be a sandal or other article that exposes a large portion of the foot being worn. Therefore, it will be understood by those of ordinary skill in the art that the materials and processes disclosed herein are suitable for a wide variety of footwear types or styles in addition to the specific types or styles discussed in the following materials and depicted in the accompanying drawings.

[0061] Disclosed textiles and articles can include yarns, fibers, or combinations of yarns and fibers including low processing temperature polymer compositions (described below) and yarns, fibers, or combinations of yarns and fibers including high processing temperature polymer compositions (also described below). Disclosed textiles and articles include at least two yarns balancing many material properties as described herein. In addition, the yarns and fibers used in the disclosed materials and processes will be selected based on multiple factors, including whether the type of footwear to be manufactured is a sports footwear article or a non-sports footwear article, and the typical uses of the footwear article. For example, when considering the type of yarn and fiber used in the sports footwear article, the type of sports used by the sports footwear article and / or the conditions (for example, indoors or outdoors) in which the sports footwear article will be worn can be considered.

[0062] Disclosed articles can include formed parts, films, fibers, yarns or combinations thereof comprising low processing temperature polymer compositions (described below) and formed parts, films, fibers, yarns or combinations thereof comprising high processing temperature polymer compositions (also described below). Disclosed articles include at least two polymer compositions that balance many material properties as described herein. In addition, the compositions and processes for forming these articles will be selected based on multiple factors, including the type of article to be manufactured and the typical uses of the article.

[0063] In various aspects, the disclosed shaped parts, films, textiles and articles comprise two different polymer compositions, one of which can melt or deform in a thermoforming process carried out within a first temperature range (referred to herein as a low processing temperature polymer composition), while the other polymer composition maintains its shape within the first temperature range (referred to herein as a high processing temperature polymer composition). It should be understood that reference to a "polymer composition" is intended to refer to a composition comprising at least one polymer. Optionally, additional ingredients such as pigments, dyes, fillers, processing aids and the like may be present in the polymer composition. The low processing temperature polymer composition comprises one or more first thermoplastic polymers. The high processing temperature polymer composition comprises one or more second polymers. In some embodiments, the high processing temperature polymer composition is a thermoplastic composition and comprises one or more second thermoplastic polymers. The polymer compositions of the present disclosure can be used to form shaped parts, films and / or fibers. The shaped parts and / or films can, in turn, be incorporated into articles as described herein. The fibers can, in turn, be used to form yarns and textiles as described herein, and these yarns and textiles can also be incorporated into articles as described herein. In additional aspects, the disclosed textiles and articles include a first film, fiber, or yarn comprising a low processing temperature polymer composition and a second film, fiber, or yarn comprising a high processing temperature polymer composition.

[0064] As mentioned above, the articles described herein may include materials, such as formed parts, films, fibers, yarns, and / or textiles, wherein the articles are formed at least in part from a low processing temperature polymeric composition and a high processing temperature polymeric composition. In some embodiments, the materials are formed at least in part from a low processing temperature polymeric composition and a high processing temperature polymeric composition. As used herein, "low processing temperature polymeric composition" and "high processing temperature polymeric composition" are relative creep relaxation temperatures (T) relative to each of these compositions. cr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) and / or melting temperature (T m ) is a relative term. The creep relaxation temperature (T cr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) and melting temperature (T m ) is also understood to be lower than the decomposition temperature of the high processing temperature polymeric composition.These parameters are described in further detail hereinafter.Should be understood that other characteristics and parameters can be different between the low processing temperature polymeric composition and the high processing temperature polymeric composition, as discussed in detail below.In various fields, the low processing temperature polymeric composition and / or the high processing temperature polymeric composition or both can be present in a formed part, film, textile, yarn or fiber.

[0065] In various aspects, when both the low processing temperature polymer composition and the high processing temperature polymer composition are thermoplastic compositions, the melting temperature (T m ) is lower than at least one of the following properties of the high processing temperature polymer composition: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m That is, for example, the low processing temperature polymer composition exhibits a creep relaxation temperature (T) that is lower than the high processing temperature polymer composition. cr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) or melting temperature (T m ) of one or more of the temperatures (T m ).

[0066] In another aspect, the melting temperature (T m ) is lower than the creep relaxation temperature (Tcr In still other aspects, the melting temperature (T m ) is lower than the Vicat softening temperature (T vs In yet another aspect, the melting temperature (T m ) is lower than the heat distortion temperature (T hd In even further aspects, the melting temperature (T m ) is lower than the melting temperature (T m ).

[0067] In various aspects, the melting temperature (T m ) is greater than at least one of the following properties of the low processing temperature polymer composition: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m That is, for example, a high processing temperature polymer composition exhibits a creep relaxation temperature (T cr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) or melting temperature (T m ) of one or more of the temperatures (T m ).

[0068] In another aspect, the melting temperature (T m ) is greater than the creep relaxation temperature (T cr In still other aspects, the melting temperature (T m ) is greater than the Vicat softening temperature (T vs In yet another aspect, the melting temperature (T m ) is greater than the heat distortion temperature (T hd In even further aspects, the melting temperature (T m ) is greater than the melting temperature (T m ).

[0069] In various aspects, the low processing temperature polymer composition and the high processing temperature polymer composition can be selectively incorporated into a textile or article to provide one or more structural properties and / or other advantageous properties to the textile or article. In various aspects, such textiles can be thermoformed to impart such structural properties and / or other advantageous properties. Thermoforming can be performed within a temperature range below at least one of the following properties of the high processing temperature polymer composition: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m Thermoforming can be performed at temperatures below the creep relaxation temperature (T cr Thermoforming can be carried out in a temperature range below the Vicat softening temperature (T vs Thermoforming can be carried out in a temperature range below the heat deformation temperature (T hd Thermoforming can be carried out at a temperature below the melting temperature (T m ) within the temperature range.

[0070] In various aspects, low processing temperature polymer composition can be used to form fiber.As used herein, " fiber " is understood to include filament (filament).Similarly, in various aspects, high processing temperature polymer composition can be used to form fiber.In various aspects, fiber can be the bicomponent fiber that comprises the first part formed by low processing temperature polymer composition and the second part formed by high processing temperature polymer composition.For example, low processing temperature polymer composition and high processing temperature polymer composition can be coextruded to form bicomponent fiber.Fiber can be extruded from low processing temperature polymer composition, and is coated with high processing temperature polymer composition subsequently.Selectively, fiber can be extruded from high processing temperature polymer composition, and is coated with low processing temperature polymer composition subsequently.In other aspect, fiber can be the multicomponent fiber that comprises three or more polymer compositions, and described three or more polymer compositions comprise one or more low processing temperature polymer compositions and one or more high processing temperature polymer compositions.

[0071] In various aspects, the disclosed fiber can be used to prepare yarn. The yarn can be formed using staple fibers or continuous fibers. The yarn of the present disclosure comprises at least one of a low processing temperature polymer composition and a high processing temperature polymer composition. Embodiments of the present disclosure include both a low processing temperature polymer composition and a high processing temperature polymer composition. For example, the yarn can include one or more disclosed fibers, the fibers comprising a low processing temperature polymer composition, a mixture of two or more low processing temperature polymer compositions, a high processing temperature polymer composition, a mixture of two or more high processing temperature polymer compositions, or a mixture of one or more low processing temperature polymer compositions and one or more high processing temperature polymer compositions. Substantially all or most of the fibers of the yarn can be formed by the low processing temperature polymer composition. Alternatively, substantially all or most of the fibers of the yarn can be formed by the high processing temperature polymer composition. The yarn can include fibers formed by the low processing temperature polymer composition or fibers formed by the high processing temperature polymer composition, or two types of fibers. The yarn can include fibers formed by the low processing temperature polymer composition, wherein the yarn is coated with the high processing temperature polymer composition. Alternatively, the yarn may include fibers formed from a high processing temperature polymer composition, wherein the yarn is covered with a low processing temperature polymer composition.

[0072] In various aspects, the aforementioned fibers or yarns can be used to prepare textiles. The textiles can include one or more of the disclosed fibers or yarns. In various aspects, the textiles can be woven textiles including one or more of the disclosed yarns. In other aspects, the textiles can be knitted textiles including one or more of the disclosed yarns. In still other aspects, the textiles can be non-woven textiles including one or more of the disclosed fibers.

[0073] In various aspects, low processing temperature polymer composition or high processing temperature polymer composition or both can be used to prepare shaped parts.Shaped parts can be the molded parts made by injection molding, compression molding, blow molding, rotational molding or other molding techniques well known to those skilled in the art. In some aspects, shaped parts can comprise the mixture of two or more low processing temperature polymer compositions. In selectable aspect, shaped parts can comprise the mixture of two or more high processing temperature polymer compositions. In other aspect, shaped parts can comprise one or more low processing temperature polymer compositions and one or more high processing temperature polymer compositions. For example, shaped parts can comprise two or more parts, wherein the first portion is formed by the low processing temperature polymer composition and the second portion is formed by the high processing temperature polymer composition. Two or more parts can be formed using a double-shot molding process (double-shot molding process).

[0074] In various aspects, low processing temperature polymer composition or high processing temperature polymer composition can be used to make film.In some aspects, film can comprise one or more low processing temperature polymer composition.Selectively, in some aspects, film can comprise one or more high processing temperature polymer composition.In other aspects, film can comprise one or more low processing temperature polymer composition and one or more high processing temperature polymer composition.In various aspects, film can be the multilayer film comprising one or more disclosed films, for example, comprising the first layer comprising the low processing temperature polymer composition and the double-layer film comprising the second layer of the high processing temperature polymer composition.Multilayer film can be formed by coextrusion or lamination.

[0075] In conventional manufacturing of articles, including articles of wear, the transition from a first functional area to a second functional area can be achieved by changing the material imparting the functionality. This transition from a first material with a first functional description to a second material with a different functional description can introduce limitations to the final article. For example, in the case of a shoe, the transition from the sole to the upper occurs near the shoe's bite line. This transition can be referred to as a hard-to-soft transition because the sole typically has a relatively rigid response to foot movement, while the upper has a relatively generally non-rigid response to foot movement. Other such hard-to-soft transitions can exist in other locations on the shoe, depending on the design and construction methods used. At this transition, the wearer of the shoe may experience discomfort because the portion of the foot on one side of the transition is allowed to move differently (e.g., more freely) than the portion of the foot on the other side of the transition. This abrupt change in the allowed freedom of movement of the wearer's foot (e.g., a hard-to-soft transition) can affect the perceived performance and feel of the shoe. To limit the impact of the hard-to-soft transition, manufacturers may insert multiple material layers or otherwise mechanically manipulate the transition area to mask the change. Each of these changes may insert complexity, additional processing steps and / or materials, which can further impact the efficiency, cost, and weight of the shoe.

[0076] Therefore, aspect contemplated herein allows an integrally formed article portion, which has a transition from a first functional area to a second functional area, the transition being engineered into the formation of the area and being engineered during the formation of the area. For example, the manipulation of material and technology can be implemented, such as knitting stitches (knitting stitches), to allow a gradient from the first functional area to the second functional area. Making this return to being relevant to the hard-to-soft transition of shoes, it is contemplated that the first functional area (e.g., sole area) of shoes can be formed (e.g., knitted) with a first type of material (e.g., a low processing temperature polymer composition described below), and the second functional area (e.g., upper part) of shoes is formed (e.g., knitted) with different materials (e.g., a high processing temperature polymer composition described below). Additionally or alternatively, the sole area of ​​shoes is knitted with the stitch of the first type, and the upper part of shoes is knitted with the stitch of the second type. Furthermore, in this embodiment, the transition from a first functional area (e.g., a sole area) to a second functional area (e.g., an upper area) can include one or more transition zones in which knitting techniques (e.g., stitch selection, layer manipulation) and / or materials are blended in a defined manner to integrally form a more natural transition from the first functional area to the second functional area during manufacture of the area. In an exemplary aspect, this integral transition between functional areas can positively impact the wearer's perceived performance and / or feel of the shoe.

[0077] In one aspect, a textile is provided, comprising a first plurality of fibers comprising a low processing temperature polymer composition. The textile further comprises a second plurality of fibers comprising a high processing temperature polymer composition. The first plurality of fibers and the second plurality of fibers may be deposited to form separate zones of the textile. For example, the first plurality of fibers may form a first surface of the textile, and the second plurality of fibers may form a second surface of the textile opposite the first surface. Alternatively or additionally, the first plurality of fibers may form an inner portion of the first surface of the textile, and the second plurality of fibers may form an outer portion of the first surface of the textile. The first plurality of fibers and the second plurality of fibers may be laid in a first zone, a second zone, and a third zone, the second zone being positioned between the first zone and the third zone, wherein the first zone comprises a second plurality of fibers having an increased concentration compared to the second zone, and wherein the third zone comprises a first plurality of fibers having an increased concentration compared to the second zone. In a particular embodiment, the textile is a nonwoven textile. In some embodiments, the textile is a component of an article of the present disclosure, such as an article of clothing, an article of footwear, or an article of athletic equipment. In a particular embodiment, the textile is a component of a shoe upper of an article of footwear. The textile component may constitute at least 75 wt % of an upper for an article of footwear.

[0078] In one aspect, a textile is provided, comprising a first yarn comprising a low processing temperature polymer composition. The textile further comprises a second yarn comprising a high processing temperature polymer composition. The first yarn and the second yarn can be used to form separate zones of the textile. The first yarn and the second yarn can be included in a first zone, a second zone, and a third zone, the second zone being positioned between the first zone and the third zone, wherein the first zone comprises the second yarn with an increased concentration compared to the second zone, and wherein the third zone comprises the first yarn with an increased concentration compared to the second zone. In some embodiments, the textile is a component of an article of the present disclosure, such as an article of clothing, an article of footwear, or an article of athletic equipment. In a particular embodiment, the textile is a component of an upper of an article of footwear. The textile component can constitute at least 75 wt % of the upper for the article of footwear.

[0079] In one aspect, there is provided a woven textile including a first yarn comprising a low processing temperature polymer composition. The woven textile article further includes a second yarn comprising a high processing temperature polymer composition. The first yarn and the second yarn can be used to form separate zones of the woven textile article. For example, the first yarn can form substantially all or a portion of the warp of the weave of the woven textile article, and the second yarn can form substantially all or a portion of the weft of the weave of the woven textile article, or vice versa. The first yarn and the second yarn can form a first zone, a second zone, and a third zone, with the second zone positioned between the first zone and the third zone, where the first zone includes an increased concentration of the second yarn compared to the second zone, and where the third zone includes an increased concentration of the first yarn compared to the second zone. In some embodiments, the woven textile is a component of an article of the present disclosure, such as a clothing article or a footwear article or a sports equipment article. In a particular embodiment, the woven textile is a component of the upper of a footwear article. The woven textile component can constitute at least 75 wt% of the upper for a footwear article.

[0080] In one aspect, there is provided a knitted textile including a first yarn comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The knitted textile further includes a second yarn comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The first yarn and the second yarn at least partially form a plurality of interconnected courses in at least one knitted layer of the knitted textile, the at least one knitted layer having at least a first zone, a second zone, and a third zone, with the second zone positioned between the first zone and the third zone, where the first zone includes an increased concentration of the second yarn compared to the second zone, and where the third zone includes an increased concentration of the first yarn compared to the second zone. In some embodiments, the knitted textile is a component of an article of the present disclosure, such as a clothing article or a footwear article or a sports equipment article. In a particular embodiment, the knitted textile is a component of the upper of a footwear article. The knitted textile component can constitute at least 75 wt% of the upper for a footwear article.

[0081] Knitted textiles can be formed by knitting processes such as flat knitting or circular knitting. In some aspects, the knitted textile can be a knitted article having a substantially seam-free construction. In additional aspects, the knitted textile can be a knitted article formed from an integral knitted construction. As used herein, a knitted article is defined as being formed from an “integral knitted construction” when formed as a one-piece element by a knitting process. That is, the knitting process substantially forms the various features and structures of the knitted article without a substantial number of additional manufacturing steps or processes. Although portions of the knitted article may be joined to one another after the knitting process (e.g., the edges of the knitted article are joined together, such as at a seam), the knitted article remains formed from an integral knitted construction because the knitted article is formed as a one-piece knitted element. In various aspects, the knitted article can also include other elements (e.g., tongues, strobel, laces, heel stabilizers, logos, trademarks, tags) that can be added after the knitting process.

[0082] The knitted textile can incorporate various types and combinations of stitches and yarns. With regard to stitches, the knitted textile can have one type of stitch in one area of the knitted textile and another type of stitch in another area of the knitted textile. Depending on the type and combination of stitches used, an area of the knitted textile can have, for example, a plain knit structure, a mesh knit structure, or a rib knit structure. Different types of stitches can affect the physical properties of the knitted textile, including aesthetics, stretch, thickness, breathability, and abrasion resistance. That is, different types of stitches can impart different properties to different areas of the knitted textile. With regard to yarns, the knitted textile can have one type of yarn in one area of the knitted textile and another type of yarn in another area of the knitted textile, e.g., a yarn comprising a low processing temperature polymer composition in one area of the knitted textile and a yarn comprising a high processing temperature polymer composition in another area of the knitted textile. Depending on various design criteria, the knitted textile can incorporate yarns having, for example, different deniers, materials (e.g., cotton, spandex, polyester, rayon, wool, and nylon), and degrees of twist. Different types of yarns can affect the physical properties of the knitted textile, including aesthetics, stretch, thickness, breathability, and abrasion resistance. That is, different types of yarns can impart different properties to different areas of the knitted textile. By combining various types and combinations of stitches and yarns, each area of the knitted article can have specific properties that enhance the comfort, durability, and performance of the knitted textile as needed through the use of the knitted textile in a footwear article, a clothing article, or a sports equipment article.

[0083] Knitted textiles can be prepared by a variety of suitable processes. For example, flat knitting process can be utilized to manufacture knitted textiles. Although flat knitting can provide a suitable process for forming knitted textiles, other knitting processes can also be utilized, such as wide tube circular knitting, narrow tube jacquard circular knitting, single knit circular knitting, double jacquard circular knitting, tricot type warp knitting, warp knit raschel and double needle bar raschel. In various aspects, knitted textiles can be subjected to post-processing steps, for example, to remove a part of knitted textiles, to add components to knitted textiles, to produce fleece texture etc. In other aspects, knitted textiles can include various knitting structures and / or include different knitting sublayers.

[0084] In some aspects, the entire knitted article can be seamless. Seamless knitted articles can be provided, for example, by circular knitting. Circular knitted articles can allow for the provision of three-dimensional preformed articles without having to be sewn up at specific locations. Thus, unwanted seams in the knitted article can be avoided, and the three-dimensional preformed knitted article can have a particularly good fit and the other aforementioned benefits of a seamless structure.

[0085] However, it should be noted that the textiles and textile articles of the present disclosure, including knitted articles, can be utilized in the manufacture of composite elements. In some aspects, a composite element can include a first textile prepared as disclosed herein and a second textile, a film, or a formed component. That is, the composite element includes a first textile region and a second region selected from a region comprising a second textile, a region comprising a film, a region comprising a formed component, or a combination thereof.

[0086] In one aspect, a textile is provided that includes a first plurality of fibers comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile can be a nonwoven textile. The textile can be a textile article. The textile article can be a component of an article of sporting equipment. The textile article can be a component of an article of clothing. The textile article can be a component of an article of footwear. The textile article can be an upper portion of an article of footwear.

[0087] In various aspects, the textile comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition in the first plurality of fibers. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ).

[0088] In further aspects, the textile comprises a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first plurality of fibers. m ) creep relaxation temperature (T cr ).

[0089] In further aspects, the textile comprises a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first plurality of fibers. m ) heat deformation temperature (T hd ).

[0090] In further aspects, the textile comprises a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first plurality of fibers. m ) of the Vicat softening temperature (T vs ).

[0091] In further aspects, the textile comprises a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first plurality of fibers. m ) melting temperature (T m ).

[0092] In another aspect, a textile comprises a first yarn comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile can be a knitted textile. The textile can be a woven textile. The textile can be a textile article. The textile article can be an upper portion for an article of footwear.

[0093] In various aspects, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ).

[0094] In a further aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) creep relaxation temperature (T cr ).

[0095] In a further aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) heat deformation temperature (T hd ).

[0096] In a further aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) of the Vicat softening temperature (T vs ).

[0097] In a further aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) melting temperature (T m ).

[0098] In certain aspects, a textile article is provided, the textile article comprising a melted fiber component that is thermoformed from a first state as a first plurality of fibers to a second state as a melted fiber component (i.e., a component formed of a plurality of fibers, wherein at least a portion of the plurality of fibers has been at least partially melted and resolidified into a new structure different from their fiber structure). The first plurality of fibers comprises a low processing temperature polymer composition. It should be understood that the melted fiber component can include structures such as a partially melted first plurality of fibers, a substantially completely melted first plurality of fibers, and mixtures thereof. The textile article can also include a second plurality of fibers comprising a high processing temperature polymer composition. Optionally, the melted fiber component and the second plurality of fibers at least partially form a structure having at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. The first zone comprises a higher concentration of the second plurality of fibers than the second zone, and the third zone comprises a higher concentration of the melted plurality of fiber components than the second zone. In some embodiments, this structure can form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface.

[0099] In one aspect, a textile article comprises a first plurality of fibers comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile article may be a component of an article of clothing. The textile article may be a nonwoven textile article. The textile article may be a component of an article of sporting equipment. The textile article may be a component of an article of footwear. The textile article may be an upper portion of an article of footwear.

[0100] In various aspects, the textile article includes a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first plurality of fibers. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0101] In a further aspect, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T m ) creep relaxation temperature (T cr), the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0102] In a further aspect, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T m ) heat deformation temperature (T hd ), the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0103] In a further aspect, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T m ) of the Vicat softening temperature (T vs ), the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0104] In further aspects, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition of the first plurality of fibers. m ) melting temperature (T m ), the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0105] In certain aspects, a textile article is provided, the textile article comprising a melted yarn component that is thermoformed from a first state as a first yarn to a second state as a melted yarn component (i.e., a component formed by a yarn that has been at least partially melted and resolidified into a new structure different from its yarn structure). The first yarn comprises a low processing temperature polymer composition. It should be understood that the melted yarn component can include structures such as a partially melted first yarn, a substantially completely melted first yarn, and a mixture thereof. The knitted article can also include a second yarn comprising a high processing temperature polymer composition. Optionally, the melted yarn component and the second yarn at least partially form a structure having at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. The first zone includes a higher concentration of the second yarn than the second zone, and the third zone includes a higher concentration of the melted yarn component than the second zone. In some embodiments, this structure can form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a part of the outer surface.

[0106] In one aspect, a textile article includes a first yarn comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile article may be a knitted article. The textile article may be a woven article. The textile article may be a component of an article of clothing. The textile article may be a component of an article of footwear. The textile article may be an upper portion of an article of footwear. The textile article may be a knitted upper portion of an article of footwear.

[0107] In various aspects, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0108] In a further aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) creep relaxation temperature (T cr ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0109] In a further aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) heat deformation temperature (T hd ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0110] In a further aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) of the Vicat softening temperature (T vs ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0111] In a further aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition in the first yarn. m ) melting temperature (T m ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0112] In certain aspects, the textile article is a knitted article comprising a plurality of interconnected rows. Each row in the plurality of interconnected rows comprises a first yarn and a second yarn. The first yarn comprises a low processing temperature polymer composition. The second yarn comprises a high processing temperature polymer composition. The knitted article further comprises at least one knit layer comprising at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. Each row in the plurality of interconnected rows extends through the first zone, the second zone, and the third zone, wherein the third zone has a first yarn with an increased concentration compared to the second zone. In some embodiments, this structure can form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface. In addition, the knitted article comprises an anchor yarn extending through at least a portion of the third zone. The anchor yarn comprises a high processing temperature polymer composition, such as, for example, a fiber formed from the high processing temperature polymer composition. The anchor yarn exhibits an elongation that is less than the elongation of the first yarn.

[0113] In addition to textiles and articles including textiles, the present disclosure also relates to articles including a melted film component that is thermoformed from a first state as a film to a second state as a melted film (i.e., a film comprising a low processing temperature polymer material, wherein at least a portion of the low processing temperature polymer material of the film has been melted on a substrate and resolidified into a new structure different from its film structure). The article may also include a high processing temperature polymer composition. Optionally, the melted film component and the high processing temperature polymer composition at least partially form a structure having at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. The first zone includes a higher concentration of the high processing temperature polymer composition than the second zone, and the third zone includes a higher concentration of the melted film component than the second zone. In some embodiments, this structure can form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface.

[0114] In one aspect, an article comprises a molten film component comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The article can be a component of an article of clothing. The article can be a component of an article of sporting equipment. The article can be a component of an article of footwear. The article can be an upper portion for an article of footwear.

[0115] In various aspects, the article includes a second element (e.g., a formed part, film, textile, fiber, yarn) comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than that of the low processing temperature polymer composition of the melted film part. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0116] In a further aspect, the article comprises a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition of the melted film component. m ) creep relaxation temperature (T cr ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0117] In a further aspect, the article comprises a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition of the melted film component. m ) heat deformation temperature (T hd ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0118] In a further aspect, the article comprises a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition of the melted film component. m ) of the Vicat softening temperature (T vs ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0119] In further aspects, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition of the first plurality of fibers. m ) melting temperature (T m ), the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0120] The present disclosure also relates to an article comprising a first polymeric component comprising a molten region, the first polymeric component being thermoformed from a first state as a formed component to a second state as a molten formed component (i.e., a formed component comprising a low processing temperature polymeric material, wherein at least a portion of the low processing temperature polymeric material has melted and resolidified into a new configuration different from its original formed component configuration). The first component may further comprise a region formed from a high processing temperature polymeric composition. Alternatively or additionally, the article may further comprise a second component comprising a high processing temperature polymeric composition.

[0121] In one aspect, an article includes a first formed part comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The article can be a component of an article of apparel. The article can be a component of an article of sporting equipment. The article can be a component of an article of footwear. The article can be an upper portion for an article of footwear. The article can be a sole element for an article of footwear.

[0122] In various aspects, the article includes a second element (e.g., a shaped part, film, textile, fiber, yarn) comprising a high processing temperature polymer composition that exhibits a melting temperature (T) greater than the low processing temperature polymer composition of the first shaped part. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), the first formed part is transformed from a first state as a formed part to a second state as a molten formed part.

[0123] In a further aspect, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition of the first formed part. m ) creep relaxation temperature (T cr ), the first formed part is transformed from a first state as a first formed part to a second state as a molten formed part.

[0124] In a further aspect, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition of the first forming element. m ) heat deformation temperature (T hd ), the first forming element is transformed from a first state as a forming element to a second state as a molten forming part.

[0125] In a further aspect, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition of the first forming element. m ) of the Vicat softening temperature (T vs ), the first forming element is transformed from a first state as a first forming element to a second state as a molten forming part.

[0126] In further aspects, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition of the first plurality of fibers. m ) melting temperature (T m ), the first plurality of fibers are transformed from a first state as a first formed part to a second state as a molten formed part.

[0127] In one aspect, a knitted upper for an article of footwear is provided, the knitted upper comprising a first yarn comprising a low processing temperature polymer composition. The knitted upper for the article of footwear further comprises a second yarn comprising a high processing temperature polymer composition. The first yarn and the second yarn at least partially form a plurality of interconnected courses in at least one knit layer of the knitted upper for the article of footwear, the at least one knit layer having at least a first region, a second region, and a third region, the second region being positioned between the first and third regions, wherein the first region comprises an increased concentration of the second yarn compared to the second region, and wherein the third region comprises an increased concentration of the first yarn compared to the second region. In some embodiments, this structure can form an exterior surface of the article, wherein the first region, the second region, and the third region each form a portion of the exterior surface.

[0128] In certain aspects, a knitted upper for an article of footwear is provided, the knitted upper comprising a melted yarn component comprising a low processing temperature polymer composition. The melted yarn component is thermoformed from a first state as a first yarn to a second state as a melted yarn component. The knitted upper for an article of footwear also comprises a second yarn comprising a high processing temperature polymer composition. The melted yarn component and the second yarn at least partially form a surface having at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first and third zones. The first zone comprises a higher concentration of the second yarn than the second zone, and the third zone comprises a higher concentration of the melted yarn component than the second zone. In some embodiments, this structure can form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface.

[0129] In some aspects, the wearable article is an article of footwear, which includes but is not limited to articles such as shoes. Articles of footwear generally include an upper and a sole structure. The upper provides a covering for the foot, which comfortably receives the foot and securely positions the foot relative to the sole structure. In addition, the upper generally provides protection for the foot. The sole structure can provide a variety of support, cushioning, and shock absorption. The sole structure is fixed to the lower portion of the upper and is generally positioned between the foot and the ground. In addition to reducing ground reaction forces (i.e., providing cushioning) during walking, running, and other ambulatory activities, the sole structure can, for example, affect foot movement (e.g., by resisting pronation), impart stability, and provide traction. Therefore, the upper and sole structure operate in synergy to provide a comfortable structure suitable for a variety of athletic activities.

[0130] The upper forms a structure that provides a covering for some or all of the wearer's foot and positions the foot relative to the sole structure of the shoe. The upper forms a cavity on the interior of the footwear for receiving the foot. The cavity has the general shape of the foot, and the entrance to the cavity is located at the ankle opening. In some aspects, the upper extends over the instep area and toe area of ​​the foot, along the medial and lateral sides of the foot, and around the heel area of ​​the foot. The upper can have any design, shape, size, and / or color. For example, in some aspects, for example, if the article is a basketball shoe, the upper can be a high-top upper that is shaped to provide high support to the ankle. Alternatively, in some aspects, for example, if the article is a running shoe, the upper can be a low-top upper.

[0131] The upper may also incorporate a lacing system to adjust the fit of the footwear and to allow the foot to enter and remove from the cavity within the upper. Lacing systems are often incorporated into the upper to selectively change the size of the ankle opening and allow the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with different proportions. In addition, the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to adjust the pressure applied to the foot by the laces), and the upper may also include a heel stabilizer to limit or control the movement of the heel. In addition, the upper may include a tongue that extends under the lacing system to enhance the adjustability and comfort of the footwear, and the upper may incorporate a heel stabilizer.

[0132] In some aspects, sole structure can comprise one or more parts or layers, and these one or more parts or layers can provide many attributes for article of footwear individually or jointly, such as support, rigidity, flexibility, stability, cushioning, comfort, reduced weight or other attributes. In some aspects, sole structure can comprise the layer that is called as insole, midsole and outsole. However, in some aspects, one or more of these parts can be omitted. In some aspects, sole can optionally comprise sole plate. In some aspects, sole structure comprises outsole components, and outsole components comprise the outside main surface that can be exposed and contact ground, and inner main surface. In other aspect, sole structure can also comprise the midsole components that can be attached to the upper along the whole length of the upper. When existing, the midsole forms the intermediate layer of sole structure and is used for comprising the multiple purposes of controlling foot motion and weakening impact force.

[0133] The midsole, which may be attached to the upper along its entire length, forms the middle layer of the sole structure and serves a variety of purposes, including controlling foot motion and attenuating impact forces. Many midsole constructions are primarily formed from a resilient polymer foam material, such as polyurethane (PU) or ethylene vinyl acetate (EVA), that extends across the length and width of the footwear. The midsole may also incorporate plates, adjusters, fluid-filled chambers, and / or other elements that, for example, further attenuate forces, influence foot motion, and / or impart stability.

[0134] The outsole forms the ground-contacting element of the footwear and is typically formed of a durable, wear-resistant material that includes texture or other features that improve traction. The outsole can be formed of a durable and wear-resistant material (e.g., rubber) that includes texture that improves traction. The outsole may also optionally include cleats.

[0135] In some aspects, articles of footwear may also include an insole, which is a thin member located within the shoe upper and adjacent to the plantar (lower) surface of the foot to enhance footwear comfort, for example, by wicking away moisture and providing a soft, comfortable feel. In some aspects, the insole may be formed from a foam material such as polyurethane foam, foam rubber, or ethylene vinyl acetate. In certain aspects, the insole is not glued to or otherwise attached to the sole structure. Alternatively, the insole may be attached to the sole structure.

[0136] In certain aspects, a knitted upper for an article of footwear is provided, comprising a plurality of interconnected courses. Each of the plurality of interconnected courses comprises a first yarn and a second yarn. The first yarn comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The knitted upper for an article of footwear further comprises at least one knitted layer, the at least one knitted layer comprising at least a first region, a second region, and a third region, wherein the second region is positioned between the first and third regions. Each of the plurality of interconnected courses extends through the first, second, and third regions, wherein the third region has an increased concentration of the first yarn compared to the second region. Furthermore, the knitted upper for an article of footwear comprises an anchor yarn extending through at least a portion of the third region. The anchor yarn comprises an anchor yarn composition comprising one or more polymers. The anchor yarn exhibits an elongation that is less than the elongation of the first yarn.

[0137] Exemplary Aspects of Articles of Sporting Equipment, Articles of Wear, and Textiles

[0138] As discussed above, certain aspects relate to one or more textiles comprising fibers and / or yarns comprising a low processing temperature polymer composition and a high processing temperature polymer composition. In certain aspects, such textiles can form at least a portion of an article of sports equipment or an article of wear. In certain aspects, the disclosed textiles can form at least a portion of a component of an article of footwear. In certain aspects, the disclosed textiles can form at least a portion of a component of an article of sports equipment. For example, the disclosed textiles can form at least a portion of an upper for a shoe, such as a sneaker.

[0139] Turning now to the drawings, in particular Figure 1A and Figure 1B , article of footwear 100 is depicted as an exemplary article of wear. Figure 1A and Figure 1B Article of footwear 100 is depicted, but it should be understood that other articles of wear are also encompassed by the present disclosure. Figure 1A and Figure 1B The article of footwear 100 may generally include a ground-facing outsole region 110, an ankle collar region 112, a lateral midsole region 114a and a medial midsole region 114b, a toe box region 116, and a heel region 118. In addition, the article of footwear 100 may include a plurality of eyelets 120, a toe box region 122, a tongue region 124, and a throat region 126. Figure 1A and Figure 1B As shown in FIG, article of footwear 100 is intended for use with a right foot; however, it should be understood that the following discussion may apply equally to a mirror image of article of footwear 100 intended for use with a left foot.

[0140] exist Figure 1A and Figure 1B 100 may include at least one textile 102 that at least partially forms a portion of article of footwear 100. Textile 102 of article of footwear 100 may include at least three separate textile zones, e.g., zone 104, zone 106, and zone 108, that identify specific functional areas of article of footwear 100. In certain aspects, these specific functional areas may be at least partially associated with the targeted incorporation of specific textile media into these textile zones in varying amounts, techniques, and combinations (e.g., zones 104, 106, and 108). Figure 1A and Figure 1B 104, 106, and 108). It should be understood that while textile 102 includes three specific functional regions, more than three functional regions are also contemplated.

[0141] In some aspects, textile region 104 can exhibit rigid or semi-rigid functionality suitable for use as a ground-facing outsole 110 for article of footwear 100. Thus, in some aspects, textile region 104 can be positioned to include at least a portion of ground-facing outsole 110 of article of footwear 100. In some aspects, after thermoforming, targeted incorporation of a low processing temperature polymer composition into textile region 104 of textile 102 can at least partially provide rigid or semi-rigid functionality for use as ground-facing outsole 110. As used herein, "thermoforming" refers to a process that can include melting and / or deforming a low processing temperature polymer composition and / or one or more thermoplastic polymers and subsequently cooling the melted and / or deformed material to form a plaque or film that can be rigid or semi-rigid. Thermoforming processes are discussed in detail below.

[0142] Additionally, in various aspects, another textile region, such as, for example, textile region 108, can exhibit flexibility and / or pliability to accommodate movement from the wearer. In certain aspects, textile region 108 can include ankle collar region 112, tongue region 124, and / or throat region 126 of article of footwear 100. In various aspects, textile region 108 can include a high processing temperature polymer composition.

[0143] In some aspects, another textile zone, such as, for example, textile zone 106, may be positioned between textile zone 104 and textile zone 108. In some aspects, textile zone 106 may include at least a portion of lateral midfoot region 114a and / or medial midfoot region 114b on article of footwear 100. In some aspects, textile zone 106 may include a combination of a low processing temperature polymer composition from textile zone 104 and a high processing temperature polymer composition from textile zone 108. In such aspects, this combination of textile media present in textile zone 106 allows textile zone 106 to serve as a transition between the rigid or semi-rigid functionality of textile zone 104 and the flexible toughness functionality of textile zone 108, allowing for a smoother transition from rigidity to flexibility of textile 102.

[0144] Furthermore, in such aspects, textile region 106 may be rigid or semi-rigid to a lesser extent than textile region 104 but to a greater extent than textile region 108. Furthermore, in the same or alternative aspects, textile region 106 may be flexible to a lesser extent than textile region 108 but to a greater extent than textile region 104.

[0145] Alternatively or additionally, three textile areas 104 , 106 , and 108 may be located at least partially within a midfoot region, such as within lateral midfoot region 114 a and / or medial midfoot region 114 b .

[0146] In some aspects, in textile region 106, the combination of the low processing temperature polymer composition present in textile region 104 and the high processing temperature polymer composition present in textile region 108 can impart one or more structural properties to the article of footwear 100 when exposed to a thermoforming process, such as semi-rigid support in the lateral mid-shoe region 114a and / or the medial mid-shoe region 114b, and / or imparting a three-dimensional shape or three-dimensional structure to one or more portions of the article of footwear 100.

[0147] In some aspects, such as Figure 1AAs seen in FIG, textile region 106 extends from textile region 104 toward eyelet 120. In such aspects, the combination of textile media comprising a low processing temperature polymer composition and textile media comprising a high processing temperature polymer composition can allow forces transmitted from eyelet 120 or other lacing mechanisms to be transferred to this combination of textile media present in lateral midfoot region 114a and / or medial midfoot region 114b. In certain aspects, to successfully transfer forces transmitted from eyelet 120, textile region 104 and / or the low processing temperature polymer composition present in textile region 104 can terminate in region 128, which, when textile 102 is a knitted textile formed on a commercial knitting machine, is at least about 0.5 cm, about 1.0 cm, or about 2.0 cm from eyelet 120 and / or at least about 3 stitches, at least about 4 stitches, or at least about 5 stitches below eyelet 120. In such aspects, the flexibility and toughness characteristics of the high processing temperature polymer composition present in zone 108 adjacent to the eyelet 120 can facilitate the transfer of forces transmitted from the eyelet 120 to the textile zone 106, and / or the low processing temperature polymer composition present in the lateral mid-shoe area 114a and / or the medial mid-shoe area 114b.

[0148] exist Figure 1A and Figure 1B In the aspect depicted in , textile region 106 is positioned in toe box area 116 and heel area 118. In such an aspect, the combination of the low processing temperature polymer composition and the high processing temperature polymer composition can provide structure and / or support due to the rigidity provided by the thermoformed material. In addition, the thermoformed material can provide wear resistance in toe box area 116 and / or heel area 118. In an alternative aspect, textile region 104 can form at least a portion of toe box area 116 and / or heel area 118 for increased rigidity or increased wear resistance because textile region 104 includes a greater amount of the low processing temperature polymer composition or an alternative positioning of the low processing temperature polymer composition (e.g., an outer knit surface) as compared to textile region 106.

[0149] Figure 1C 100a. In such aspects, article of footwear 100a can generally include at least three types of textile regions: textile region 104a, textile region 106a, and textile region 108a. In certain aspects, textile regions 104a, 106a, and 108a can have the same characteristics as those described above. Figure 1A The same characteristics and parameters of textile regions 104 , 106 , and 108 of article of footwear 100 are discussed.

[0150] exist Figure 1CIn the aspects depicted in FIG, portions of textile region 104a, such as portion 104b and portion 104c, can extend from the outsole region upward through midsole region 115A and toward plurality of eyelets 120a. In such aspects, the rigid or semi-rigid functionality provided by portions 104b and 104c extending from the outsole region through midsole region 115A to plurality of eyelets 120a can provide increased wearer stability in midsole region 115A. Furthermore, in various aspects, forces applied through one or more of plurality of eyelets 120a can be at least partially transferred to rigid or semi-rigid portions 104b and 104c extending through midsole region 115A and to rigid or semi-rigid textile region 104a present in the outsole region, providing increased support and comfort to the wearer.

[0151] In certain aspects, in addition to providing structure, rigidity, strength, and / or support to one or more areas of an article of wear, the thermoformed material can provide a waterproof or water-resistant surface.

[0152] Figure 2A and Figure 2B A shirt 200 is depicted as an exemplary article of apparel. Figure 2A and Figure 2B The shirt 200 depicted in FIG includes at least one textile 202 that at least partially forms a portion of the shirt 200. Figure 2B As best seen in FIG, textile 202 may include three separate textile regions 204, 206a-d, and 208 that may identify specific functional areas of shirt 200. In certain aspects, these specific functional areas are associated, at least in part, with the targeted incorporation of specific textile media into these textile regions 204, 206a-d, and 208 in varying amounts and combinations.

[0153] In certain aspects, textile region 204 can include a reinforced area, such as an exterior-facing film or patch 210, which can provide abrasion resistance, for example, to elbow regions 212 of shirt 200. In such aspects, the targeted, integral incorporation of a low processing temperature polymer composition into textile region 204 can at least partially form patch 210 when textile 202 is thermoformed by melting or deforming the low processing temperature polymer composition and subsequently cooling and solidifying the molten material to form patch 210.

[0154] In various aspects, textile region 208 can exhibit flexibility and / or toughness similar to conventional shirting materials. In such aspects, textile region 208 can include or consist solely of a high processing temperature polymer composition. Furthermore, in certain aspects, textile region 206 can at least partially provide a transition within textile 202 from a rigid or semi-rigid patch 210 present in textile region 204 to a flexible, tough portion present in textile region 208. In such aspects, textile regions 206a-d can include a combination of a low processing temperature polymer composition present in textile region 204 and a high processing temperature polymer composition present in textile region 208. While in Figure 2A and Figure 2B Not shown, textile regions 206b - d also provide a transition to a flexible, flexible material such as that present in textile region 208 .

[0155] In certain aspects, the Figure 1A and Figure 1B As with textile region 106 of textile 102 discussed above, this combination of the low processing temperature polymer composition from textile region 204 and the high processing temperature polymer composition from textile region 208 can provide a seamless or integral transition from patch 210 of shirt 200 to the flexible, tough portion present in textile region 208.

[0156] Although Figure 2A and Figure 2B This exemplary description of the middle textile regions 204, 206a-d, and 208 relates to the elbow areas of the article of apparel 200, but it should be understood that the textile regions 204, 206a-d, and 208 and the associated characteristics can be applied to other areas of a shirt or other article of apparel, such as the knees, thighs, buttocks, chest, and / or lower back areas of an article of apparel, or areas requiring reinforcement, such as areas adjacent to fasteners such as zippers, buttons, buckles, pull cords, and the like.

[0157] Now turn Figure 3 , provides a plan view of an illustrative textile 300. It should be understood that textile 300 can be any type of textile known to those skilled in the art. A non-limiting list of textiles suitable for use in the wearable articles and methods disclosed herein includes knitted textiles, woven textiles, non-woven textiles, and braided textiles.

[0158] Similar to Figure 1A and Figure 1B Textiles 102 and Figure 2A and Figure 2B Textiles 202, Figure 3The textile 300 includes three types of textile regions. For example, the textile 300 includes: a textile region 302, which may include fibers and / or yarns comprising a low processing temperature polymer composition; textile regions 306a and 306b, which may include a high processing temperature polymer composition; and textile regions 304a and 304b, which may include a combination of fibers and / or yarns comprising a low processing temperature polymer composition and fibers and / or yarns comprising a high processing temperature polymer composition. Figure 3 In textile 300 , textile regions 304a and 304b may be positioned on either side of textile region 302 , while textile regions 306a and 306b may be positioned on opposite sides of textile regions 304a and 304b , respectively.

[0159] In certain aspects, fibers and / or yarns comprising the low processing temperature polymer composition present in textile region 302, when exposed to a thermoforming process, can impart structural or functional properties to textile 300 that can be used to form an article of wear. For example, textile region 302 can represent a portion of a shoe outsole 110 that faces the ground. Figure 1A and Figure 1B In various aspects, fibers and / or yarns comprising the high processing temperature polymer composition present in textile regions 306a and 306b may be added to textile 300 such as in Figure 1A and Figure 1B . Furthermore, in various aspects, textile regions 304a and 304b can include a combination of fibers and / or yarns comprising the low processing temperature polymer composition present in textile region 302 and fibers and / or yarns comprising the high processing temperature polymer composition present in textile regions 306a and 306b to provide structural support and three-dimensional structure to a particular article of wear. Furthermore, as discussed above, in certain aspects, this combination of fibers and / or yarns comprising the low processing temperature polymer composition and fibers and / or yarns comprising the high processing temperature polymer composition in textile regions 304a and 304b can provide an integral transition between the rigid thermoformable material in textile region 302 and the flexible and tough high processing temperature polymer composition in textile regions 306a and 306b.

[0160] In one or more aspects, textile zones 304a and 304b may include a plurality of sub-zones, such as sub-zones 305a, 305b, 305c, and 305d of textile zone 304a, which may include different combinations and / or different positioning of fibers and / or yarns comprising low processing temperature polymer compositions and fibers and / or yarns comprising high processing temperature polymer compositions. In certain aspects, sub-zone 305a may include fibers and / or yarns comprising low processing temperature polymer compositions, but does not include fibers and / or yarns comprising high processing temperature polymer compositions present in textile zones 306a and / or 306b. In the same or alternative aspects, sub-zone 305d may include fibers and / or yarns comprising high processing temperature polymer compositions, but does not include fibers and / or yarns comprising low processing temperature polymer compositions present in textile zone 302.

[0161] It should be understood that, although only sub-regions of textile region 304a may be further described herein, such description applies to sub-regions present in textile region 304b. Furthermore, it should be understood that if only textile regions 304a and / or 306a are further discussed in certain descriptions, such description also applies to textile regions 304b and 306b, respectively.

[0162] In certain aspects, the textile 300 can have different concentrations of the low processing temperature polymer composition and / or the high processing temperature polymer composition in the textile regions 302, 304a, 306a based on the relative positioning of the fibers and / or yarns comprising the low processing temperature polymer composition and the fibers and / or yarns comprising the high processing temperature polymer composition in these textile regions 302, 304a, 306a.

[0163] As used herein, the term "concentration" refers to clustering or congregation in a specific volume. Thus, the term concentration includes measurements of a specified volume (e.g., cm 3 ) in a single knit layer of the textile can have an increased concentration of the first yarn compared to a second portion of the textile by having more stitches (e.g., knit stitches, tuck stitches, and / or float stitches) of the first yarn than the second portion of the textile of equal size. In another example, in a nonwoven textile, the first portion of the textile can have an increased concentration of the first fiber if the first portion of the textile is formed from more of the first fiber (e.g., by weight in grams) than the second portion of the textile of equal size.

[0164] In various aspects, textile region 302 may include an increased concentration of fibers and / or yarns comprising a low processing temperature polymer composition compared to textile regions 304a and / or 306a. For example, in such aspects, textile region 302 may have at least 5 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile regions 304a and / or 306a. In another aspect, textile region 302 may have at least 10 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile regions 304a and / or 306a. In one aspect, textile region 302 may have at least 25 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile regions 304a and / or 306a.

[0165] In the same or alternative aspects, textile region 304a can include an increased concentration of fibers and / or yarns comprising a low processing temperature polymer composition compared to textile region 306a. For example, in such an aspect, textile region 304a can have at least 5% by weight more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile region 306a. In another aspect, textile region 304a can have at least 10% by weight more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile region 306a. In one aspect, textile region 304a can have at least 25% by weight more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile region 306a.

[0166] In various aspects, textile region 306a can include an increased concentration of fibers and / or yarns comprising a high processing temperature polymer composition compared to textile regions 302 and / or 304a. For example, in such aspects, textile region 306a can have at least 5 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile regions 302 and / or 304a. In another aspect, textile region 306a can have at least 10 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile regions 302 and / or 304a. In one aspect, textile region 306a can have at least 25 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile regions 302 and / or 304a.

[0167] In certain aspects, textile region 304a can include an increased concentration of fibers and / or yarns comprising a high processing temperature polymer composition compared to textile region 302. For example, in such aspects, textile region 304a can have at least 5 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile region 302. In another aspect, textile region 304a can have at least 10 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile region 302. In one aspect, textile region 304a can have at least 25 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile region 302.

[0168] Figures 4A-4D Schematically depicted are exemplary cross-sections of textile regions 302, 304a, and 306a of textile 300. In general, Figure 4A An exemplary cross-section from textile region 306a is depicted, and in certain aspects further illustrates how this portion of textile region 306a includes fibers and / or yarns comprising a high processing temperature polymer composition but does not include fibers and / or yarns comprising a low processing temperature polymer composition present in textile region 302. Figure 4B An exemplary cross-section of textile region 302 is depicted, and in various aspects also illustrates how this portion of textile region 302 includes fibers and / or yarns comprising a low processing temperature polymer composition but does not include fibers and / or yarns comprising a high processing temperature polymer composition present in textile region 306a. Figure 4C and Figure 4D Two exemplary cross-sections from textile region 304a are depicted and further illustrate how both fibers and / or yarns comprising a low processing temperature polymer composition and fibers and / or yarns comprising a high processing temperature polymer composition are present in these exemplary portions of textile region 304a.

[0169] The textile 300 will now be described from the perspective of being a knitted textile. Figures 4A-4DThe cross section depicted in . The various processes for forming knitted textiles and the types of yarns that can be used are discussed in detail below. It is expected that a variety of knitting techniques can be implemented to achieve the described results. For example, in some aspects, a "knit stitch" can be replaced by a purl stitch to achieve comparable results with different aesthetics and / or textures. For simplicity, "knit stitch" will be discussed herein, but it is expected that functional equivalents can be substituted. Similarly, "tuck stitch" can be discussed in specific aspects, but it is also expected that optional stitching techniques can be implemented to achieve comparable results. Although relatively simple knitting structures are depicted and discussed, many warp knitting structures and weft knitting structures can be formed by, for example, flat knitting, wide tube circular knitting, narrow tube jacquard circular knitting, single jacquard circular knitting, double jacquard circular knitting, double needle bed raschel warp knitting, warp knit jacquard (warp knit jacquard) and tricot warp knitting.

[0170] It should be understood that Figures 4A-4D The cross sections depicted in are schematic, and each cross section is organized into sections to highlight potential knitted structures that may be present. Potential knitted structures that may be present in the sections of these cross sections are first described.

[0171] Figures 5A-5J Describing can exist in Figures 4A-4D Exemplary potential knit structures in various segments of the cross-section depicted in FIG. Figure 5A Depicts a knit stitch (or sometimes referred to as a Jersey stitch) structure 502 formed by a back needle bed 504. It will be appreciated that the rows of small circles associated with the back needle bed 504 represent the needles (e.g., needles 505) of the back needle bed 504, according to conventional stitch diagrams. Additionally, for the front needle bed, e.g., Figure 5B The same is true for the front needle bed 508 depicted in FIG; that is, the row of small circles associated with the front needle bed 508 represents the needles in the front needle bed 508 (eg, needle 507 ).

[0172] Figure 5B A knit stitch structure 506 formed by a front needle bed 508 is depicted. Figure 5C A float and tuck stitch structure 510 is depicted having tuck stitches formed by a front needle bed 512 and a back needle bed 514 . Figure 5D Another float and tuck stitch structure 516 is depicted having tuck stitches formed by a front needle bed 518 and a back needle bed 520 . Figure 5E A float stitch structure 522 is depicted. Figure 5F A knit and tuck stitch structure 524 is depicted having a knit stitch 524a formed by a rear needle bed 528 and a tuck stitch 524b formed by a front needle bed 526 . Figure 5G A knit and float stitch structure 530 is depicted having a knit stitch formed on a front needle bed 532 . Figure 5H A knit and float stitch structure 534 is depicted having a knit stitch formed on a rear needle bed 536 . Figure 5I A tuck and float knit structure 538 is depicted having a tuck stitch formed by a front needle bed 540 . Figure 5J A tuck and float knit structure 542 is depicted having a tuck stitch formed by a back needle bed 544 .

[0173] Now return to Textiles 300 Figures 4A-4D Typically, Figures 4A-4D The cross-sections depicted in are similarly structured due to the primary structure of the knitted textile. For example, in various aspects, there are tubular knit structures that include a knit structure primarily formed by a rear needle bed (such as in Figure 5A The knitted structure 502 depicted in FIG) and the knitted structure formed mainly on the front needle bed (such as in FIG). Figure 5B ). In addition, in such aspects, this tubular knitted structure is formed by one or more tuck and float stitch structures (such as, respectively, Figure 5C and Figure 5D , where the tuck stitches are formed by the rear and front needle beds.

[0174] This connected tubular knitted structure is Figures 4A-4D The three horizontal lines highlighted in the depicted cross section are schematically depicted. For example, Figure 4A depiction Figure 3 Cross-section 402 of textile region 306a comprising a high processing temperature polymer composition.

[0175] Figure 4A The cross section 402 schematically depicts a top segment 404, an intermediate segment 406, and a bottom segment 408. The top segment 404 and the bottom segment 408 represent the knitting structure used to form the tubular knitting structure, while the intermediate segment 406 represents the tuck and float stitch structures that connect the tubular knitting structure together. Thus, in some aspects, the top segment 404 may include a plurality of loops, a plurality of loops, and a plurality of loops. Figure 5A and Figure 5F One or more of the knitted structures 502 and 524 depicted in FIG. The bottom segment 408 may include Figure 5B The knitted structure 506 is depicted in FIG. The intermediate segment 406 may include Figure 5C and Figure 5D One or more of the knitted structures 510 and 516 depicted in .

[0176] Figure 4BDepicts a cross section 410 of a textile region 302 comprising yarn comprising a low processing temperature polymer composition. The cross section 410 includes a top segment 412, a middle segment 414, and a bottom segment 416, which may include the yarns described above with respect to Figure 4A The same knit structure is identified in the top segment 404, the middle segment 406 and the bottom segment 408 of the cross-section 402.

[0177] In some aspects, it may be desirable to bulk up the low processing temperature polymer composition in textile region 302 so as to provide a desired thickness and rigidity to the thermoformed textile region 302, for example, to form a ground-facing outsole of an article of footwear. In such aspects, textile region 302 may include repeating stitches to increase the concentration of yarns comprising the low processing temperature polymer composition relative to other textile regions, such as textile regions 304a and / or 306a. In some aspects, repeating stitches may be provided, for example, by including multiple stitch structures in any or all of the top segment 412, the middle segment 414, and the bottom segment 416 of cross-section 410. In one embodiment, multiple overlapping tuck and float stitch structures (such as in the middle segment 414 of cross-section 410) may be provided in the middle segment 414 of cross-section 410. Figure 5C 、 Figure 5D 、 Figure 5I and Figure 5J structure depicted in ).

[0178] In certain aspects, in areas of textile 300 that include a plurality of yarns comprising a low processing temperature polymer composition, such as textile region 302, anchor yarns 413 can be provided in textile 300 to help constrain the flow of the molten low processing temperature polymer composition and / or provide some flexibility to the thermoformed material. Figure 4B , anchor yarns 413 are depicted as being present in intermediate segments 414 between top and bottom segments 412, 416, respectively. In such aspects, such positioning of anchor yarns 413 can result in embedding or encapsulating anchor yarns 413 by the low processing temperature polymer composition after textile 300 is thermoformed.

[0179] Although it will Figure 4B The anchor yarn 413 in FIG is depicted as a straight line, but it should be understood that this is a schematic representation of the anchor yarn 413 and is not intended to specify any particular type of knit structure. For example, the anchor yarn 413 can be used as a thread in many different types of knit structures such as in FIG. Figure 5E and Figure 5G-5JOne or more of the structures depicted in FIG are present in textile 300. In certain aspects, the stitch selection for anchor yarn 413 can depend on the desired resistance to elongation of the material through which anchor yarn 413 extends. For example, an anchor yarn stitch that floats five stitches between tuck stitches or knit stitches will provide greater resistance to stretching of the material through which anchor yarn 413 extends than an anchor yarn stitch that floats only two or three stitches between tuck stitches or knit stitches. In such an embodiment, the different resistance to elongation between the lengths of the float is a result of the nonlinear sections (e.g., stitch loops) being more susceptible to elongation than linear segments, resulting in different amounts of resistance to elongation.

[0180] In certain aspects, when the anchor yarn 413 is used as Figure 5G-5J When one or more of the knit structures depicted in FIG. 1 are present, the anchor yarn 413 extends as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low processing temperature polymer composition because the yarn comprising the low processing temperature polymer composition also serves as a Figure 5A and Figure 5B In some aspects, anchor yarn 413 may extend as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of a yarn comprising a low processing temperature polymer composition, and may also form at least a portion of a tuck stitch and / or a knit stitch with the yarn comprising a low processing temperature polymer composition. In such aspects, the length between the tuck stitches or knit stitches is at least partially formed with the yarn comprising a low processing temperature polymer composition and the anchor yarn, and anchor yarn 413 may extend through at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising a low processing temperature polymer composition. In the same or alternative aspects, anchor yarn 413 may be sewn, for example, as a tuck stitch or a knit stitch, at loops spaced apart by an amount within 50% or within 25% of the gauge of the knitting machine used to form at least a portion of textile 300, as represented by the number of needles on a conventional needle bed.

[0181] Figure 4C and Figure 4D Portions of textile regions 302 and 306a and a cross-section of textile region 304a are depicted. For example, Figure 4C Cross-section 418 includes portion 422 corresponding to textile region 302, and portion 420 corresponding to textile region 306a. Portions 424a, 424b, 424c, and 424d correspond to sub-regions 305a, 305b, 305c, and 305d, respectively, of textile region 304a of textile 300. Figure 4C-4EThe cross-section is schematically simplified; however, it is contemplated that one or more regions and / or portions of the cross-section may include a variety of fibers and / or yarns in different configurations and concentrations. For example, textile zone 424c in intermediate segment 428 may include both fibers and / or yarns comprising a low processing temperature polymer composition and fibers and / or yarns comprising a high processing temperature polymer composition, but in a configuration / concentration that is different from the configuration / concentration found in textile zones 424b and / or 424d of intermediate segment 428. In other words, various construction techniques allow for combinations of fibers and / or yarns in a given segment and textile zone through variations in the methods of combining, including, attaching, depositing, or applying fibers and / or yarns (e.g., stitch selection) that allow for variations in fiber and / or yarn concentration at the segment level and / or textile zone level.

[0182] Figure 4C The cross section 418 includes the above Figure 4A and Figure 4B The cross-section 402 and 410 of FIGURE 400 are similar to the cross-sections 402 and 410 discussed above. Thus, the cross-section 418 includes a top segment 426, an intermediate segment 428, and a bottom segment 430. The top segment 426, the intermediate segment 428, and the bottom segment 430 may each include the same type of generally tubular knitted structure discussed above with reference to FIGURE 400. Figure 4A The top segment 404 , the middle segment 406 , and the bottom segment 408 of the cross-section 402 have the same knit structure discussed above.

[0183] exist Figure 4C In cross-section 418, portions 422 and 424a comprise knitted structures made with yarns comprising a low processing temperature polymer composition, while portions 420, 424d, and 424c comprise knitted structures made with yarns comprising a high processing temperature polymer composition. However, as provided above, it is contemplated that a combination of fibers and / or yarns based on different stitching techniques may be implemented in various portions to achieve a transition from one primary material to another.

[0184] Section 424b comprises a tubular knit structure made from yarn comprising a high processing temperature polymer composition; however, the knit structure formed by the front and rear needle beds (with yarn comprising a high processing temperature polymer composition) is connected via float and tuck stitches (or equivalent effective stitches) from yarn comprising a low processing temperature polymer composition. This section 424b illustrates how the low processing temperature polymer composition, when melted and solidified, can physically connect the two outer knit layers together via a plaque or film of thermoforming material after the textile 300 undergoes thermoforming. In such an aspect, a wearable article having this type of tubular knit structure that has been thermoformed and connected via an integral thermoforming material would primarily comprise typical knit yarn layers connected together via a thermoforming film on opposite outer surfaces of the textile. Such a structure can be utilized to provide waterproofing / water resistance or other weather proofing to a wearable article while still maintaining the aesthetics and feel of a typical knitted article.

[0185] and Figure 4C The cross section 418 is the same as that of Figure 4D Cross-section 432 includes portion 436 corresponding to textile region 302 and portion 434 corresponding to textile region 306a. Portions 438a, 438b, 438c, and 438d correspond to sub-regions 305a, 305b, 305c, and 305d, respectively, of textile region 304a of textile 300.

[0186] Figure 4D The top region 440, the middle region 442 and the bottom region 444 of the cross section 432 may respectively include the above reference Figure 4A The top segment 404, the middle segment 406, and the bottom segment 408 of the cross-section 402 may be constructed using the same knitted structure discussed above to provide the same type of generally tubular structure.

[0187] In an exemplary aspect, Figure 4DThe cross-section 432 of the portion 434 and 438d comprises a knitted structure comprising a yarn comprising a high processing temperature polymer composition, while the portions 436, 438a and 438b comprise a knitted structure made of a yarn comprising a low processing temperature polymer composition. However, as also provided above, it is contemplated that a primary but non-exclusive material selection may be used. For example, in portion 438b, a yarn comprising a high processing temperature polymer composition may be present in the intermediate region 442 to assist in the transition of the material. The concentration of the yarn comprising a high processing temperature polymer composition in portion 438b may be less than the concentration of the yarn in portion 438c present in the same intermediate region 442. For example, portion 438b may have at least 5 wt%, 10 wt% or 25 wt% less yarn comprising a high processing temperature polymer composition than the yarn comprising a high processing temperature polymer composition in portion 438c present in the same intermediate region 442.

[0188] Section 438c comprises a tubular structure comprising yarns comprising a low-processing-temperature polymer composition, the yarns comprising the low-processing-temperature polymer composition being connected via float and tuck stitches from yarns comprising a high-processing-temperature polymer composition. In such aspects, after thermoforming, this section 438c can encapsulate the yarns comprising the high-processing-temperature polymer composition within a panel of melted and cooled thermoform material. In certain aspects, such a structure can provide a degree of flexibility to an otherwise rigid thermoform material.

[0189] For example, Figure 4E Describing and Figure 4D The cross-section 432 is the same as the cross-section 446, except that the anchor yarn 448 has been added to at least a portion of the area including the yarn comprising the low processing temperature polymer composition. In certain aspects, the anchor yarn 448 can have the same cross-section 446 as described above with respect to Figure 4B Any or all of the characteristics discussed for the anchor yarn 413. For example, the anchor yarn may be incorporated into a Figure 5E and Figure 5G-5J In one or more textiles having the knitted structure depicted.

[0190] If you can Figure 4E As seen in FIG, anchor yarn 448 extends from portion 450 corresponding to cross-section 446 of textile region 302 and into portions 452a and 452b corresponding to sub-regions 305a and 305b of textile region 304a. Figure 4E The figure shows that yarns comprising low processing temperature polymer compositions are also present (e.g., as Figure 5A and Figure 5BIn some aspects, the anchor yarn 448 can extend along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low processing temperature polymer composition as a float stitch. In addition, in some aspects, the anchor yarn 448 can extend along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low processing temperature polymer composition as a float stitch, and can also form at least a portion of a tuck stitch and / or a knit stitch with the yarn comprising the low processing temperature polymer composition. In such aspects, the anchor yarn 448 can extend between the tuck stitch or knit stitch at least partially formed with the yarn comprising the low processing temperature polymer composition and the anchor yarn 448. In the same or alternative aspects, anchor yarn 448 can be stitched, for example, at loops spaced apart by needle count, at an amount within 50% or within 25% of the gauge of a knitting machine used to form at least a portion of textile 300, such as tuck stitches or knit stitches.

[0191] As discussed above, in one or more aspects, anchor yarn 448 may extend from textile region 302 into textile region 304a and toward textile region 306a. In such aspects, anchor yarn 448 may not extend as far from textile region 302 into textile region 304a and toward textile region 306a as the yarn comprising the low processing temperature polymer composition extends into region 304a and toward textile region 306a because there is less need to constrain flow and / or provide flexibility to the thermoformed material during thermoforming because yarn comprising the high processing temperature polymer composition from region 306a is also present in textile region 304a.

[0192] For example, in Figure 4E In cross-section 446, the anchor yarn extends from portion 450 (corresponding to a portion of textile region 302) and into portion 452b (corresponding to sub-region 305b of textile 300). Furthermore, cross-section 446 illustrates that top segment 456 and bottom segment 460 of cross-section 446 show yarn comprising a low processing temperature polymer composition extending from portion 450 and toward portion 454 (corresponding to textile region 406a) into portion 452c, beyond the extension of anchor yarn 448 in the same direction. However, in intermediate segment 458, in portions 452c and 452d, yarn comprising a high processing temperature polymer composition is present, which can provide flexibility to the thermoformed textile and / or restrict flow during thermoforming.

[0193] As discussed above, in certain aspects, when textile 300 is a knitted textile, Figures 4A-4E The cross-section of the textile depicted in is depicted as having a top segment, a bottom segment, and a middle segment, wherein the top segment and the bottom segment can form a tubular knit structure having a top knit layer and a bottom knit layer (and wherein the tuck stitches or other connecting stitches present in the middle segment can also form a tubular knit structure or portion of a substantially knit structure). In such an aspect, each of the top outer knit layer and the bottom outer knit layer can include a plurality of interconnected courses.

[0194] In addition, as in Figure 3 As can be seen in textile 300 of FIGURE 304, in region 304a, subregions 305a-d have at least one staggered interface, such as staggered interface 306. Staggered interfaces, such as staggered interface 306, provide staggered or nonlinear transitions between subregions of textile 300 along the width w of textile. In such aspects, when textile 300 is thermoformed, these staggered interfaces provide a more refined, integrated transition between the rigid region formed by the low-processing-temperature polymer composition in textile region 302 and the flexible, tough region formed by yarns comprising the high-processing-temperature polymer composition in textile region 306a. In various aspects, this refined, integrated transition, provided at least in part by the staggered interfaces, can increase the durability or tear resistance of thermoformed textile 300, as opposed to similar textiles that have a linear abrupt transition between an integral rigid material and a flexible material.

[0195] In aspects where the textile 300 is a knitted textile, the interleaving interface 306 can depict how different rows of yarn on a top outer knit layer or a bottom outer knit layer can have different amounts of loops (or general stitch selections) of yarn comprising a low processing temperature polymer composition and / or yarn comprising a high processing temperature polymer composition. Because a textile can have multiple layers (e.g., top, middle, and bottom), the interleaving interface can be addressed in any combination of layers and is not limited to the exposed or depicted surface. Instead, as provided herein and as intended, the transition from a first primary material (e.g., fibers and / or yarns comprising a high processing temperature polymer composition) to a second primary material (e.g., fibers and / or yarns comprising a low processing temperature polymer composition) that forms the textile can occur exclusively at an intermediate layer or at an intermediate layer in combination with one or more outer layers. It should be understood that for purposes of the following discussion of the knit layer, it is assumed that when Figure 3 When textile 300 is a knitted textile, the view of textile 300 depicts the top layer. In addition, the same description also applies to the bottom knitted layer.

[0196] Figure 6 An exemplary portion 600 of the top layer of textile 300 is schematically depicted, showing a portion of interlaced interface 306. Figure 6 As can be seen in section 600, a first row 602 of coils is interconnected to a second row 604 of coils. It should be understood that although Figure 6 Only two interconnected rows are depicted in , but more than two rows may be interconnected in the top knit layer of textile 300. As used herein, "interconnected" when referring to interconnected rows refers to how at least a portion of a stitch in a first row of stitches is tied to at least a portion of a stitch in a second row of stitches. Figure 6 , wherein individual loops from the second course 604 are intertwined with individual loops from the first course 602. As used herein, "intertwined" refers to how loops from one course can be looped around loops of another course, such as in a knit stitch, and also refers to how one loop can have another section of yarn drawn through the loop (or through the loop and around the yarn forming the loop) to form a second loop, such as in a crochet process.

[0197] As can be seen in portion 600 of textile 300, both first course 602 and second course 604 include two types of yarns: first yarn 606, which may include a high processing temperature polymer composition, and second yarn 608, which may include a low processing temperature polymer composition. Although only two courses are depicted in portion 600, it should be understood that the top knit layer of textile 300 may include any number of courses. In various aspects, each of the courses present in the top knit layer of textile 300 may include two or more types of yarns, such as Figure 6 Depicted in.

[0198] As in Figure 6 As can be seen in FIG, each course, e.g., first course 602 and second course 604, can extend from textile area 302 to textile area 306a (in various aspects, each of the courses can extend from textile area 306a to textile area 306b). In certain aspects, as in Figure 6 As can be seen in FIG, second yarn 608 in both first course 602 and second course 604 can extend from textile region 302 into textile region 304a. In the same or alternative aspects, first yarn 606 can extend from textile region 304a into textile region 306a. It should be understood that although schematic portion 600 of textile 300 depicts each loop as having only a single yarn, more than one yarn can be present at one or more loops (e.g., another yarn can be present at the same loop). Figure 6The loops of part 600 together form a tuck stitch), such as Figures 4A-4E depicted in cross section.

[0199] As discussed above, portion 600 of the outer knit layer of textile 300 illustrates at least a portion of interlaced interface 306. In certain aspects, interlaced interface 306 (and any other interlaced interfaces) can be formed by the same type of yarn in multiple courses extending different distances from one region (or sub-region) into the next region or sub-region. For example, as in Figure 6 As can be seen in FIG, in first course 602, second yarn 608 extends from textile region 302 into textile region 304a and toward textile region 306a further than second yarn 608 extends from textile region 302 into textile region 304a and toward textile region 306a. In such aspects, the different distances that second yarn 608 extends into textile region 304a results in different amounts of loops of second yarn 608 in each of first course 602 and second course 604, which can change the concentration of yarns in a given zone / sub-zone. Thus, in such aspects, within textile region 304a, the loops of second yarn 608 in first course 602 can interlace with the loops of second yarn 608 in first course 602 at a first wale, while at a second wale 610, second yarn 608 in first course 602 can interlace with the loops of first yarn 606 in first course 602. In the same or alternative aspects, within textile region 304a , first yarn 606 in first course 602 may be interlocked with first yarn 606 in second course 604 at third wale 612 .

[0200] In one or more aspects, a staggered interface, such as staggered interface 306, can result in adjacent courses of the plurality of courses in textile 300 having different numbers of stitches of yarn comprising a low processing temperature polymer composition and yarn comprising a high processing temperature polymer composition. Figure 6 As can be seen in portion 600 of the upper knit layer of textile 300 depicted in FIG, in at least a portion of textile region 304a, first course 602 has a different number of stitches of first yarn 606 and / or second yarn 608 than second course 604. Furthermore, in the same or alternative aspects, within at least a portion of textile region 304a, adjacent wales can have one or more stitches of different yarns. For example, as Figure 6 As illustrated in portion 600 of the upper knit layer of textile 300 in FIG. 1 , wale 610 includes loops of both first yarn 606 and second yarn 608 , while wale 612 includes loops of first yarn 606 .

[0201] As discussed above, the textiles described herein, which may include fibers and / or yarns comprising a low processing temperature polymer composition, may be thermoformed to impart structural properties to an article of wear. Furthermore, as discussed above, the thermoforming process may cause at least a portion of the low processing temperature polymer composition present in the textile to melt or deform and subsequently solidify.

[0202] Figure 7A Schematic depiction of the process before thermoforming Figure 3 3. A portion 700 of textile region 304a of an upper knit layer of textile 300 is shown. Portion 700 includes a first course 702 and a second course 704 having a first yarn 708 comprising a high processing temperature polymer composition. Portion 700 also includes a third course 706 of second yarn 710 comprising a low processing temperature polymer composition. In such an aspect, third course 706 of loops of second yarn 710 can be interconnected, e.g., interlaced, to first course 702 and second course 704 having first yarn 708.

[0203] Figure 7B Depicted is portion 700 after exposure to a thermoforming process. Figure 7A and Figure 7B As can be seen, the second yarn 710 comprising the low processing temperature polymer composition is thermoformed from the yarn material into a molten yarn component 712. In certain aspects, the heating step of the thermoforming process at least partially causes the low processing temperature polymer composition in the second yarn 710 to melt and flow, and then subsequently solidify into the molten yarn component 712 by completing the thermoforming process.

[0204] In various aspects, such as Figure 7A and Figure 7B As can be seen in the figure, the hot forming process has also been used Figure 3 At least a portion of the knit structure of portion 700 of the upper knit layer of textile 300 is transformed. For example, Figure 7A The courses 702, 704, and 706 depicted in FIG have been transformed such that portion 700 no longer includes courses of interconnected loops of yarn comprising a low processing temperature polymer composition and yarn comprising a high processing temperature polymer composition, at least in part due to the transformation of yarn 710 in third course 706 into melted yarn component 712. Figure 7B As can be seen in the figure, although the hot forming process can eliminate Figure 3 The interconnected loops in the portion 700 of the upper knit layer of the textile 300, but the remaining courses 702 and 704 can be connected by melted yarn components 712. In such an aspect, Figure 3This portion 700 of the upper knit layer of textile 300 can fix the positions of courses 702 and 704 relative to each other, as opposed to when courses 702 and 704 are interconnected via course 706 prior to thermoforming. Moreover, in such an aspect, top portions 714 of the stitches of first course 702 can still freely interconnect with other courses of yarn, allowing an individual to adjust the level of stiffness and / or three-dimensional shaping provided by textile area 304a.

[0205] Figure 8 Depicts the Figure 7B The cutting line 8 shown in the figure Figure 3 A cross section of a portion 700 of the upper knitted layer of the textile 300. Figure 8 , at least a portion of the first yarn 708 can be encapsulated within the melted yarn component 712. Depending on the conditions used during the thermoforming process, the melted yarn component 712 can solidify into a film-like structure that surrounds at least a portion of the loops of the first course 702 and the second course 704 of the first yarn 708 comprising the high processing temperature polymer composition.

[0206] As in Figure 7B and Figure 8 As can be seen in the aspects depicted in , the first yarn 708 comprising the high processing temperature polymer composition does not melt or deform after exposure to the thermoforming process. Additionally, in certain aspects, the first yarn 708 can contain a dye 716 (depicted as spots within the first yarn 708) that does not leach out after exposure to the thermoforming process. For example, as in Figure 7B and Figure 8 As can be seen in the diagram, there is no visible leaching of dye 716 from the first yarn 708 into adjacent areas of the melted yarn component 712, such as adjacent area 718. In certain aspects, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, or at least 99 wt% of the dye 716 remains within the first yarn 708 or remains within the first yarn 708. Figure 3 In the same or alternative aspect, after thermoforming, there is no visible leaching of the dye into the upper knit layer of the textile 300. Figure 3 Portion 700 of the upper knit layer of textile 300 is incorporated into any additional material with which the final article of wear is associated.

[0207] Figure 9A and Figure 9B The following aspects are depicted, among which Figure 3 The portion 700 of the upper knit layer of the textile 300 is exposed to a thermoforming process that only results in deformation of the low processing temperature polymer composition of the second yarn 710 without eliminating Figure 7AAs used herein, "deform" and "deforming" in the context of a thermoforming process for a knitted textile refer to changing the structure of the yarn so that the yarn does not melt and flow in such a manner as to substantially eliminate the knit structure of the textile (e.g., eliminating one or more interconnected loops or nested rows).

[0208] Figure 9A Depicted along cutting line 9A-B prior to the thermoforming process Figure 3 a cross-section of a portion 700 of the upper knit layer of the textile 300, and Figure 9B Depicted is the same cross section after the thermoforming process. Figure 9B As can be seen in FIG, after exposure to the thermoforming process, the second yarn 710 in the third course 706 has a modified yarn structure 710a, while the structure of the first yarn 708 has not been modified. In this aspect, the second yarn 710 in the third course 706 remains interlaced with the first course 702 and the second course 704, and remains Figure 3 The overall knit structure of portion 700 of the upper knit layer of textile 300 .

[0209] In certain aspects, this altered yarn structure 710a can cause the second yarn 710 to be mechanically coupled or physically bonded to another yarn, such as the first yarn 708 (or another portion of the second yarn 710). In certain aspects, during the thermoforming process, the yarn 710 may have been exposed to temperatures above the glass transition temperature, T, of the low processing temperature polymer composition. g In one embodiment, the second yarn 710 is exposed to an elevated temperature, but not above the melting temperature of the low processing temperature polymer composition. In such an aspect, when the second yarn 710 is exposed to such an elevated temperature, the second yarn can soften and become ductile but not melt, allowing the yarn to slightly mold around at least a portion of an adjacent yarn, such as the first yarn 708, and upon cooling, this altered yarn structure can be mechanically locked in place to physically bond to the adjacent yarn.

[0210] Figures 10A-10C Depicted before and after thermoforming Figure 3 Portion 1000 of the upper knit layer of textile region 302 of textile 300 . Figure 10A Three courses 1010, 1012, 1014 of yarn comprising a low processing temperature polymer composition are depicted. Figure 10A Also depicted is the presence of anchor yarn 1016 extending as float stitch 1016a and tuck stitch 1016b.

[0211] Figure 10B Depicted after exposure to the thermoforming process Figure 3The same portion 1000 of the upper knit layer of the textile region 302 of the textile 300. Figure 10B As can be seen in FIG, the nested rows of yarns 1010, 1012, and 1014 have been transformed into melted yarn components 1018. Figure 10B and Figure 10C (It is along Figure 10B As can be seen in the cross section of cut line 10C of FIG, the anchor yarn 1016 has retained its yarn structure and is now encapsulated within the melted yarn component 1018. It should be understood that although Figure 10B The anchoring yarn 1016 is depicted as being encapsulated within the melted yarn component 1018, but it is also contemplated that the anchoring yarn 1016 can be at least partially embedded within the melted yarn component 1018 such that at least a portion of the anchoring yarn 1016 is not completely covered in the melted yarn component 1018.

[0212] As discussed above, in certain aspects, the textiles described herein may include knitted textiles, for example, such as in Figures 4A-10C . A knitted upper for an article of footwear is an exemplary knitted textile. In such aspects, at least a portion of the knitted upper of the article of footwear, and in some aspects substantially the entire upper, can be formed from a knitted textile. The knitted textile can additionally or alternatively form another element of the article of footwear, such as, for example, a midsole or a ground-facing outsole. The knitted textile can have a first side that forms an inner surface of the upper (e.g., facing a cavity of the article of footwear) and a second side that forms an outer surface of the upper. The upper comprising the knitted textile can generally surround the cavity so as to generally enclose a person's foot when the article of footwear is in use. The first side and the second side of the knitted textile can exhibit different characteristics (e.g., the first side can provide wear resistance and comfort, while the second side can be relatively rigid and provide water resistance).

[0213] In various aspects, the knitted textile can be formed as an integral one-piece element during a knitting process such as a weft knitting process (e.g., with a flat knitting machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process can generally form the knitted structure of the knitted textile without requiring a large number of post-knitting processes or steps. Alternatively, two or more parts of the knitted textile can be formed separately and then attached. In some embodiments, the knitted textile can be shaped after the knitting process to form and maintain the desired shape of the upper (e.g., by using a foot-shaped shoe last). The shaping process can include attaching the knitted textile to another object (e.g., a strobel) by sewing, by using an adhesive, or by another suitable attachment process, and / or attaching one part of a knitted component to another part of a knitted component at a seam.

[0214] Forming a shoe upper with a knitted textile can provide advantageous characteristics for the shoe upper, including but not limited to a particular degree of elasticity (e.g., expressed as Young's modulus), breathability, flexibility, strength, moisture wicking, weight, and wear resistance. These characteristics can be achieved by selecting a particular single-layer knit structure or a multi-layer knit structure (e.g., a rib knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed from a particular material (e.g., a polyester material, a monofilament material, or an elastic material such as spandex), by selecting a yarn of a particular size (e.g., denier), or a combination thereof.

[0215] Knitted textiles can also provide desirable aesthetic features by incorporating yarns of different colors or other visual features arranged in a particular pattern. The yarn and / or knit structure of a knitted textile can be varied at different locations, such that a knitted component has two or more portions with different properties (e.g., a portion forming the throat area of ​​a shoe upper can be relatively elastic, while another portion can be relatively inelastic). In some aspects, a knitted textile can incorporate one or more materials having properties that change in response to a stimulus (e.g., temperature, moisture, electric current, magnetic field, or light).

[0216] In some aspects, a knitted textile may include one or more yarns or strands that are at least partially inlaid or otherwise inserted into the knit structure of the knitted textile during or after the knitting process, referred to herein as "strands." The strands may be substantially inelastic so as to have a substantially fixed length. The strands may extend through multiple horizontal rows of the knitted textile or through channels within the knitted textile and may limit the stretching of the knitted textile in at least one direction. For example, the strands may extend generally from the bite line of the upper to the throat area of ​​the upper to limit the stretching of the upper in a lateral direction. The strands may form one or more eyelets for receiving shoelaces and / or may extend around at least a portion of the eyelets formed in the knit structure of the knitted textile.

[0217] In an alternative aspect, the textiles described herein may comprise nonwoven textiles. The nonwoven textiles described herein may be produced by any conventional method, such as any conventional mechanical, chemical, or thermal method for binding fibers together, including needle entangling and water entangling.

[0218] Figures 11A-11C The following aspects are depicted, among which Figure 3 The textile 300 is a non-woven textile and undergoes a thermoforming process. Figure 11A yes Figure 3 Schematic depiction of portion 1100 of textile region 304a of textile 300. Figure 11A , portion 1100 includes first grouping 1110 of first fibers 1116 comprising a high processing temperature polymer composition, second grouping 1112 of first fibers 1116, and third grouping 1114 of second fibers 1118 comprising a low processing temperature polymer composition. It should be understood that portion 1100 of textile 300 is schematic and that the placement and spacing of first fibers 1116 and second fibers 1118 may vary in the textile.

[0219] Although Figures 11A-11C Not depicted in FIG, but in aspects where textile 300 is a nonwoven textile, the one or more interfaces between different portions of different fibers can also include one or more staggered interfaces, such as, for example, staggered interface 306. In such aspects, staggered interface 306 can depict how the transition between regions or sub-regions having different concentrations of fibers comprising a low processing temperature polymer composition and / or fibers comprising a high processing temperature polymer composition does not follow the same pattern as described above. Figure 3 The width w of textile 300 occurs in a linear manner.

[0220] Now return to Figures 11A-11C and in particular Figure 11C In aspects where the thermoforming process causes melting and flow of the low processing temperature polymer composition in the second fibers 1118, the second fibers 1118 have been converted to the non-fibrous material 1120, while the first fibers 1116 have not been converted and therefore remain in fibrous form. In such aspects, the non-fibrous material 1120 can connect the first grouping 1110 of the first fibers 1116 with the second grouping 1112 of the first fibers 1116. Figure 11C A cross-section along cut line 11C is shown, which in certain aspects illustrates how at least a portion of the first fibers 1116 can be encapsulated within the non-fibrous material 1120. In various aspects, it is contemplated that at least a portion of the first fibers 1116 can be at least partially embedded within the non-fibrous material 1120 such that the first fibers 1116 are not completely encapsulated by the non-fibrous material 1120.

[0221] Although not depicted in the figures, in some aspects, upon exposure to the thermoforming process, the second fibers 1118 may not melt and flow, but instead may deform and change shape. Figure 9A and Figure 9B This deformation of the fiber or yarn is depicted in FIG. Figure 9A and Figure 9BAs with the deformation of fibers or yarns discussed above, in certain aspects, a second fiber can be deformed and molded over another first fiber or second fiber (or the same fiber) and mechanically coupled or physically bonded to that fiber.

[0222] Process used for manufacturing

[0223] Certain conventional thermoforming processes include selectively thermoforming only a portion of an article, for example, by masking portions of the article that are not desired to be exposed to the thermoforming process, or using tooling that contacts or covers only a portion of the article. However, such conventional methods result in a time and energy intensive manufacturing process because multiple steps are required to mask and unmask portions of the article before and after the thermoforming process, or multiple sets of tooling are required. Other conventional thermoforming processes include thermoforming the article components prior to assembly into the article. This conventional process is also a time and resource intensive process because multiple steps and machines are required to individually form the article components prior to assembly of the article. In addition, articles formed from several separate components produce multiple seams where the separate components meet, thereby providing weaknesses in the article, a less natural feel to the wearer, and / or actual discomfort or harm to the wearer.

[0224] The manufacturing process disclosed herein solves one or more of the aforementioned problems. The manufacturing process disclosed herein utilizes one or more of the formed parts, films, textiles, yarns and fibers disclosed herein, wherein the one or more formed parts, films, textiles, yarns and fibers contain at least one low processing temperature polymer composition as disclosed herein. The manufacturing process disclosed herein also utilizes one or more of the formed parts, films, textiles, yarns and fibers disclosed herein, wherein the one or more formed parts, films, textiles, yarns and fibers contain at least one high processing temperature polymer composition as disclosed herein. The disclosed manufacturing process includes a thermoforming step, wherein the low processing temperature polymer composition is softened or melted, and the high processing temperature polymer composition does not melt or soften. The thermoforming is carried out within a temperature range lower than at least one of the following properties of the high processing temperature polymer composition: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m Thermoforming can be performed at temperatures below the creep relaxation temperature (T cr Thermoforming can be carried out in a temperature range below the Vicat softening temperature (T vs Thermoforming can be carried out in a temperature range below the heat deformation temperature (T hdThermoforming can be carried out at a temperature below the melting temperature (T m ) within the temperature range.

[0225] For example, in certain aspects, as discussed further below, the specific and selective incorporation of low processing temperature polymer compositions and high processing temperature polymer compositions into articles provides a way to program structural features into articles that can be formed after thermoforming. In some aspects, an article can include a textile comprising a low processing temperature polymer composition and a high processing temperature polymer composition, such as a textile comprising at least one of a plurality of fibers or yarns, wherein at least a portion of the textile comprises a low processing temperature polymer composition. In another aspect, an article can include a first forming part, film, textile, yarn, or multiple fibers comprising a low processing temperature polymer composition; and a second forming part, film, textile, yarn, or multiple fibers comprising a high processing temperature polymer composition, such as a knitted upper of an article of footwear comprising a high processing temperature polymer composition and a film comprising a low processing temperature polymer composition. In another aspect, an article can include an aggregation of parts, at least a portion of which comprises a low processing temperature polymer composition and a high processing temperature polymer composition to which the disclosed thermoforming process has been applied.

[0226] In various aspects, because such structural features are built into the article based on the location of the low processing temperature polymer composition and the high processing temperature polymer composition in the article, after thermoforming, these structural features become integrated with each other, allowing for a more natural feel for the wearer or user. For example, a knitting program for an electronic knitting device can be used to determine the location of the structural features. However, as already mentioned, the manufacturing processes (and the advantages associated with these processes) are not limited to the use of the textiles disclosed herein. For example, the process of forming structural features in the disclosed article can utilize a film comprising a low processing temperature polymer composition, wherein a textile comprising a high processing temperature polymer composition is also contemplated as a process for programming structural features into the disclosed article. Alternatively, the process of effectively programming structural features into the disclosed article can utilize a formed part comprising a low processing temperature polymer composition together with a textile comprising a high processing temperature polymer composition.

[0227] In addition, the selective incorporation of low processing temperature polymer compositions and high processing temperature polymer compositions into articles provides a streamlined manufacturing process. For example, in some aspects, the entire article can be formed by arranging components and exposing the arranged components to a thermoforming process, wherein the components comprising the low processing temperature polymer composition melt, flow, and resolidify into structural features of greater rigidity, while the components comprising the high processing temperature polymer composition do not deform during the thermoforming process. In such aspects, this allows the entire article to be exposed to the thermoforming process without the need to mask or protect areas where the manufacturer does not wish to melt, flow, and resolidify, thereby producing a more time- and energy-efficient manufacturing process. In addition, in some cases, using the article described herein in the manufacturing process described herein also allows for providing several different structural features or other advantageous features in the article without the need to combine separate components into the final article, because such features can be built into the article at the textile level using the low processing temperature polymer composition and the high processing temperature polymer composition.

[0228] In various aspects, the thermoforming process occurs at a temperature below that at which the yarn or fiber has been dyed (e.g., below that at which the yarn or fiber comprising the high processing temperature polymer composition is dyed), such that such dye does not leach out of the yarn or fiber and into the surrounding low processing temperature polymer composition during the thermoforming process. Thus, to form the various textiles and articles described herein, the melting temperature of the low processing temperature polymer composition in the first yarn or fiber is lower than the temperature used to dye a second yarn or fiber, such as a second yarn or fiber comprising a high processing temperature polymer composition.

[0229] Furthermore, compositions having a melting temperature in this range (i.e., a melting temperature below the temperature at which the second yarn or second fiber comprising the high processing temperature polymer composition is dyed) present another problem because many of the low processing temperature polymer compositions tested that were evaluated did not produce yarns suitable for use in commercial knitting equipment because the yarns appreciably shrank when exposed to the temperatures at which commercial knitting equipment typically operates.

[0230] In certain embodiments, the low processing temperature polymer compositions described herein have melting characteristics and acceptable levels of shrinkage when present in yarn and used in commercial knitting equipment. For example, in certain aspects, the low processing temperature polymer compositions can exhibit a melting temperature T of 135° C. or less. m .

[0231] In certain aspects, thermoforming the articles and textiles described herein can be performed within a temperature range that causes the low processing temperature polymer composition to melt or deform (and subsequently solidify), while the high processing temperature polymer composition does not melt and / or deform, thereby maintaining the structure of the element, such as yarn or fiber, comprising the high processing temperature polymer composition. In such aspects, this thermoforming process can produce a more rigid structural component (such as an outsole portion of a shoe) that is integrally connected to a less rigid portion of the article or textile, such as an upper portion of a shoe having yarn or fiber comprising the high processing temperature polymer composition.

[0232] Therefore, in one aspect, a process for manufacturing an article is provided. The article can be a component of an article of footwear, a component of an article of clothing, or a component of an article of sporting equipment. For example, the component of the article of sporting equipment can be a component of a hat, a component of a bag, a component of a ball, and a component of protective equipment. The process includes receiving an article, wherein the article includes a first forming part, a first film, a first textile, a first yarn, or a first fiber; and a second forming part, a second film, a second textile, a second yarn, or a second fiber. The first forming part, the first film, the first textile, the first yarn, or the first fiber comprises a low processing temperature polymer composition, which comprises one or more first thermoplastic polymers, wherein the second forming part, the second film, the second textile, the second yarn, or the second fiber comprises a high processing temperature polymer composition, which comprises one or more second thermoplastic polymers, and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than the low processing temperature polymer composition. m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs The process further comprises placing at least a portion of the article on the molding surface. Furthermore, while at least a portion of the article is on the molding surface, the process comprises raising the temperature of the entire article to a temperature above the melting temperature T of the low processing temperature polymer composition. m and below 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs After raising the temperature of the entire article, while at least a portion of the article is held on the molding surface, the temperature of the entire article is lowered to below the melting temperature T of the low processing temperature polymer composition. m temperature, thereby forming a thermoformed article.

[0233] In another aspect, a process for making an upper for an article of clothing is provided. The process includes knitting a first course, wherein knitting the first course includes interweaving a first yarn with a second yarn. The first yarn includes a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn includes a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits a melting temperature (T) greater than the low processing temperature polymer composition. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m ). In some aspects, at least a portion of the first yarn is a warp yarn; and wherein at least a portion of the second yarn is a weft yarn. In an alternative aspect, at least a portion of the first yarn is a weft yarn; and wherein at least a portion of the second yarn is a warp yarn.

[0234] In yet another aspect, a process for manufacturing an upper for a shoe is provided. The process includes receiving an upper comprising a first yarn and a second yarn. The first yarn comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits a melting temperature (T) greater than the low processing temperature polymer composition. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m ). In the first portion of the upper, at least one of the first yarn and the second yarn forms a plurality of interconnected loops. The process further includes placing the upper on a shoe last. In addition, the process includes heating the entire upper to a temperature greater than the melting temperature (T) of the low processing temperature polymer composition while the entire upper is on the shoe last. m ) and less than at least one of the following of the high processing temperature polymer composition: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m After heating the entire shoe upper, the entire shoe upper is cooled to a temperature below the melting temperature T of the first yarn composition while the entire shoe upper is on the shoe last. m temperature, thus forming a thermoformed upper.

[0235] In yet another aspect, a process for manufacturing an upper for a shoe is provided. The process includes receiving an upper comprising one or more first fibers, first yarns, first films, or first forming parts comprising a low processing temperature polymer composition; and one or more second fibers, second yarns, second films, or second forming parts comprising a high processing temperature polymer composition. Each of the one or more first fibers, first yarns, first films, or first forming parts comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. Each of the one or more second fibers, second yarns, second films, or second forming parts comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition of the one or more second fibers exhibits a melting temperature (T) greater than the low processing temperature polymer composition of the one or more first fibers. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m The shoe upper includes a ground-facing outsole region, and at least a portion of the one or more first fibers is present on the ground-facing outsole region. The process further includes placing the shoe upper on a shoe last such that at least a portion of the ground-facing outsole region covers at least a portion of a bottom of the shoe last. The process further includes heating the entire shoe upper to a temperature greater than the melting temperature, T, of the low processing temperature polymer composition of the one or more first fibers while the entire shoe upper is on the shoe last. m and less than at least one of the following of the high processing temperature polymer composition of the one or more second fibers: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m After heating the entire upper, the entire upper is cooled to a temperature below the melting temperature (T ) of the low processing temperature polymer composition of the one or more first fibers while the entire upper is on the last. m ) temperature, thereby forming a thermoformed upper.

[0236] In yet another aspect, a process for making a knitted upper for an article of footwear is provided. The process includes knitting a first course comprising loops of a first yarn and loops of a second yarn. The first yarn comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits a melting temperature (T) greater than the low processing temperature polymer composition. m ) at least one of the following: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m The process further includes knitting a second course comprising loops of the first yarn and loops of the second yarn. At least a portion of the first course and at least a portion of the second course form a plurality of interconnected loops.

[0237] The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless expressly identified as an order of performance. Additional or alternative steps may be employed.

[0238] Exemplary Pre-Thermoforming and Thermoforming Processes

[0239] As discussed above, in certain aspects, the articles and textiles described above, e.g. Figure 3 The textile 300 can form at least a portion of an article of wear, such as an article of footwear. In such an aspect, the textile can form an upper for the article of footwear, wherein the upper includes a ground-facing outsole portion.

[0240] In some aspects, the article or textile can be combined with additional materials that form an upper for an article of footwear. For example, in one or more aspects, the textile can be combined or layered with one or more of an ankle collar lining, ankle collar foam, an upper lining, or an upper foam layer. In some aspects, one or more of these additional materials can be secured to the textile, such as by knitting, stitching, or adhering, prior to thermoforming the textile.

[0241] In certain aspects, to provide additional comfort and / or support to a wearer of an article of footwear formed at least in part from the textiles described herein, an internal support device or internal support base plate may be provided. Figure 12 and Figure 13An article of footwear 1200 is depicted that includes a base plate 1210. The article of footwear 1200 includes a textile 1212 that forms an upper 1214 having a ground-facing outsole portion 1216. In certain aspects, as in Figure 13 This can be best seen in Figure 13 A cross-section of article of footwear 1200 is depicted, with base plate 1210 positioned within interior portion 1218 of article of footwear 1200 and contacting interior surface 1220 of textile 1212. In certain aspects, base plate 1210 can comprise a polymeric material, such as a high processing temperature polymeric material, e.g., a polyether block amide, having a melting temperature or a deformation temperature above a temperature range within which a thermoforming process is performed, such that the polymeric material does not melt or deform during the thermoforming process described herein.

[0242] In various aspects, heel counter 1222 can be positioned on interior portion 1218 of upper 1214 or on exterior portion of upper 1214 for support of the wearer's heel, or can form a portion of upper 1214. In various aspects, similar to base plate 1210, heel counter 1222 can comprise a polymer material, such as a high processing temperature polymer material, for example, a polyether block amide that is capable of not melting or deforming when exposed to a thermoforming process. In various aspects, similar to base plate 1210, heel counter 1222 can include a portion formed from a low processing temperature polymer composition in addition to a portion formed from a high processing temperature polymer composition.

[0243] In some aspects, sockliner 1224 can be positioned on top of bottom plate 1210 in interior 1218 of article of footwear 1200. In such aspects, sockliner 1224 can include conventional insole materials, such as one or more layers of foam or memory foam and textile layers. It should be understood that while bottom plate 1210, heel counter 1222, and sockliner 1224 are depicted as additional materials used to form an upper for an article of footwear, other materials, such as a plate, toe cap, and / or structure along the sides, can also be added.

[0244] In various aspects, prior to thermoforming, heel counter 1222 and base plate 1210 can be positioned within interior 1218 of article of footwear 1200. In certain aspects, a sockliner can be applied after the thermoforming process is complete.

[0245] In some aspects, such as Figure 14 In the aspects depicted in FIG, ground engaging cleats 1410 may be applied to article of footwear 1400. In various aspects, article of footwear 1400 may include the same Figure 12 and Figure 13The same features as described for article of footwear 1200. Figure 14 As can be seen in FIG, ground engaging cleats 1410 can be applied to a ground facing outsole area 1412 of article of footwear 1400 to provide increased stability and traction. In various aspects, ground engaging cleats 1410 can be applied to ground facing outsole area 1412 after the thermoforming process is completed. In other aspects, ground engaging cleats 1410 can be applied to ground facing outsole area 1412 as part of the thermoforming process.

[0246] In various aspects, prior to thermoforming the article of footwear, any of the textiles discussed above, as well as additional materials, may be braided, woven, knitted, or preformed into a generally boot-shaped upper having a ground-facing outsole portion, such as Figure 15 In such an aspect, the upper 1500 may further include a base plate or heel counter positioned on the interior 1510 of the upper 1500, such as described above with respect to Figure 12 Base plate 1210 and heel counter 1222 are discussed.

[0247] To prepare the upper 1500 for the thermoforming process, the upper 1500 is placed on a last 1520 such that the last 1520 enters the interior 1510 of the upper 1500. In certain aspects, the last 1520 can be formed from a polymer material such as a high processing temperature polymer composition. In particular aspects, the last 1520 can be formed from a polymer material having a melting temperature T greater than 250° C. or greater than 300° C. m The shoe last 1520 may be formed of a polymer material such as, for example, a silicone polymer that has a low or low degradation temperature. The shoe last 1520 may be made of other types of materials as long as such materials do not deform or melt during the thermoforming process or otherwise adversely affect the thermoforming of the upper. Figure 16 Depicted is a shoe upper 1500 positioned on a shoe last 1520. Figure 16 As can be seen in FIG, upper 1500 wraps around last 1520 to cover bottom portion 1522 of last 1520, forefoot portion 1524 of last 1520, and heel portion 1526 of last 1520. In such an aspect, ground-facing outsole portion 1512 of the upper covers forefoot portion 1524 of last 1520. Although Figure 15 and Figure 161500 is illustrated as having a sock-like structure that surrounds and covers a bottom portion 1522, a forefoot portion 1524, and a heel portion 1526 of a last 1520, but in other aspects, the upper 1500 may only partially surround the last 1520. Similarly, in other aspects, the upper 1500 may cover only the bottom portion 1522 of the last 1520, only the forefoot portion 1524 of the last 1520, only the heel portion 1526 of the last 1520, or a combination thereof. In still other aspects, the upper 1500 may cover only a portion of the bottom portion 1522 of the last 1520, a portion of the forefoot portion 1524 of the last 1520, a portion of the heel portion 1526 of the last 1520, or a combination thereof.

[0248] Figure 17 A cross section of upper 1500 positioned on last 1520 is shown along cut line 17. Cross section 1700 reveals that last 1520 contacts inner surface 1540 of upper 1500. Cross section 1700 also reveals that two types of materials are present in upper 1500. For example, cross section 1700 reveals three types of textile areas forming the textile of upper 1500. Figure 17 As can be seen in FIG, textile area 1710 associated with ground-facing outsole portion 1512 of the upper covers bottom portion 1522 of last 1520. In such an aspect, when the upper is a knitted textile forming a knit upper, at least a portion of the yarn comprising the low processing temperature polymer composition covers at least a portion of bottom portion 1522 of last 1520.

[0249] Additionally, textile region 1714 covers forefoot portion 1524 of last 1520, while textile region 1712 covers midfoot region 1528 of last. In certain aspects, textile regions 1710, 1712, and 1714 can each have the same dimensions as those described above with reference to FIG. Figure 3 Any or all of the characteristics discussed in textile areas 302, 304a, 306a.

[0250] In some aspects, a first layer may be placed on a molding surface such as a last before an article such as an article of footwear or a component of an article of footwear is molded. For example, a first layer such as a lining may be optionally placed over a molding surface such as a last. For example, referring to Figure 17To further illustrate the following aspects of the first layer: Before the article lining can be placed over last 1520, the first layer can optionally be placed on a molding surface, such as last, such that the forefoot area of ​​the lining covers forefoot area 1524. Thus, the upper, including textile regions 1710, 1712, and 1714, is then placed such that the upper covers at least a portion of the lining. Thus, at least a portion of the yarn comprising the low processing temperature polymer composition covers at least a portion of the lining. It should be understood that in certain aspects, textile regions 1710, 1712, and 1714 can each have the same dimensions as those described above with reference to FIG. Figure 3 Any or all of the characteristics discussed in textile areas 302, 304a, 306a.

[0251] In other aspects, an outer layer can optionally be positioned over at least a portion of the article positioned on a molding surface and cover at least a portion of the article. An outer layer, which can be a film, can optionally be placed over at least a portion of the article, such as an upper positioned on a molding surface, such as a last. For example, referring to Figure 17 To further illustrate the following aspects, the outer layer can optionally be placed over at least a portion of the upper that has been positioned on the last so that the textile area 1710 associated with the ground-facing outsole portion 1512 of the upper covers the bottom portion 1522 of the last 1520. Thus, at least a portion of the upper, including textile areas 1710, 1712, and 1714, can be covered by at least a portion of the outer layer. Thus, at least a portion of the yarn comprising the low processing temperature polymer composition is in contact with at least a portion of the outer layer. It should be understood that in certain aspects, textile areas 1710, 1712, and 1714 can each have the same or similar properties as described above with reference to the preceding text. Figure 3 Any or all of the characteristics discussed for textile regions 302, 304a, 306a. The outer layer may be utilized in conjunction with the first layer, as described in the previous paragraph.

[0252] In certain aspects, a forming component, such as a heel counter or toe cap, can optionally be placed on exterior surface 1530 of upper 1500. Alternatively, a forming component, such as a heel counter or toe cap, can optionally be placed on interior surface 1540 of upper 1500. It should be understood that placement of the forming component on either exterior surface 1530 or interior surface 1540 of upper 1500 is accomplished prior to applying a protective cover, vacuum, or protective cover and vacuum bag as described below.

[0253] In certain aspects, during the thermoforming process, the low processing temperature polymer composition may melt and flow. In various aspects, it may be desirable to restrict the flow of the molten low processing temperature polymer composition. In such aspects, a protective cover may be applied over the upper positioned on the last. For example, Figure 18 and Figure 19 As can be seen in FIG, protective cover 1800 is positioned over upper 1500 positioned on last 1520. In certain aspects, protective cover 1800 can be formed from a polymer material such as a high processing temperature polymer composition. In particular aspects, protective cover 1800 can be formed from a polymer material having a melting temperature T greater than 250° C. or greater than 300° C. m The protective cover 1800 can be formed from an elastomeric polymer material with a low or low-processing temperature, such as a silicone polymer. The protective cover 1800 can be made of other types of materials, as long as such materials do not deform or melt during the thermoforming process, or otherwise adversely affect the thermoforming of the upper. In various aspects, the protective cover 1800 can apply a compressive force to the outer surface 1530 of the upper 1500, which can help limit the flow of the molten low-processing temperature polymer composition. In addition, in such aspects, the combination of the shoe last 1520, the upper 1500 positioned on the shoe last, and the protective cover positioned on the upper 1500 can be vacuumed. For example, a bag under vacuum can be compressed on the outside of the protective cover 1800 to apply a compressive force to the protective cover 1800 to ensure that the cover 1800 is in flush contact with the outer surface 1530 of the upper 1500. Vacuum bags are discussed in more detail below.

[0254] In certain aspects, protective cover 1800 can be utilized to provide a pattern or indicia on the exterior surface of upper 1500. For example, interior surface 1810 of protective cover 1800 can include a pattern or indicia that can be embossed or imprinted onto exterior surface 1530 of upper 1500 during the thermoforming process due to the melting and cooling of the low processing temperature polymer composition in upper 1500 in combination with the compressive forces applied to upper 1500 by protective cover 1800 (and optionally, the vacuum bag). In such aspects, because protective cover 1800 can cover the entirety of upper 1500, it is possible for protective cover 1800 to emboss or imprint a pattern onto any portion of exterior surface 1530 of upper 1500 that includes a low processing temperature polymer composition.

[0255] In some aspects, it may be desirable to optionally use both a protective cover and a vacuum bag together. In such aspects, the protective cover may be applied over the upper positioned on the last. For example, Figure 18 and Figure 19 As can be seen in FIG, the protective cover 1800 is positioned over the shoe upper 1500 positioned on the shoe last 1520. As disclosed above, the protective cover 1800 may be made of a material having a melting temperature T greater than 250° C. or greater than 300° C. mThe protective cover 1800 is formed of an elastomeric polymer material, such as a silicone polymer, that has a low or high degradation temperature. Thus, the protective cover 1800 is positioned on the shoe last and inside the vacuum bag 2010. As used herein, the term "vacuum bag" refers to any material that can be compressed onto the outer surface of an object. It should be understood that various methods of applying compressive force to the protective cover or vacuum bag, as discussed in this disclosure, can be used to apply compressive force to both the protective cover and vacuum bag when used together.

[0256] In certain aspects, the use of protective cover 1800, alone and when used under a vacuum, can effectively reduce the number of bubbles that become trapped in the low processing temperature polymer material during the thermoforming process, compared to the same upper thermoformed under similar conditions except without protective cover 1800.

[0257] exist Figures 15-19 In the aspects depicted in FIG, last 1520 is formed of a rigid material. Furthermore, in these aspects, when last 1520 is made of a rigid material, the compressive force applied via protective cover 1800 (and / or vacuum bag) creates a force or pressure differential between inner surface 1540 and outer surface 1530 of upper 1500 (because rigid last 1520 at least partially resists this compressive force, which causes upper 1500 to experience the compressive force). In such aspects, this pressure differential can at least partially provide the environment necessary to restrict the flow of the molten low processing temperature polymer composition and / or provide embossing or patterning of outer surface 1530 of upper 1500.

[0258] In some aspects, when the last 1520 is formed of a rigid material, the upper 1500 can be positioned on the last 1520, and the outer surface 1530 of the upper 1500 (with or without the protective cover 1800) can be exposed to a pressure above atmospheric pressure to create this pressure differential. In another aspect, the upper 1500 can be positioned on the last 1520, and negative pressure can be applied between the inner surface 1540 of the upper 1500 and the last 1520 to compress the upper 1500 onto the rigid last 1520.

[0259] In various aspects, the pressure differential across the interior surface 1540 and exterior surface 1530 of upper 1500 can also help form the three-dimensional structure of the article of footwear during the thermoforming process. That is, in such aspects, as the low processing temperature polymer composition melts, the molten material and upper 1500 are forced against rigid last 1520, which upon cooling creates upper 1500 that takes the shape of last 1520.

[0260] In alternative aspects, this force or pressure differential between inner surface 1540 and outer surface 1530 of upper 1500 can be achieved in another manner. For example, in some aspects, last 1520 can be an expandable last 1520 that can apply an outward force to inner surface 1540 of upper 1500. In such aspects, to achieve the pressure differential, outer surface 1530 of upper 1500 can contact a type of material that will at least partially resist the outward force applied by expansion of last 1520.

[0261] As discussed above, a vacuum bag may be applied to upper 1500 positioned on last 1520 with or without protective cover 1800 . Figure 20A Shoe upper 1500 is depicted positioned inside vacuum bag 2010 on last 1520. As used herein, the term "vacuum bag" refers to any material that can be compressed onto the outer surface of an object.

[0262] exist Figure 20A In the aspect depicted in FIG, vacuum bag 2010 may include a valve 2012 for reducing the pressure inside vacuum bag 2010. For example, the pressure between exterior surface 1530 of upper 1500 (or the exterior surface of protective cover 1800 over upper 1500) and interior 2014 of vacuum bag 2010 may be reduced, which will cause the vacuum bag to compress against exterior surface 1530 of upper 1500 (or the exterior surface of protective cover 1800 over upper 1500). Figure 20B Depicted is a vacuum bag 2010 compressed onto the exterior surface 1530 of the upper 1500 (or the exterior surface of the protective cover 1800 on the upper 1500). As discussed above, compressing the vacuum bag 2010 onto the upper 1500 can at least partially provide the above-referenced Figures 15-19 Discuss the pressure difference.

[0263] Figure 21 A thermoforming system 2100 is depicted. Figure 21 The thermoforming system 2100 may include an upper 1500 positioned on a last 1520, with a vacuum bag 2010 compressed onto the upper 1500, as described above with respect to Figure 20A and Figure 20B discussed.

[0264] As discussed above, the thermoforming process includes raising the temperature of a textile material, such as upper 1500, to a temperature that causes at least a portion of the low processing temperature polymer composition present in upper 1500 to melt and flow or deform. Furthermore, the thermoforming process includes subsequently lowering the temperature of upper 1500 to solidify the molten low processing temperature polymer composition into a desired shape, such as an article of footwear.

[0265] Thermoforming system 2100 includes heating zone 2110, which can be configured to heat the entire upper 1500. In various aspects, heating zone 2110 heats the entire upper 1500 to a temperature above the melting temperature T of the low processing temperature polymer composition present in upper 1500. m temperature.

[0266] In various aspects, it should be understood that although heating used in thermoforming has been specifically discussed with respect to its application in the context of upper 1500, this is merely an exemplary aspect of heating and thermoforming for the disclosed articles and processes. That is, the present disclosure contemplates that heating can be utilized with any of the disclosed heating methods for providing a heating zone in a thermoforming system and process for thermoforming any of the disclosed articles comprising a first forming part, a first film, a first textile, a first yarn, or a first fiber and a second forming part, a second film, a second textile, a second yarn, or a second fiber positioned on a molding surface, wherein the ensemble is at least partially covered with a vacuum bag, a protective sleeve, or a combination of a protective sleeve and a vacuum bag, and then heated to a temperature above the T of the low processing temperature polymer composition. m The first forming component, the first film, the first textile, the first yarn or the first fiber comprises a low processing temperature polymer composition.

[0267] In various aspects, heating the entire upper 1500 can provide a more efficient, streamlined thermoforming process. For example, because the forming parts, films, textiles, fibers, and / or yarns comprising the low processing temperature polymer composition and the forming parts, films, textiles, fibers, and / or yarns comprising the high processing temperature polymer composition are selected and targeted to specific areas of the upper, it is not necessary to thermoform only a portion of the upper (such as, for example, by masking a portion of the upper or applying heat to only a portion of the upper) because the high processing temperature polymer composition can be resistant to any deformation or melting under conditions where the low processing temperature polymer composition can be thermoformed. However, optionally, the thermoformed articles of the present disclosure can be subjected to additional heat treatment steps. For example, one or more surfaces of the thermoformed article can be subjected to additional thermoforming processes, such as to thermally attach cleats to the ground-facing surface of an article of footwear prepared using the thermoforming process described herein.

[0268] As discussed above, it is desirable that the thermoforming process does not deform or alter the formed parts, films, textiles, fibers, and / or yarns comprising the high processing temperature polymer composition. In such aspects, the heating zone 2110 can heat the entire upper 1500 to a temperature below the creep relaxation temperature T of the high processing temperature polymer composition or the fibers and / or yarns comprising the high processing temperature polymer composition. cr , heat deformation temperature Thd Or Vicat softening temperature T vs The temperature of at least one of the

[0269] In one or more aspects, heating zone 2110 can increase the temperature of entire upper 1500 to a temperature from about 90° C. to about 240° C. In various aspects, heating zone 2110 can increase the temperature of entire upper 1500 to a temperature from about 90° C. to about 200° C. In one aspect, heating zone 2110 can increase the temperature of entire upper 1500 to a temperature from about 110° C. to about 180° C.

[0270] In some aspects, the temperature of the entire upper 1500 can be elevated for a duration of about 10 seconds to about 5 minutes. In various aspects, the temperature of the entire upper 1500 can be elevated for a duration of about 30 seconds to about 5 minutes. In one aspect, the temperature of the entire upper 1500 can be elevated for a duration of about 30 seconds to about 3 minutes.

[0271] In one or more aspects, heating zone 2110 can expose entire upper 1500 to a temperature from about 90° C. to about 240° C. In various aspects, heating zone 2110 can expose entire upper 1500 to a temperature from about 90° C. to about 200° C. In one aspect, heating zone 2110 can expose entire upper 1500 to a temperature from about 110° C. to about 180° C.

[0272] In certain aspects, the entire upper 1500 can be exposed to one or more of the heating zone 2110 temperatures or ranges discussed above for a duration of about 10 seconds to about 5 minutes. In various aspects, the entire upper 1500 can be exposed to one or more of the heating zone 2110 temperatures or ranges discussed above for a duration of about 30 seconds to about 5 minutes. In one aspect, the entire upper 1500 can be exposed to one or more of the heating zone 2110 temperatures or ranges discussed above for a duration of about 30 seconds to about 3 minutes.

[0273] In certain aspects, heating zone 2110 can expose entire upper 1500 to a pressure of from about 50 kPa to about 300 kPa. In various aspects, heating zone 2110 can expose entire upper 1500 to a pressure of from about 50 kPa to about 250 kPa. In one aspect, heating zone 2110 can expose entire upper 1500 to a pressure of from about 100 kPa to about 300 kPa.

[0274] In some aspects, entire upper 1500 may be exposed to heating zone 2110 under the above conditions multiple times in a row before undergoing a cooling step. For example, in some aspects, entire upper 1500 may be exposed to heating zone 2110 under the above conditions 2-10 times in a row before undergoing a cooling step. In alternative embodiments, in some aspects, entire upper 1500 may be exposed to heating zone 2110 under the above conditions twice in a row before undergoing a cooling step.

[0275] In various aspects, after the temperature of the entire upper 1500 is increased, the temperature of the entire upper 1500 is reduced to below the melting temperature T of the low processing temperature polymer composition. m The temperature of the low processing temperature polymer composition is maintained for a duration sufficient to cure the low processing temperature polymer composition. For example, the heating zone 2110 can be heated using a thermal energy source, including but not limited to conventional heaters, such as convection heating, conventional ovens, air circulating ovens or forced hot air ovens, steam, targeted microwave heating, ultraviolet radiation, infrared heating, and combinations of any of the foregoing. The thermal energy source can also include multiple thermal energy sources, such as multiple similar sources, for example, multiple heating coils or infrared emitters. Alternatively, the multiple thermal energy sources can include multiple one or more different thermal energy sources, such as multiple heating coils and multiple infrared emitters that can be used simultaneously or sequentially or optionally in a mode where only one of the multiple thermal energy sources is used at any given time.

[0276] In some aspects, heating can be performed so that heat is transferred from another material or object to the entire shoe upper 1500. For example, a molding surface, such as a shoe last, can itself be directly heated, for example, via a configuration as a resistive heating element. In alternative aspects, a molding surface, such as a shoe last, can be preheated to a desired temperature immediately before the shoe upper, textile, or article is positioned thereon. In the aforementioned aspects, the molding surface itself can serve as a heating zone that transfers heat to the entire shoe upper.

[0277] In some aspects, heating of the heated zone can be performed using radio frequency heating, such as microwave radiation, such that the radio frequency heats the composition, such as a low processing temperature polymer composition, as part of an upper, textile, or article via interaction of the radio frequency field with the composition.

[0278] Furthermore, in some aspects, entire upper 1500 can be exposed to heating zone 2110 by moving entire upper 1500 into heating zone 2110, or by moving heating zone 2110 to where upper 1500 is positioned and then moving away after the heating step. The movement of upper 1500 and / or heating zone 2110 can be automated or semi-automated using conventional conveyance systems.

[0279] In certain aspects, after heating the entire upper 1500, the entire upper 1500 is cooled to a temperature below the melting temperature T of the low processing temperature polymer composition. m In such an aspect, by moving to cooling zone 2112 or by moving cooling zone 2112 to upper 1500, entire upper 1500 can be exposed to the reduced temperature in cooling zone 2112. Cooling zone 2112 can expose entire upper 1500 to a pressure of approximately 0 kPa.

[0280] In one or more aspects, entire upper 1500 can be exposed to a temperature of about -25°C to about 25°C while in cooling zone 2112. In various aspects, entire upper 1500 can be exposed to a temperature of about -10°C to about 25°C while in cooling zone 2112. In one aspect, entire upper 1500 can be exposed to a temperature of from about -10°C to about 10°C while in cooling zone 2112.

[0281] In certain aspects, the entire upper 1500 may be exposed to one or more of the cooling zone 2112 temperatures or ranges discussed above for a duration of about 10 seconds to about 5 minutes. In various aspects, the entire upper 1500 may be exposed to one or more of the cooling zone 2112 temperatures or ranges discussed above for a duration of about 10 seconds to about 3 minutes. In one aspect, the entire upper 1500 may be exposed to one or more of the cooling zone 2112 temperatures or ranges discussed above for a duration of about 10 seconds to about 2.5 minutes.

[0282] In some aspects, after upper 1500 has cooled as described above, vacuum bag 2010 and protective cover 1800 may be removed. In such aspects, any additional components may now be applied to upper 1500, such as Figure 14 Ground engaging cleats 1410 .

[0283] Figure 22 An exemplary process 2200 for making an upper for a shoe is depicted. Process 2200 may include a step 2210 of receiving an upper comprising a first material or component formed from a low processing temperature polymer composition and a second material or component formed from a high processing temperature polymer composition.

[0284] according to Figure 22 With the exemplary process 2200 of the present disclosure, generally, the low processing temperature polymer composition can exist in the form of a fiber (e.g., a fiber consisting essentially of the low processing temperature polymer composition). The low processing temperature polymer composition can exist in the received upper in the form of a yarn (e.g., a yarn comprising the low processing temperature polymer composition, a yarn formed entirely of fibers comprising the low processing temperature polymer composition, a yarn formed partially of fibers comprising the low processing temperature polymer composition). Additionally or alternatively, the low processing temperature polymer composition can exist in the form of a fiber that is not part of the yarn structure. For example, the fiber can comprise the low processing temperature polymer composition, or can consist essentially of the low processing temperature polymer composition. The low processing temperature polymer composition can also exist in the form of a textile (including knitted textiles, braided textiles, woven textiles, and non-woven textiles), a film, a sheet, or a molded article, such as an injection molded article. The low processing temperature polymer composition can also exist in the form of a foam material.

[0285] Although certain aspects of the present disclosure have been specifically illustrated with respect to articles of footwear or uppers, within the scope of the present disclosure, the illustrated aspects may generally be understood to be applicable to other disclosed aspects. For example, any disclosed low processing temperature polymeric composition may be used to form, make or manufacture shaped parts, films, textiles or other articles, and used in the process disclosed herein. Similarly, any disclosed high processing temperature polymeric composition may be used to form, make or manufacture shaped parts, films, textiles or other articles, and used in the process disclosed herein. Therefore, any such shaped parts, films, textiles or other articles comprising low processing temperature polymeric compositions may optionally be contacted with shaped parts, films, textiles or other articles comprising high processing temperature polymeric compositions and positioned on a molded surface. In some aspects, the molded surface may be a mold, a form or a shoe last. A protective cover and / or a vacuum bag may be positioned on the molded surface, a compressive force applied to the molded surface, and a heating zone provided to the molded surface, as described in the present disclosure.

[0286] In certain aspects, the second material formed from the high processing temperature polymer composition can exhibit a melting temperature T greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr , heat deformation temperature T hd Or Vicat softening temperature T vsAt least one of. The material formed by the low processing temperature polymer composition may include any one or all of the characteristics of the low processing temperature polymer composition described above. The second material formed by the high processing temperature polymer composition may include any one or all of the characteristics of the high processing temperature polymer composition described above. The second material formed by the high processing temperature polymer composition may exist in the form of a fiber (e.g., a fiber consisting essentially of the high processing temperature polymer composition). The high processing temperature polymer composition may exist in the received upper in the form of a yarn (e.g., a yarn comprising the high processing temperature polymer composition, a yarn formed entirely of fibers comprising the high processing temperature polymer composition, or a yarn formed partially of fibers comprising the high processing temperature polymer composition). Additionally or alternatively, the high processing temperature polymer composition may exist in the form of a fiber that is not part of the yarn structure. For example, the fiber may contain the high processing temperature polymer composition, or may consist essentially of the high processing temperature polymer composition. The high processing temperature polymer composition may also exist in the form of a textile (including knitted textiles, braided textiles, woven textiles, and non-woven textiles), a film, a sheet, or a molded article such as an injection molded article. The high processing temperature polymer composition may also exist in the form of a foam material. In some aspects, the upper may include the Figures 15-21 Any or all of the characteristics of the upper 1500 described above. In addition, the upper may use any of the textiles described above, such as Figure 3 The textile 300 is formed.

[0287] Although the low processing temperature polymer composition and the high processing temperature polymer composition can be present as separate materials or components of the received shoe upper (e.g., present in separate fibers, yarns, textiles, films, etc.), they can also be present in the same component (e.g., a yarn comprising fibers formed from the low processing temperature polymer composition and separate fibers formed from the high processing temperature polymer composition; a textile comprising a yarn formed from the low processing temperature polymer composition and separate yarns formed from the high processing temperature polymer composition). In other words, in the received shoe upper, the low processing temperature polymer composition and the high processing temperature polymer composition are present in separate materials or components that are different from each other at least at the fiber level.

[0288] In one or more aspects, in a first portion of the upper, when the upper comprises a knitted textile having a first yarn comprising a low processing temperature polymer composition and a second yarn comprising a high processing temperature polymer composition, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, such as Figure 6 、 Figure 7A or Figure 9A Multiple interconnected coils are depicted in FIG.

[0289] In step 2220 of process 2200, the upper is placed on a last, such as Figure 15-17 In various aspects, the last can be formed of a rigid material, or can be an expandable last. In addition, as described above, the upper can have a base plate, heel counter or other components inserted into the upper before being placed on the last.

[0290] In step 2230 of process 2200, when the entire shoe upper is on the shoe last, the temperature of the entire shoe upper is raised, for example, to a temperature above the melting temperature T of the first yarn composition. m and below the creep relaxation temperature T of the second yarn composition cr , heat deformation temperature T hd Or Vicat softening temperature T vs In various aspects, the entire upper can be used as described above with respect to Figure 21 The upper can be heated using the thermoforming system 2100 described above. Figure 21 The thermoforming system describes any or all of the parameters to heat.

[0291] In step 2240 of process 2200, after heating, the temperature of the entire upper is reduced to below the melting temperature T of the low processing temperature polymer composition while the upper remains on the last. m For example, when the entire shoe upper is on the shoe last, the entire shoe upper can be cooled to form a thermoformed shoe upper. In various aspects, the entire shoe upper can be formed using the above-mentioned Figure 21 The upper can be cooled using the thermoforming system 2100 described above. Figure 21 The parameters of the hot forming system describe any or all of the cooling.

[0292] When the first material or first component comprising the low processing temperature polymer composition has been deformed and its original structure has been modified or has melted and solidified into a new physical structure, after thermoforming the received upper, the first material or first component comprising the low processing temperature polymer composition may be deformed and its original structure has been modified or has melted and solidified into a new physical structure. m But less than the creep relaxation temperature T of the high processing temperature polymer composition cr Or heat deformation temperature T hd Or Vicat softening temperature T vs The high processing temperature polymer composition is processed at a temperature such that the second material or second component (fiber, yarn, textile, sheet, molded article, etc.) comprising the high processing temperature polymer composition retains its original physical structure (e.g., as a fiber, yarn, textile, etc.).

[0293] Figure 23An exemplary process 2300 for manufacturing an upper for a shoe is depicted. Process 2300 may include step 2310 of receiving an upper comprising a first yarn and a second yarn, wherein the first yarn comprises a low processing temperature polymer composition and the second yarn comprises a high processing temperature polymer composition. The low processing temperature polymer composition may comprise one or more first thermoplastic polymers and the high processing temperature polymer composition may comprise one or more second thermoplastic polymers. In various aspects, the first thermoplastic polymer and the second thermoplastic polymer may comprise any or all of the parameters discussed above with respect to thermoplastic polymers. In certain aspects, the upper may comprise the above-referenced Figures 15-21 Any or all of the characteristics of the upper 1500 described above. In addition, the upper can be made of any of the textiles described above such as Figure 3 The textile 300 is formed.

[0294] In certain aspects, the high processing temperature polymer composition can exhibit a melting temperature T greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr , heat deformation temperature T hd Or Vicat softening temperature T vs At least one of the following. The low processing temperature polymer composition can include any or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition can include any or all of the properties of the high processing temperature polymer composition described above. In addition, the first yarn and the second yarn can exhibit any or all of the properties and parameters discussed above.

[0295] In one or more aspects, in a first portion of the upper, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, such as Figure 6 、 Figure 7A or Figure 9A Multiple interconnected coils are depicted in FIG.

[0296] In step 2320 of process 2300, the upper is placed on a last, such as Figure 15-17 In various aspects, the last can be formed of a rigid material, or can be an expandable last. In addition, as described above, the upper can have a base plate, heel counter or other components inserted into the upper before being placed on the last.

[0297] In step 2330 of process 2300, while the entire shoe upper is on the shoe last, the entire shoe upper is heated to a temperature above the melting temperature T of the low processing temperature polymer composition. m and below the creep relaxation temperature T of the high processing temperature polymer composition cr , heat deformation temperature T hdOr Vicat softening temperature T vs In various aspects, the entire upper can be used as described above with respect to Figure 21 The upper can be heated using the thermoforming system 2100 described above. Figure 21 The thermoforming system describes any or all of the parameters to heat.

[0298] In step 2340 of process 2300, after heating the entire upper, the entire upper is cooled while on the last to form a thermoformed upper. In various aspects, the entire upper can be formed using the method described above with respect to Figure 21 The upper can be cooled using the thermoforming system 2100 described above. Figure 21 The parameters of the hot forming system describe any or all of the cooling.

[0299] Figure 24 A process 2400 for manufacturing a shoe upper is depicted. Process 2400 may include a step 2410 of receiving a shoe upper comprising one or more first fibers and one or more second fibers. The one or more first fibers may comprise a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The low processing temperature polymer composition may have any or all of the properties discussed above with respect to the low processing temperature polymer composition. The one or more second fibers may comprise a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition may have any or all of the properties discussed above with respect to the high processing temperature polymer composition. In various aspects, the first thermoplastic polymer and the second thermoplastic polymer may comprise any or all of the parameters discussed above with respect to the thermoplastic polymers. Furthermore, in various aspects, the first fiber and the second fiber may comprise any or all of the properties discussed above with respect to the fibers.

[0300] In one aspect, the high processing temperature polymer composition exhibits a melting temperature T greater than the low processing temperature polymer composition of the one or more first fibers. m Creep relaxation temperature T cr , heat deformation temperature T hd Or Vicat softening temperature T vs At least one of .

[0301] In some aspects, the upper may include a ground-facing outsole area, wherein at least a portion of the first fibers are present in the ground-facing outsole area.

[0302] Process 2400 may include step 2420 of placing the upper on a last such that at least a portion of the outsole area facing the ground covers at least a bottom portion of the last, such as a bottom portion of the last. Figure 15-17 In various aspects, the last can be formed of a rigid material, or can be an expandable last. In addition, as described above, the upper can have a base plate and / or heel counter inserted into the upper before being placed on the last.

[0303] The process 2400 may also include heating the entire shoe upper while the entire shoe upper is on the shoe last to a temperature above the melting temperature T of the low processing temperature polymer composition. m and below the creep relaxation temperature T of the high processing temperature polymer composition cr , heat deformation temperature T hd Or Vicat softening temperature T vs In various aspects, the entire upper can be used as described above with respect to Figure 21 The upper can be heated using the thermoforming system 2100 described above. Figure 21 The thermoforming system describes any or all of the parameters to heat.

[0304] In step 2440 of process 2400, after heating the entire upper, the entire upper is cooled while on the last to form a thermoformed upper. In various aspects, the entire upper can be formed using the method described above with respect to Figure 21 The upper can be cooled using the thermoforming system 2100 described above. Figure 21 The parameters of the hot forming system describe any or all of the cooling.

[0305] Figure 25 A process 2500 for making a knitted upper for an article of footwear is depicted. Process 2500 includes a step 2510 for knitting a first course, the first course including loops of a first yarn and loops of a second yarn. In various aspects, the first yarn comprises a low processing temperature polymer composition and the second yarn comprises a high processing temperature polymer composition. The low processing temperature polymer composition can include one or more first thermoplastic polymers and the high processing temperature polymer composition can include one or more second thermoplastic polymers. In various aspects, the first thermoplastic polymer and the second thermoplastic polymer can include any or all of the parameters discussed above with respect to thermoplastic polymers. In certain aspects, the upper can include the above-referenced Figures 15-21 Any or all of the characteristics of upper 1500 described.

[0306] In certain aspects, the high processing temperature polymer composition can exhibit a melting temperature T greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr , heat deformation temperature T hd Or Vicat softening temperature T vsAt least one of the following. The low processing temperature polymer composition can include any or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition can include any or all of the properties of the high processing temperature polymer composition described above. In addition, the first yarn and the second yarn can exhibit any or all of the properties and parameters discussed above.

[0307] Process 2500 may also include a step 2520 of knitting a second course, the second course comprising loops of the first yarn and loops of the second yarn. In various aspects, the first course and the second course may be knitted using any commercial knitting technique as described above. In various aspects, at least a portion of the first course and at least a portion of the second course form a plurality of interconnected loops, such as Figure 6 The interconnected coils are depicted in FIG.

[0308] Figure 26 A process 2600 for forming a knitted article is depicted. Process 2600 may include step 2610 of knitting a first course of stitches comprising a first yarn and a second yarn. In various aspects, the first yarn comprises a low processing temperature polymer composition, and the second yarn comprises a high processing temperature polymer composition. The low processing temperature polymer composition may comprise one or more first thermoplastic polymers, and the high processing temperature polymer composition may comprise one or more second thermoplastic polymers. In various aspects, the first thermoplastic polymer and the second thermoplastic polymer may comprise any or all of the parameters discussed above with respect to thermoplastic polymers.

[0309] In certain aspects, the high processing temperature polymer composition can exhibit a melting temperature T greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr , heat deformation temperature T hd Or Vicat softening temperature T vs At least one of the following. The low processing temperature polymer composition can include any or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition can include any or all of the properties of the high processing temperature polymer composition described above. In addition, the first yarn and the second yarn can exhibit any or all of the properties and parameters discussed above.

[0310] Step 2620 of process 2600 includes knitting an anchor yarn into one or more loops of the first yarn present in the first course of loops. The anchor yarn comprises an anchor yarn composition, wherein the anchor yarn composition comprises one or more polymers. The anchor yarn composition exhibits an elongation that is less than the elongation of the low processing temperature polymer composition. In various aspects, the anchor yarn may have the following properties: Figure 4B 、 Figure 4E 、 Figure 10A and Figure 10B Any or all of the properties of the anchor yarn discussed.

[0311] In various aspects, the first row of stitches may be present on the outer surface of the knitted upper. In such aspects, the outer surface of the knitted upper may include a first region, a second region, and a third region, wherein the second region is positioned between the first region and the third region. Furthermore, in such aspects, the third region has an increased concentration of the first yarn compared to the second region. The first region, the second region, and the third region may each include the first region, the second region, and the third region as described above. Figure 3 Any or all of the characteristics of textile regions 306a, 304a, and 302 discussed above for textile 300.

[0312] Figure 27 A process 2700 for manufacturing an upper for an article of footwear is depicted. Step 2710 of process 2700 includes forming a ground-facing outsole region that includes a first set of one or more first fibers. In such an aspect, the one or more first fibers may include a low processing temperature polymer composition including one or more first thermoplastic polymers.

[0313] Process 2700 may include step 2720 of forming a second region comprising one or more second fibers and a second group of one or more first fibers. In such aspects, the one or more second fibers comprise a high processing temperature polymer composition comprising one or more second thermoplastic fibers. The high processing temperature polymer composition exhibits a melting temperature T greater than the low processing temperature polymer composition of the one or more first fibers. m Creep relaxation temperature T cr , heat deformation temperature T hd Or Vicat softening temperature T vs The first and second fibers, the low and high processing temperature polymer compositions, and the first and second thermoplastic polymers can include any or all of the corresponding properties discussed above.

[0314] Textiles, yarns and fibers

[0315] As discussed above, fiber described herein, yarn, textile, film and shaped component can comprise the selectivity of low processing temperature polymer composition and / or the selectivity of high processing temperature polymer composition and incorporate into.In various fields, such low processing temperature polymer composition can exist with the form of the fiber that comprises low processing temperature polymer composition.In some respects, the fiber that comprises low processing temperature polymer composition does not contain high processing temperature polymer composition basically.In other aspects, the fiber that comprises low processing temperature polymer composition is made up of low processing temperature polymer composition basically.According to present disclosure, these fibers can be used to form yarn, and yarn can be used to form textile again, comprises knitted textile, woven textile or braided textile.According to present disclosure, these fibers can also be used to form non-woven textile.

[0316] Similarly, the high processing temperature polymer composition described above can exist with the form of the fiber that comprises the high processing temperature polymer composition.In some respects, the fiber that comprises the high processing temperature polymer composition does not contain the low processing temperature polymer composition basically.In other aspects, the fiber that comprises the high processing temperature polymer composition is made up of the high processing temperature polymer composition basically.According to the disclosure, these fibers can be used to form yarn, and yarn can be used to form textiles again, comprises knitted textiles, woven textiles or braided textiles.According to the disclosure, these fibers can also be used to form non-woven textiles.

[0317] In some respects, the fiber and / or the yarn comprising the low processing temperature polymer composition can also comprise the high processing temperature polymer composition.For example, fiber can be the bicomponent fiber with the low processing temperature polymer composition on at least a portion of the outer surface of the fiber.For example, the low processing temperature polymer composition and the high processing temperature polymer composition can have a side-by-side structure, or can have a core-and-sheath structure (core-and-sheath structure), wherein the low processing temperature polymer composition is present in the cover.In some respects, the low processing temperature polymer composition, the high processing temperature polymer composition or the two can also be included in the yarn comprising polymeric material or one or more conventional additives found in the fiber. Although the foregoing can only describe the characteristic and parameter of yarn or yarn composition, it should be understood that such characteristic and parameter are also applicable to fiber or fiber composition, unless otherwise mentioned.

[0318] In some aspects, one or more of the yarns can be monofilament yarns or multifilament yarns. In some aspects, the yarns can be spinning. In various aspects, one or more of the yarns can be formed using conventional techniques, including but not limited to melt spinning, solution spinning, or electrostatic spinning.

[0319] In certain aspects, the fibers described herein can be fibers of different sizes, including fibers that are not suitable for spinning into commercial yarns. The yarns described herein include yarns that are suitable for use in commercial knitting machines, as well as individual yarns that are not suitable for use in commercial knitting machines.

[0320] In some aspects, the yarns and / or fibers described herein can be used to provide specific functionality. For example, in some aspects, a yarn comprising a low processing temperature polymer composition can be thermoformed to form a film having waterproof or water-resistant properties. In such aspects, a film on the outer surface of an article can be provided by utilizing yarns and / or fibers comprising a low processing temperature polymer material on the outer portion of the textile (including the knitted structure forming the textile).

[0321] As discussed above, in some aspects, one or more in yarn and / or fiber can be dyed, for example, for aesthetic purposes.In various fields, yarn and / or fiber can use conventional dyeing technology such as shaft warp dyeing (package dyeing) or solution dyeing to dye.Usually, shaft warp dyeing is the process that the yarn and / or fiber that have been formed are carried out, and solution dyeing is by fiber dyeing before fiber is formed into yarn.In some aspects, the yarn or the fiber that comprise high processing temperature polymer composition can be dyed.In some aspects, the yarn or the fiber that comprise low processing temperature polymer composition are not dyed, and can be formed by the polymer composition that is substantially free of pigment or dyestuff, and this can produce the zone that is clarification (clear) or almost transparent that comprises low processing temperature polymer composition (for example, non-yarn material or non-fibrous material after thermoforming).

[0322] In some aspects, the yarn comprising the low processing temperature polymer composition can present the toughness (tenacity) from about 1 gram / denier to about 5 grams / denier. In one or more aspects, the yarn comprising the low processing temperature polymer composition can present the toughness from about 1.5 grams / denier to about 4.5 grams / denier. In one aspect, the yarn comprising the low processing temperature polymer composition can present the toughness from about 2 grams / denier to about 4.5 grams / denier. " toughness " as used herein refers to the characteristic of fiber or yarn, and uses the corresponding test method and the sampling procedure described hereinafter in property analysis and characterization procedure (theProperty Analysis And Characterization Procedures) part to determine.

[0323] In various aspects, yarns comprising a low processing temperature polymer composition can exhibit an elongation of from about 10% to about 130%. In one or more aspects, yarns comprising a low processing temperature polymer composition can exhibit an elongation of from about 20% to about 130%. In one aspect, yarns comprising a low processing temperature polymer composition can exhibit an elongation of from about 40% to about 130%. As used herein, the term "elongation" refers to a property of a fiber or yarn and is determined using the corresponding test method described below in the Property Analysis and Characterization Procedures section.

[0324] As discussed above, in some aspects, it may be desirable to utilize yarns suitable for use on commercial knitting equipment. The free-standing shrinkage of a yarn at 50°C is a predictable property of a suitable yarn for use on a commercial knitting machine. In some aspects, a yarn comprising a low processing temperature polymer composition may exhibit an unsupported shrinkage from about 0% to about 60% when heated from 20°C to 50°C. In one or more aspects, a yarn comprising a low processing temperature polymer composition may exhibit an unsupported shrinkage from about 0% to about 30% when heated from 20°C to 50°C. In one aspect, a yarn comprising a low processing temperature polymer composition may exhibit an unsupported shrinkage from about 0% to about 20% when heated from 20°C to 50°C. The term "unsupported shrinkage" as used herein refers to a property of a fiber and is determined using the corresponding test method described below in the Property Analysis and Characterization Procedure section.

[0325] In one or more aspects, the unsupported shrinkage of a yarn at 70°C can be a useful indicator of the ability of a yarn to be exposed to certain environmental conditions without any significant change in the physical structure of the yarn. In certain aspects, a yarn comprising a low processing temperature polymer composition can exhibit an unsupported shrinkage of from about 0% to about 60% when heated from 20°C to 70°C. In one or more aspects, a yarn comprising a low processing temperature polymer composition can exhibit an unsupported shrinkage of from about 0% to about 30% when heated from 20°C to 70°C. In one aspect, a yarn comprising a low processing temperature polymer composition can exhibit an unsupported shrinkage of from about 0% to about 20% when heated from 20°C to 70°C.

[0326] In one or more aspects, the yarn comprising the low processing temperature polymer composition can present a modulus from about 1Mpa to about 500MPa. In some aspects, the yarn comprising the low processing temperature polymer composition can present a modulus from about 5Mpa to about 150MPa. In one aspect, the yarn comprising the low processing temperature polymer composition can present a modulus from about 20MPa to about 130MPa. In another aspect, the yarn comprising the low processing temperature polymer composition can present a modulus from about 30MPa to about 120MPa. In another aspect again, the yarn comprising the low processing temperature polymer composition can present a modulus from about 40MPa to about 110MPa. As used herein, term " modulus " refers to the corresponding test method described hereinafter in characteristic analysis and characterization program part.

[0327] In one or more aspects, when present in the form of a plaque, the low processing temperature polymeric composition can exhibit a modulus from about 10 MPa to about 500 MPa. In certain aspects, in the form of a plaque, the low processing temperature polymeric composition can exhibit a modulus from about 5 MPa to about 150 MPa. In one aspect, in the form of a plaque, the low processing temperature polymeric composition can exhibit a modulus from about 20 MPa to about 130 MPa. In another aspect, in the form of a plaque, the low processing temperature polymeric composition can exhibit a modulus from about 30 MPa to about 120 MPa. In yet another aspect, in the form of a plaque, the low processing temperature polymeric composition can exhibit a modulus from about 40 MPa to about 110 MPa.

[0328] In one or more aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is raised to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 1 MPa to about 500 MPa when pressure tested at about 20°C and 1 atmosphere. In various aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 1 MPa to about 500 MPa when pressure tested at about 20°C and 1 atmosphere. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is reached, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 5 MPa to about 150 MPa when tested at about 20°C and 1 atmosphere of pressure. In one or more aspects, the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition. mand then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m The resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 20 MPa to about 130 MPa when tested at about 20° C. and 1 atmosphere of pressure. In one or more aspects, the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m The resulting thermoformed material (e.g., melted yarn component) can exhibit a modulus of from about 30 MPa to about 120 MPa when tested at about 20° C. and 1 atmosphere of pressure. In one or more aspects, the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m The resulting thermoformed material (eg, melted yarn component) can exhibit a modulus from about 40 MPa to about 110 MPa when tested at about 20°C and 1 atmosphere of pressure.

[0329] In various aspects, when a yarn comprising a low processing temperature polymer composition is present in a textile and has reached a temperature above the melting temperature T of the low processing temperature polymer composition, m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is reached, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross flex of from about 5000 cycles to about 500,000 cycles when pressure tested at about 20°C and 1 atmosphere. In one or more aspects, when the yarn comprising the low processing temperature polymer composition is present in the textile and has reached a melting temperature T above the low processing temperature polymer composition, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross flex of from about 5000 cycles to about 500,000 cycles when pressure tested at about 20°C and 1 atmosphere. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature is set at about 20°C and 1 atmosphere of pressure, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross deflection of from about 10,000 cycles to about 300,000 cycles. In certain aspects, when the yarn comprising the low processing temperature polymer composition is present in the textile and has reached a melting temperature T above the low processing temperature polymer composition, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross deflection of from about 10,000 cycles to about 300,000 cycles when pressure tested at about 20°C and 1 atmosphere of pressure. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. mWhen the temperature is set to 100°C and the pressure is tested at about 20°C and 1 atmosphere, the resulting thermoformed material (or molten yarn component) exhibits a cold Ross flex of at least about 150,000 cycles. As used herein, the term "cold Ross flex" refers to the corresponding test method described below in the Property Analysis and Characterization Procedures section.

[0330] In certain aspects, as discussed in detail below, anchor yarns can be used to help limit the flow of a molten material, such as a low processing temperature polymer composition, during a thermoforming process, and / or to impart a degree of flexibility to the thermoformed material. In such aspects, the anchor yarn can exhibit an elongation that is less than the elongation of the low processing temperature polymer composition, such as a yarn comprising the low processing temperature polymer composition or a molten yarn component produced by thermoforming such a yarn. For example, in various aspects, the anchor yarn can exhibit an elongation that is at least about 10% less than the elongation of the yarn comprising the low processing temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising the low processing temperature polymer composition. In one aspect, the anchor yarn can exhibit an elongation that is at least about 25% less than the elongation of the yarn comprising the low processing temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising the low processing temperature polymer composition. In another aspect, the anchor yarn can exhibit an elongation that is at least about 50% less than the elongation of a yarn comprising a low processing temperature polymer composition or a melted yarn component produced by thermoforming a yarn comprising a low processing temperature polymer composition. In yet another aspect, the anchor yarn can exhibit an elongation that is at least about 75% less than the elongation of a yarn comprising a low processing temperature polymer composition or a melted yarn component produced by thermoforming a yarn comprising a low processing temperature polymer composition. Exemplary anchor yarns include polyamide yarns, polyolefin yarns, and polyester yarns, including yarns having a tenacity of from about 5 grams per denier to about 10 grams per denier.

[0331] The anchor yarn can be formed from a high processing temperature polymer composition comprising one or more polymers. The one or more polymers of the anchor yarn high processing temperature polymer composition can be a thermoplastic polymer. In certain aspects, the one or more polymers of the high processing temperature polymer composition of the anchor yarn can be the same as the one or more polymers of the high processing temperature polymer composition forming the second yarn, the second yarn being used for a textile comprising the anchor yarn. In other aspects, the one or more polymers of the high processing temperature polymer composition of the anchor yarn are different from the one or more polymers of the high processing temperature polymer composition forming the second yarn, the second yarn being used for a textile comprising the anchor yarn.

[0332] As discussed above, in some aspects, the low processing temperature polymer composition and the high processing temperature polymer composition have different properties. In various aspects, when the thermoforming process is carried out at a temperature lower than the creep relaxation temperature, heat deformation temperature or Vicat softening temperature of the high processing temperature polymer composition, these different properties allow the low processing temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from the structure before the thermoforming process (e.g., thermoforming from yarn to melted yarn parts), while the high processing temperature polymer composition cannot be deformed or melted during such a process and can maintain its structure (e.g., as yarn). In such aspects, the melted yarn parts formed by the low processing temperature polymer composition during the thermoforming process can be integrally connected to an unchanged structure (e.g., yarn or fiber), which can provide a three-dimensional structure and / or other properties for specific spots on a wearable article.

[0333] In various aspects, one or more of the disclosed yarns can be a covered yarn. In further aspects, the covered yarn can be any suitable yarn on which a coating layer comprising a thermoplastic coating composition has been formed.

[0334] In certain aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition comprising a thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition comprising a thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0335] In certain aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition comprising a thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition comprising a thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0336] In certain aspects, the coated yarn can be a monofilament yarn or a multifilament yarn. The yarn can be based on natural or man-made fibers, including polyester yarn, high tenacity polyester yarn, polyamide yarn, metallic yarn, draw yarn, carbon yarn, glass yarn, polyethylene yarn or polyolefin yarn, bicomponent yarn, PTFE yarn, ultra-high molecular weight polyethylene (UHMWPE) yarn, liquid crystal polymer yarn, specialty decorative yarn or reflective yarn or a multicomponent yarn comprising one or more of the aforementioned yarns.

[0337] In certain aspects, the thermoplastic coating composition includes a TPU. In some aspects, the TPU can be any such material as described in the present disclosure, such as a TPU prepared by polymerizing an aromatic or aliphatic isocyanate with a polyether polyol or polycaprolactone using a short-chain glycol (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of disclosed TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0338] In various fields, the thermoplastic coating composition can also include additives, such as but not limited to one or more of thickener, processing aid, dye or colorant. In other aspects, additive is not optional, and includes at least one thickener. In still other aspects, additive is not optional, and includes at least one processing aid. In other aspects again, additive is not optional, and includes at least one thickener and at least one processing aid. In some aspects, thickener can include inorganic materials, such as silicon dioxide, talc or calcium carbonate (CaCO ).

[0339] In certain aspects, as described herein, a thickener can be used during the preparation of the thermoplastic coating composition to improve productivity and matting properties. In another aspect, the thickener is silica powder, talc, or CaCO 3 . The thickener is at least partially used to increase the viscosity of the thermoplastic coating composition. In still another aspect, the thickener used in the disclosed thermoplastic coating composition can be an alloy with a resin that can impart compatibility with thermoplastic polyurethane, such as styrene-butadiene-styrene (SBS) block copolymer, styrene-ethylene / butylene-styrene (SEBS) resin, polyacetal resin (POM), or styrene acrylonitrile resin (SAN).

[0340] In certain aspects, the thermoplastic coating composition may include a processing agent to improve productivity. In other aspects, the processing agent may be montan wax or a fatty acid ester (C5-C9) with pentaerythritol. Other processing agents are known to those skilled in the art and may also be used in the disclosed thermoplastic composition. An exemplary commercially available processing aid is ESTANE 58277 (Lubrizol).

[0341] In some aspects, a covered yarn having a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound used to cover the yarn. In other aspects, a TPU compound having a desired hardness for covering the yarn can be prepared by controlling the content of the raw materials. In still other aspects, the thickness of the covered yarn can be reduced depending on the thickness of the yarn made of polyester, nylon, spandex, or the like.

[0342] In certain aspects, the coated yarn can be prepared by compounding a thermoplastic coating composition comprising a thermoplastic polymer, such as thermoplastic polyurethane, and optionally one or more additives in a conventional extruder, and then coating the compounded thermoplastic polyurethane coating composition on the surface of the yarn. In other aspects, a process for preparing the coated yarn comprises the steps of: 1) preparing shaped thermoplastic pellets; and 2) producing the coated yarn. The shaped thermoplastic pellets can be prepared by the methods disclosed herein, by similar methods known to those skilled in the art, or obtained from commercially available sources.

[0343] The steps of preparing shaped thermoplastic pellets may include the following steps: 1) mixing a thermoplastic polymer with various additives such as a thickener and / or a processing aid, and feeding the mixture into a hopper of a conventional compounding extruder; 2) melting, kneading, and compounding the mixture in the barrel of the compounding extruder at a suitable temperature and pressure; 3) cutting the compounded thermoplastic coating composition discharged through the die of the compounding extruder in cooling water to form pellets; and 4) drying the shaped thermoplastic polyurethane pellets at a suitable temperature for about a certain period of time, and aging the dried pellets at a suitable temperature for a suitable period of time.

[0344] In a specific embodiment, the step of preparing the shaped thermoplastic pellets includes at least the following steps: 1) mixing the thermoplastic polyurethane with various additives such as a thickener and / or a processing aid, and feeding the mixture into the hopper of a conventional compounding extruder; 2) melting, kneading, and compounding the mixture in the barrel of the compounding extruder at a temperature of about 150° C. to 250° C. and a pressure of about 50 kgf to 150 kgf;

[0345] 3) cutting the compounded thermoplastic polyurethane discharged through the die of the compounding extruder in cooling water to form pellets; and 4) drying the formed thermoplastic polyurethane pellets at a temperature of 60° C. to 80° C. for about 4 hours to 6 hours, and aging the dried pellets at a temperature of 30° C. to 50° C. for about 7 days or more.

[0346] In some aspects, the step of producing the coated yarn may include the following steps: 1) mixing the shaped thermoplastic polymer pellets prepared as described above with a masterbatch corresponding to the desired color, and feeding the mixture into the funnel of the yarn coating extruder; 2) melting the mixture of the shaped thermoplastic polymer pellets and the masterbatch in the barrel of the yarn coating extruder at a suitable temperature and a suitable pressure; 3) coating the composite thermoplastic polymer and masterbatch on the surface of the yarn passing through a nipple and a core to produce a coated yarn; and 4) winding the coated yarn around a spool using a winder.

[0347] In particular, the step of producing the coated yarn may include the following steps: 1) mixing shaped thermoplastic polyurethane pellets with a masterbatch corresponding to a desired color and feeding the mixture into a hopper of a yarn coating extruder; 2) melting the mixture of the shaped thermoplastic polyurethane pellets and the masterbatch in the barrel of the yarn coating extruder at a temperature of about 150°C-250°C and a pressure of about 50kgf-150kgf; 3) coating the composite TPU and masterbatch on the surface of a yarn (made of polyester, nylon, spandex or the like) passing through a tube and a core to produce a coated yarn; and 4) winding the coated yarn around a bobbin using a winder.

[0348] An illustrative, non-limiting example of a suitable commercially available covered yarn is Dream-Sil, a TPU covered yarn available from SambuFine Chemicals (Korea).

[0349] As discussed above, anchor yarns can be used to help restrict the flow of a molten material, such as a low processing temperature polymer composition, during a thermoforming process and / or to impart a degree of flexibility to the thermoformed material. In such aspects, the anchor yarn may not melt or deform during the thermoforming process. Thus, in certain aspects, the anchor yarn may comprise an anchor yarn composition comprising one or more third thermoplastic polymers such that the anchor yarn composition exhibits a melting temperature, T, greater than that of the low processing temperature polymer composition. m Creep relaxation temperature T cr , Vicat softening temperature T vs , heat deformation temperature T hd Or melting temperature T mIn certain aspects, the anchor yarn composition can have specific ranges associated with the properties discussed above with respect to the high processing temperature polymer composition. In certain aspects, the anchor yarn can be formed from the high processing temperature polymer composition and, thus, can include any of the thermoplastic polymers discussed above with reference to the high processing temperature polymer composition.

[0350] In various aspects, when according to the AS T described below m When determined by D3418-97, a fiber or yarn comprising a low processing temperature polymer composition comprises a fiber or yarn having a melting temperature (T) from about 90°C to about 120°C. m In another aspect, when the polyamide or poly(ether-block-amide) is prepared according to the AS T as described below, m The polyamide or poly(ether-block-amide) has a melting temperature (T) of from about 93°C to about 99°C as determined by D3418-97. m In still further aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a melting temperature (T) of from about 112°C to about 118°C as determined by D3418-97. m ). In some aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a melting temperature of about 90°C, about 91°C, about 92°C, about 93°C, about 94°C, about 95°C, about 96°C, about 97°C, about 98°C, about 99°C, about 100°C, about 101°C, about 102°C, about 103°C, about 104°C, about 105°C, about 106°C, about 107°C, about 108°C, about 109°C, about 110°C, about 111°C, about 112°C, about 113°C, about 114°C, about 115°C, about 116°C, about 117°C, about 118°C, about 119°C, about 120°C, or a melting temperature encompassed by any of the foregoing values ​​(T m ) value range or the aforementioned melting temperature (T m ) values.

[0351] In various aspects, when according to the AS T described below m The fiber or yarn comprising the low processing temperature polymer composition comprises a fiber or yarn having a glass transition temperature (T) from about -20°C to about 30°C, as determined by D3418-97. g In another aspect, when the polyamide or poly(ether-block-amide) is prepared according to the AS T as described below, mThe polyamide or poly(ether-block-amide) has a glass transition temperature (T) of from about -13°C to about -7°C, as determined by D3418-97. g In still further aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a glass transition temperature (T) of from about 17°C to about 23°C, as determined by D3418-97. g ). In some aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a glass transition temperature (Tg) of about -20°C, about -19°C, about -18°C, about -17°C, about -16°C, about -15°C, about -14°C, about -13°C, about -12°C, about -10°C, about -9°C, about -8°C, about -7°C, about -6°C, about -5°C, about -4°C, about -3°C, about -2°C, about -1°C, about 0°C, about 1°C, about 2°C, about 3°C, about 4°C, about 5°C, about 6°C, about 7°C, about 8°C, about 9°C, about 10°C, about 11°C, about 12°C, about 13°C, about 14°C, about 15°C, about 16°C, about 17°C, about 18°C, about 19°C, about 20°C g ), any range of glass transition temperature values ​​encompassed by any of the aforementioned values, or any combination of the aforementioned glass transition temperature values.

[0352] In various aspects, when according to the AS T described below m D1238-13 Fibers or yarns comprising a low processing temperature polymer composition having a thickness from about 10 cm to about 10 cm when tested at 160°C using a 2.16 kg weight 3 / 10min to about 30cm 3 In another aspect, when the melt flow rate is 0.01% of the melt flow rate of the polyamide or poly(ether-block-amide) as described below, m D1238-13 Polyamide or poly(ether-block-amide) has a viscosity from about 22 cm when tested at 160°C using a 2.16 kg weight. 3 / 10min to about 28cm 3 In some aspects, when the melt flow index is 10 min according to the AST described below, m Polyamide or poly(ether-block-amide) has a viscosity of about 10 cm when determined by D1238-13 at 160°C using a 2.16 kg weight. 3 / 10min, about 11cm 3 / 10min, about 12cm 3 / 10min, about 13cm 3 / 10min, about 14cm3 / 10min, about 15cm 3 / 10min, about 16cm 3 / 10min, about 17cm 3 / 10min, about 18cm 3 / 10min, about 19cm 3 / 10min, about 20cm 3 / 10min, about 21cm 3 / 10min, about 22cm 3 / 10min, about 23cm 3 / 10min, about 24cm 3 / 10min, about 25cm 3 / 10min, about 26cm 3 / 10min, about 27cm 3 / 10min, about 28cm 3 / 10min, about 29cm 3 / 10min, about 30cm 3

[0045] The present invention relates to a melt flow index of 100 t / 10 min, any range of melt flow index values ​​encompassed by any of the preceding values, or any combination of the preceding melt flow index values.

[0353] In various aspects, the fiber or yarn comprising the low processing temperature polymer composition comprises a polyamide or poly(ether-block-amide) having a Cold Ross Flex Test result of about 120,000 to about 180,000 when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below. In further aspects, the polyamide or poly(ether-block-amide) has a Cold Ross Flex Test result of about 140,000 to about 160,000 when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below. In still further aspects, the polyamide or poly(ether-block-amide) has a Cold Ross Flex Test result of about 130,000 to about 170,000 when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below. In some aspects, when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below, the polyamide or poly(ether-block-amide) has a Cold Ross Flex Test result of about 120,000, about 125,000, about 130,000, about 135,000, about 140,000, about 145,000, about 150,000, about 155,000, about 160,000, about 165,000, about 170,000, about 175,000, about 180,000, any range of Cold Ross Flex Test values ​​encompassed by any of the foregoing values, or any combination of the foregoing Cold Ross Flex Test values.

[0354] In various aspects, when the AS T for vulcanized rubber and thermoplastic rubber and thermoplastic elastomer-tension is used according to the modification described below m The fiber or yarn comprising the low processing temperature polymer composition comprises a polyamide or poly(ether-block-amide) having a modulus of from about 5 MPa to about 100 MPa as determined by D412-98 Standard Test Method for Thermoformed Trim. In another aspect, the fiber or yarn comprising the low processing temperature polymer composition comprises a polyamide or poly(ether-block-amide) having a modulus of from about 5 MPa to about 100 MPa when tested according to AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer - Tensile Strength with the modifications described below. m The polyamide or poly(ether-block-amide) has a modulus of from about 20 MPa to about 80 MPa as determined by D412-98 Standard Test Method for Thermoformed Plaques. In some aspects, the polyamide or poly(ether-block-amide) has a modulus of from about 20 MPa to about 80 MPa when tested according to ASTM D412-98 Standard Test Method for Thermoformed Plaques. mWhen polyamide or poly(ether-block-amide) is tested according to standard test method D412-98 for thermoformed plaques of polyamide or poly(ether-block-amide), the polyamide or poly(ether-block-amide) has a modulus of about 5 MPa, about 10 MPa, about 15 MPa, about 20 MPa, about 25 MPa, about 30 MPa, about 35 MPa, about 40 MPa, about 45 MPa, about 50 MPa, about 55 MPa, about 60 MPa, about 65 MPa, about 70 MPa, about 75 MPa, about 80 MPa, about 85 MPa, about 90 MPa, about 95 MPa, about 100 MPa, any range of modulus values ​​encompassed by any of the foregoing values, or any combination of the foregoing modulus values.

[0355] In various aspects, a fiber or yarn comprising a low processing temperature polymer composition comprises a polyamide or poly(ether-block-amide) having: m When determined by D3418-97, the melting temperature (T m ); when according to AS T described below m When determined by D3418-97, the glass transition temperature (T g ); when according to the AS T described below m When D1238-13 is tested at 160℃ with a weight of 2.16kg, the 3 / 10min melt flow index; when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below, a Cold Ross Flex Test result of about 150,000; and when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension with the modifications described below. m The modulus ranges from about 25 MPa to about 70 MPa when determined by Standard Test Method D412-98 for thermoformed plaques.

[0356] In various aspects, a fiber or yarn comprising a low processing temperature polymer composition comprises a polyamide or poly(ether-block-amide) having: m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); a Cold Ross Flex Test result of approximately 150,000 when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below; and a Cold Ross Flex Test result of approximately 150,000 when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension Test with modifications described below. mA modulus of less than or equal to about 10 MPa when determined in accordance with Standard Test Method D412-98 for thermoformed veneers.

[0357] In various aspects, a fiber or yarn comprising a low processing temperature polymer composition comprises a polyamide or poly(ether-block-amide) blend comprising a first polyamide or first poly(ether-block-amide) and a second polyamide or second poly(ether-block-amide), the first polyamide or first poly(ether-block-amide) having a low processing temperature when processed according to the AS T as described below. m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); when according to the AS T described below m When D1238-13 is tested at 160℃ with a weight of 2.16kg, the 3 / 10min melt flow index; when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below, a Cold Ross Flex Test result of about 150,000; and when tested according to the AST for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension with the modifications described below. m The second polyamide or second poly(ether-block-amide) has a modulus of from about 25 MPa to about 70 MPa when determined according to Standard Test Method D412-98 for Thermoformed Plaques. m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); a Cold Ross Flex Test result of approximately 150,000 when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below; and a Cold Ross Flex Test result of approximately 150,000 when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension Test with modifications described below. m A modulus of less than or equal to about 10 MPa when determined in accordance with Standard Test Method D412-98 for thermoformed veneers.

[0358] In various aspects, the yarn comprising the low processing temperature polymer composition has a denier of about 750 to about 1100.

[0359] In various aspects, the yarn comprising the low processing temperature polymer composition has a yarn toughness greater than or equal to about 1.5g / denier when tested according to EN ISO 2062 with modification described below. In other aspects, the yarn comprising the low processing temperature polymer composition has a yarn toughness from about 1.5g / denier to about 3.0g / denier when tested according to EN ISO 2062 with modification described below. In still other aspects, the yarn comprising the low processing temperature polymer composition has a yarn toughness from about 1.7g / denier to about 1.8g / denier when tested according to EN ISO 2062 with modification described below. In still other aspects, the yarn comprising the low processing temperature polymer composition has a yarn toughness from about 3.3g / denier to about 3.6g / denier when tested according to EN ISO 2062 with modification described below. In some aspects, the yarn comprising the low processing temperature polymer composition has a yarn tenacity of about 1.5 g / denier, about 1.6 g / denier, about 1.7 g / denier, about 1.8 g / denier, about 1.9 g / denier, about 2.0 g / denier, about 2.1 g / denier, about 2.2 g / denier, about 2.3 g / denier, about 2.4 g / denier, about 2.5 g / denier, about 2.6 g / denier, about 2.7 g / denier, about 2.8 g / denier, about 2.9 g / denier, about 3.0 g / denier, any range of tenacity values ​​encompassed by any of the foregoing values, or any combination of the foregoing tenacity values ​​when tested according to EN ISO 2062 with the modifications described below.

[0360] In various aspects, the yarn comprising the low processing temperature polymer composition has a yarn elongation of less than or equal to about 150% when tested according to EN ISO 2062 with modifications described below. In another aspect, the yarn comprising the low processing temperature polymer composition has a yarn elongation of from about 30% to about 130% when tested according to EN ISO 2062 with modifications described below. In still another aspect, the yarn comprising the low processing temperature polymer composition has a yarn elongation of from about 115% to about 120% when tested according to EN ISO 2062 with modifications described below. In even another aspect, the yarn comprising the low processing temperature polymer composition has a yarn elongation of from about 120% to about 140% when tested according to EN ISO 2062 with modifications described below. In yet another aspect, the yarn comprising the low processing temperature polymer composition has a yarn elongation of from about 35% to about 45% when tested according to EN ISO 2062 with modifications described below. In some aspects, the yarn comprising the low processing temperature polymer composition has a yarn elongation of about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 100%, about 105%, about 110%, about 115%, about 120%, about 125%, about 130%, any range of elongation values ​​encompassed by any of the foregoing values, or any combination of the foregoing elongation values ​​when tested according to EN ISO 2062 with the modifications described below.

[0361] In various aspects, yarns comprising a low processing temperature polymer composition have a yarn shrinkage of less than or equal to about 15% when tested at 50°C according to the method described below. In additional aspects, yarns comprising a low processing temperature polymer composition have a yarn shrinkage of from about 70% to about 13% when tested at 50°C according to the method described below. In still additional aspects, yarns comprising a low processing temperature polymer composition have a yarn shrinkage of from about 9.5% to about 10.5% when tested at 50°C according to the method described below. In still additional aspects, yarns comprising a low processing temperature polymer composition have a yarn shrinkage of from about 0% to about 5% when tested at 50°C according to the method described below. In some aspects, the yarn comprising the low processing temperature polymer composition has a yarn shrinkage of about 0%, about 0.5%, about 1.0%, about 1.5%, about 2.0%, about 2.5%, about 3.0%, about 3.5%, about 4.0%, about 5.5%, about 6.0%, about 6.5%, about 7.0%, about 7.5%, about 8.0%, about 8.5%, about 9.0%, about 9.5%, about 10%, any range of shrinkage values ​​encompassed by any of the foregoing values, or any combination of the foregoing shrinkage values ​​when tested at 50°C according to the method described below.

[0362] In various aspects, the yarn comprising low processing temperature polymer composition has the fusion enthalpy (measurement of crystallinity) when tested according to method described herein from about 15J / g to about 50J / g. In other aspects, the yarn comprising low processing temperature polymer composition has the fusion enthalpy (measurement of crystallinity) when tested according to method described herein from about 17J / g to about 23J / g. In still other aspects, the yarn comprising low processing temperature polymer composition has the fusion enthalpy when tested according to method described herein from about 35J / g to about 42J / g. In some aspects, the yarn comprising low processing temperature polymer composition has the fusion enthalpy when tested according to method described herein from about 15J / g, about 20J / g, about 25J / g, about 30J / g, about 35J / g, about 40J / g, about 45J / g, about 50J / g, any scope of the fusion enthalpy value encompassed by any aforementioned value or any combination of aforementioned fusion enthalpy value.

[0363] In various aspects, yarns comprising the low processing temperature polymer composition have a yarn tenacity of about 2.0 g / denier to about 2.2 g / denier when tested according to EN ISO 2062 with modifications described below; a yarn elongation of about 116% to about 122% when tested according to EN ISO 2062 with modifications described below; a yarn shrinkage of about 8% to about 12% when tested at 50° C. according to the method described below; and a melting enthalpy of about 18 J / g to about 22 J / g when tested according to the method described herein. Contemplated yarns include yarns having any value within a given range, including values ​​at or about the lower or upper limit of the given range.

[0364] In various aspects, yarns comprising the low processing temperature polymer composition have a yarn tenacity of about 3.2 g / denier to about 3.6 g / denier when tested according to EN ISO 2062 with modifications described below; a yarn elongation of about 37% to about 43% when tested according to EN ISO 2062 with modifications described below; a yarn shrinkage of from about 0% to about 3% when tested at 50° C. according to the method described below; and a melting enthalpy of about 35 J / g to about 42 J / g when tested according to the method described herein. Contemplated yarns include yarns having any value within a given range, including values ​​at or about the lower or upper limit of the given range.

[0365] In various aspects, yarns comprising a low processing temperature polymer composition include a first yarn and a second yarn, the first yarn having a yarn tenacity of about 2.0 g / denier to about 2.2 g / denier when tested according to EN ISO 2062 with modifications described below; a yarn elongation of about 116% to about 122% when tested according to EN ISO 2062 with modifications described below; a yarn shrinkage of about 8% to about 12% when tested at 50° C. according to the method described below; and a melting enthalpy of about 18 J / g to about 22 J / g when tested according to the method described herein. Contemplated yarns include yarns having any value within a given range, including values ​​at or about the lower or upper limit of the given range. The second yarn has a yarn tenacity of about 3.2 g / denier to about 3.6 g / denier when tested according to EN ISO 2062 with modifications described below; a yarn elongation of about 37% to about 43% when tested according to EN ISO 2062 with modifications described below; a yarn shrinkage of from about 0% to about 3% when tested at 50° C. according to the method described below; and a melting enthalpy of about 35 J / g to about 42 J / g when tested according to the method described herein. Contemplated yarns include yarns having any value within a given range, including values ​​at or about the lower or upper limit of the given range.

[0366] Formed articles and films

[0367] As discussed above, disclosed film described herein and shaped parts can comprise the selectivity of low processing temperature polymer composition and / or the selectivity of high processing temperature polymer composition and be incorporated into.In various fields, such low processing temperature polymer composition can exist with the form of film or shaped parts comprising low processing temperature polymer composition.In some respects, the film or shaped parts comprising low processing temperature polymer composition are substantially free of high processing temperature polymer composition.In other aspects, the film or shaped parts comprising low processing temperature polymer composition are basically composed of low processing temperature polymer composition.These shaped parts can be manufactured by any suitable means for making shaped parts known in the art, and suitable means are such as polymer extrusion, polymer blow molding, injection molding and machining.These films can be manufactured by any suitable means for making film known in the art such as polymer extrusion.

[0368] Similarly, the high processing temperature polymer composition described above can exist with the form of the film or the shaped parts that comprise the high processing temperature polymer composition.In some respects, the film or the shaped parts that comprise the high processing temperature polymer composition do not contain the low processing temperature polymer composition basically.In other aspects, the film or the shaped parts that comprise the high processing temperature polymer composition are made up of the high processing temperature polymer composition basically.These shaped parts can be made by any suitable means known in the art for the manufacture of shaped parts, and suitable means are such as polymer extrusion, polymer blow molding, injection molding and machining.These films can be made by any suitable means known in the art for the manufacture of film such as polymer extrusion.

[0369] In some aspects, the film or formed part comprising the low processing temperature polymer composition may also comprise a high processing temperature polymer composition. For example, the film or formed part may be a two-component material formed by coextrusion or co-injection of a low processing temperature polymer composition and a high processing temperature polymer composition.

[0370] In some aspects, the films or formed parts described herein can be used to provide specific functionality. For example, in some aspects, a film comprising a low processing temperature polymer composition can be thermoformed to form a film having waterproof or water-resistant properties. In such aspects, a film on the outer surface of an article can be provided by utilizing a film comprising a low processing temperature polymer material.

[0371] As discussed above, in some aspects, film or shaped parts can be painted, for example, for aesthetic purposes. In various fields, film or shaped parts can be painted using conventional coloring techniques. In some aspects, film or shaped parts comprising low processing temperature polymeric composition are not painted, and can be formed by a polymeric composition that is substantially free of pigment, colorant or dye, which can produce a clear or almost transparent region comprising low processing temperature polymeric composition (for example, non-yarn material or non-fibrous material after thermoforming).

[0372] In one or more aspects, the film or the formed parts that comprise the low processing temperature polymer composition can present the modulus from about 1MPa to about 500MPa. In some aspects, the yarn that comprises the low processing temperature polymer composition can present the modulus from about 5MPa to about 150MPa. In one aspect, the yarn that comprises the low processing temperature polymer composition can present the modulus from about 20MPa to about 130MPa. In another aspect, the yarn that comprises the low processing temperature polymer composition can present the modulus from about 30MPa to about 120MPa. In another aspect again, the yarn that comprises the low processing temperature polymer composition can present the modulus from about 40MPa to about 110MPa. As used herein, term " modulus " refers to the corresponding test method described hereinafter in characteristic analysis and characterization program part.

[0373] In one or more aspects, when a film or formed part comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is raised to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 1 MPa to about 500 MPa when pressure tested at about 20°C and 1 atmosphere. In various aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 1 MPa to about 500 MPa when pressure tested at about 20°C and 1 atmosphere. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is reached, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 5 MPa to about 150 MPa when tested at about 20°C and 1 atmosphere of pressure. In one or more aspects, the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. mThe resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 20 MPa to about 130 MPa when tested at about 20° C. and 1 atmosphere of pressure. In one or more aspects, the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m The resulting thermoformed material (e.g., melted yarn component) can exhibit a modulus of from about 30 MPa to about 120 MPa when tested at about 20° C. and 1 atmosphere of pressure. In one or more aspects, the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition. m and then reaches a temperature below the melting temperature T of the low processing temperature polymer composition. m The resulting thermoformed material (eg, melted yarn component) can exhibit a modulus from about 40 MPa to about 110 MPa when tested at about 20°C and 1 atmosphere of pressure.

[0374] As discussed above, in certain aspects, the low processing temperature polymer composition and the high processing temperature polymer composition have different properties. In various aspects, when the thermoforming process is performed at a temperature below the creep relaxation temperature, heat deformation temperature, or Vicat softening temperature of the high processing temperature polymer composition, these different properties allow the low processing temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from the structure before the thermoforming process (e.g., thermoforming from a film or formed part into a melted or partially melted film or formed part), while the high processing temperature polymer composition cannot deform or melt during such a process and can maintain its structure (e.g., as a film or formed part). In such aspects, the melted yarn component formed by the low processing temperature polymer composition during the thermoforming process can be integrally connected to an unchanged structure (e.g., a textile or article, or another film or another formed part), which can provide a three-dimensional structure and / or other properties targeted to a specific point on the wearable article.

[0375] In various aspects, the film or shaped part can be a coated film or a coated shaped part. In further aspects, the coated film or the coated shaped part can be any suitable film or shaped part on which a coating comprising a thermoplastic coating composition or other suitable coating has been formed.

[0376] In certain aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition comprising a thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition comprising a thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0377] In certain aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition comprising a thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition comprising a thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0378] In certain aspects, the thermoplastic coating composition includes a TPU. In some aspects, the TPU can be any such material as described in the present disclosure, such as a TPU prepared by polymerizing an aromatic or aliphatic isocyanate with a polyether polyol or polycaprolactone using a short-chain glycol (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of disclosed TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0379] In various fields, the thermoplastic coating composition can also include additives, such as but not limited to one or more of thickener, processing aid, dye or colorant. In other aspects, additive is not optional, and includes at least one thickener. In still other aspects, additive is not optional, and includes at least one processing aid. In other aspects again, additive is not optional, and includes at least one thickener and at least one processing aid. In some aspects, thickener can include inorganic materials, such as silicon dioxide, talc or calcium carbonate (CaCO ).

[0380] In certain aspects, as described herein, a thickener can be used during the preparation of the thermoplastic coating composition to improve productivity and delustering properties. In other aspects, the thickener is silicon dioxide powder, talc, or CaCO 3 . The thickener is at least partially used to increase the viscosity of the thermoplastic coating composition. In still other aspects, the thickener used in the disclosed thermoplastic coating composition can be an alloy with a resin that can impart compatibility with thermoplastic polyurethane, such as styrene-butadiene-styrene (SBS) block copolymer, styrene-ethylene / butylene-styrene (SEBS) resin, polyacetal resin (POM), or styrene acrylonitrile resin (SAN).

[0381] In certain aspects, the thermoplastic coating composition may include a processing agent to improve productivity. In other aspects, the processing agent may be montan wax or a fatty acid ester (C5-C9) with pentaerythritol. Other processing agents are known to those skilled in the art and may also be used in the disclosed thermoplastic composition. An exemplary commercially available processing aid is ESTANE 58277 (Lubrizol).

[0382] In certain aspects, a film or formed part having a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound used to cover the film or formed part. In other aspects, a TPU compound having a desired hardness for the film or formed part can be prepared by controlling the content of the raw materials.

[0383] In certain aspects, the coated film or shaped part can be prepared by compounding a thermoplastic coating composition comprising a thermoplastic polymer, such as a thermoplastic polyurethane, and optionally one or more additives, in a conventional extruder, and then coating the compounded thermoplastic polyurethane coating composition on the surface of the film or shaped part. In other aspects, a process for preparing the coated film or shaped part comprises the steps of: 1) preparing a shaped thermoplastic pellet; and 2) producing the coated film or shaped part. The shaped thermoplastic pellet can be prepared by the methods disclosed herein, by similar methods known to those skilled in the art, or obtained from commercially available sources.

[0384] The steps of preparing shaped thermoplastic pellets may include the following steps: 1) mixing a thermoplastic polymer with various additives such as a thickener and / or a processing aid, and feeding the mixture into a hopper of a conventional compounding extruder; 2) melting, kneading, and compounding the mixture in the barrel of the compounding extruder at a suitable temperature and pressure; 3) cutting the compounded thermoplastic coating composition discharged through the die of the compounding extruder in cooling water to form pellets; and 4) drying the shaped thermoplastic polyurethane pellets at a suitable temperature for about a certain period of time, and aging the dried pellets at a suitable temperature for a suitable period of time.

[0385] In a specific embodiment, the step of preparing shaped thermoplastic pellets includes at least the following steps: 1) mixing thermoplastic polyurethane with various additives such as thickeners and / or processing aids, and feeding the mixture into the funnel of a conventional compounding extruder; 2) melting, kneading and compounding the mixture in the barrel of the compounding extruder at a temperature of about 150° C. to 250° C. and a pressure of about 50 kgf to 150 kgf; 3) cutting the compounded thermoplastic polyurethane discharged through the tube core of the compounding extruder in cooling water to form pellets; and 4) drying the shaped thermoplastic polyurethane pellets at a temperature of 60° C. to 80° C. for about 4 hours to 6 hours, and aging the dried pellets at a temperature of 30° C. to 50° C. for about 7 days or more.

[0386] In various aspects, when according to the AS T described below m When determined by D3418-97, the formed part or film comprises a melt temperature (T m In another aspect, when the polyamide or poly(ether-block-amide) is prepared according to the AS T as described below, m The polyamide or poly(ether-block-amide) has a melting temperature (T) of from about 93°C to about 99°C as determined by D3418-97. m In still further aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a melting temperature (T) of from about 112°C to about 118°C as determined by D3418-97. m ). In some aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a melting temperature of about 90°C, about 91°C, about 92°C, about 93°C, about 94°C, about 95°C, about 96°C, about 97°C, about 98°C, about 99°C, about 100°C, about 101°C, about 102°C, about 103°C, about 104°C, about 105°C, about 106°C, about 107°C, about 108°C, about 109°C, about 110°C, about 111°C, about 112°C, about 113°C, about 114°C, about 115°C, about 116°C, about 117°C, about 118°C, about 119°C, about 120°C, or a melting temperature encompassed by any of the foregoing values ​​(T m ) value range or the aforementioned melting temperature (T m ) values.

[0387] In various aspects, when according to the AS T described below m When determined by D3418-97, the formed part or film comprises a glass transition temperature (T gIn another aspect, when the polyamide or poly(ether-block-amide) is prepared according to the AS T as described below, m The polyamide or poly(ether-block-amide) has a glass transition temperature (T) of from about -13°C to about -7°C, as determined by D3418-97. g In still further aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a glass transition temperature (T) of from about 17°C to about 23°C, as determined by D3418-97. g ). In some aspects, when according to the AS T described below m The polyamide or poly(ether-block-amide) has a glass transition temperature (Tg) of about -20°C, about -19°C, about -18°C, about -17°C, about -16°C, about -15°C, about -14°C, about -13°C, about -12°C, about -10°C, about -9°C, about -8°C, about -7°C, about -6°C, about -5°C, about -4°C, about -3°C, about -2°C, about -1°C, about 0°C, about 1°C, about 2°C, about 3°C, about 4°C, about 5°C, about 6°C, about 7°C, about 8°C, about 9°C, about 10°C, about 11°C, about 12°C, about 13°C, about 14°C, about 15°C, about 16°C, about 17°C, about 18°C, about 19°C, about 20°C g ), any range of glass transition temperature values ​​encompassed by any of the aforementioned values, or any combination of the aforementioned glass transition temperature values.

[0388] In various aspects, when according to the AS T described below m D1238-13 When tested at 160°C using a 2.16 kg weight, the shaped part or film contains a 3 / 10min to about 30cm 3 In another aspect, when the melt flow rate is 0.01% of the melt flow rate of the polyamide or poly(ether-block-amide) as described below, m D1238-13 Polyamide or poly(ether-block-amide) has a viscosity from about 22 cm when tested at 160°C using a 2.16 kg weight. 3 / 10min to about 28cm 3 In certain aspects, when the melt flow rate is 10 min according to the AS T described below, m Polyamide or poly(ether-block-amide) has a viscosity of about 10 cm when determined by D1238-13 at 160°C using a 2.16 kg weight. 3 / 10min, about 11cm 3 / 10min, about 12cm 3 / 10min, about 13cm 3 / 10min, about 14cm 3 / 10min, about 15cm 3 / 10min, about 16cm 3 / 10min, about 17cm 3 / 10min, about 18cm 3 / 10min, about 19cm 3 / 10min, about 20cm 3 / 10min, about 21cm 3 / 10min, about 22cm 3 / 10min, about 23cm 3 / 10min, about 24cm 3 / 10min, about 25cm 3 / 10min, about 26cm 3 / 10min, about 27cm 3 / 10min, about 28cm 3 / 10min, about 29cm 3 / 10min, about 30cm 3

[0045] The present invention relates to a melt flow index of 100 t / 10 min, any range of melt flow index values ​​encompassed by any of the preceding values, or any combination of the preceding melt flow index values.

[0389] In various aspects, the formed part or film comprises a polyamide or poly(ether-block-amide) having a Cold Ross Flex Test result of about 120,000 to about 180,000 when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below. In further aspects, the polyamide or poly(ether-block-amide) has a Cold Ross Flex Test result of about 140,000 to about 160,000 when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below. In still further aspects, the polyamide or poly(ether-block-amide) has a Cold Ross Flex Test result of about 130,000 to about 170,000 when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below. In some aspects, the polyamide or poly(ether-block-amide) has a Cold Ross Flex Test result of about 120,000, about 125,000, about 130,000, about 135,000, about 140,000, about 145,000, about 150,000, about 155,000, about 160,000, about 165,000, about 170,000, about 175,000, about 180,000, any range of Cold Ross Flex Test values ​​encompassed by any of the foregoing values, or any combination of the foregoing Cold Ross Flex Test values, when a thermoformed plaque of the polyamide or poly(ether-block-amide) is tested according to the Cold Ross Flex Test as described below.

[0390] In various aspects, when the AS T for vulcanized rubber and thermoplastic rubber and thermoplastic elastomer-tension is used according to the modification described below m The formed part or film comprises a polyamide or poly(ether-block-amide) having a modulus of from about 5 MPa to about 100 MPa as determined by D412-98 Standard Test Method for Thermoformed Plaques. In another aspect, when tested according to AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer - Tensile Strength with the modifications described below, m The polyamide or poly(ether-block-amide) has a modulus of from about 20 MPa to about 80 MPa as determined by D412-98 Standard Test Method for Thermoformed Plaques. In some aspects, the polyamide or poly(ether-block-amide) has a modulus of from about 20 MPa to about 80 MPa when tested according to ASTM D412-98 Standard Test Method for Thermoformed Plaques. mWhen the polyamide or poly(ether-block-amide) is tested in accordance with standard test method D412-98 for thermoformed plaques of polyamide or poly(ether-block-amide), the polyamide or poly(ether-block-amide) has a modulus of about 5 MPa, about 10 MPa, about 15 MPa, about 20 MPa, about 25 MPa, about 30 MPa, about 35 MPa, about 40 MPa, about 45 MPa, about 50 MPa, about 55 MPa, about 60 MPa, about 65 MPa, about 70 MPa, about 75 MPa, about 80 MPa, about 85 MPa, about 90 MPa, about 95 MPa, about 100 MPa, any range of modulus values ​​encompassed by any of the foregoing values, or any combination of the foregoing modulus values.

[0391] In various aspects, the shaped part or film comprises a polyamide or poly(ether-block-amide) having: when subjected to the AS T as described below. m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); when according to the AS T described below m When D1238-13 is tested at 160℃ with a weight of 2.16kg, the 3 / 10min melt flow index; when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below, a Cold Ross Flex Test result of about 150,000; and when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension with the modifications described below. m The modulus ranges from about 25 MPa to about 70 MPa when determined by Standard Test Method D412-98 for thermoformed plaques.

[0392] In various aspects, the shaped part or film comprises a polyamide or poly(ether-block-amide) having: when subjected to the AS T as described below. m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); a Cold Ross Flex Test result of approximately 150,000 when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below; and a Cold Ross Flex Test result of approximately 150,000 when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension Test with modifications described below. m A modulus of less than or equal to about 10 MPa when determined in accordance with Standard Test Method D412-98 for thermoformed veneers.

[0393] In various aspects, the shaped part or film comprises a polyamide or poly(ether-block-amide) mixture comprising a first polyamide or first poly(ether-block-amide) and a second polyamide or second poly(ether-block-amide), the first polyamide or first poly(ether-block-amide) having a morphology of about 100 Å when subjected to an AST as described below. m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); when according to the AS T described below m When D1238-13 is tested at 160℃ with a weight of 2.16kg, the 3 / 10min melt flow index; when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below, a Cold Ross Flex Test result of about 150,000; and when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension with the modifications described below. m The second polyamide or second poly(ether-block-amide) has a modulus of from about 25 MPa to about 70 MPa when determined according to Standard Test Method D412-98 for Thermoformed Plaques. m When determined by D3418-97, the melting temperature (T m ); when according to the AS T described below m When determined by D3418-97, the glass transition temperature (T g ); a Cold Ross Flex Test result of approximately 150,000 when the thermoformed plaque is tested according to the Cold Ross Flex Test as described below; and a Cold Ross Flex Test result of approximately 150,000 when tested according to the AS T for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomer-Tension Test with modifications described below. m A modulus of less than or equal to about 10 MPa when determined in accordance with Standard Test Method D412-98 for thermoformed veneers.

[0394] Low processing temperature polymer composition

[0395] As discussed above, in certain aspects, the low processing temperature polymer composition comprises one or more first thermoplastic polymers and can exhibit a heat distortion temperature T lower than that of the high processing temperature ...

Claims

1. An upper and an outsole for an article of footwear, comprising: first reflow material; and a second yarn or a second fiber; wherein the upper and the outsole are integrally connected and include a textile comprising the first backflow material and the second yarn or the second fiber; wherein the first reflow material is a melted and resolidified product of a first yarn or a first fiber; and wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second yarn or the second fiber comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition m At least one of the following: 1) creep relaxation temperature T cr ; 2) Heat deformation temperature T hd ; or 3) Vicat softening temperature T vs ;and wherein the textile comprises at least an inner midshoe region of the upper of an integrally connected upper and an outsole, an outer midshoe region of the upper of the integrally connected upper and an outsole, and an outsole region facing the ground, and at least a portion of the first reflow material is present on a portion of the textile of the integrally connected upper and outsole forming the outsole region facing the ground, The textile comprises an outermost layer comprising at least a portion of the first yarn or the first fiber, the outermost layer comprising a first region and a second region, wherein the first region comprises an increased concentration of the first yarn or the first fiber compared to the second region.

2. The upper and outsole of claim 1 , wherein the at least a portion of the first reflow material is on at least 40% of the ground-facing outsole area.

3. The upper and outsole of claim 2, wherein the at least a portion of the first reflow material is on at least 90% of the ground facing outsole area.

4. An upper and outsole according to claim 1, wherein the integrally connected upper and outsole also include an outer surface having at least a first zone, a second zone and a third zone, the second zone being positioned between the first zone and the third zone, wherein the first zone includes the second yarn having an increased concentration compared to the second zone, and wherein the third zone includes the first reflow material having an increased concentration compared to the second zone.

5. The upper and outsole of claim 4, wherein the third zone is in a ground-facing area of ​​the outsole.

6. An upper for an article of footwear, comprising: a first reflow material, the first reflow material being the melted and resolidified product of a first element selected from a first formed part, a first film, a first textile, a first yarn, or a first fiber, or any combination thereof; a second element selected from a second forming member, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers, wherein the low processing temperature polymer composition exhibits a melting temperature T from 80°C to 135°C m ; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymer composition exhibits a melting temperature T of each lower than that of the low processing temperature polymer composition m 1) Creep relaxation temperature T at least 10°C greater cr ; 2) Heat deformation temperature T hd ; or 3) Vicat softening temperature T vs ; The upper includes a ground-facing outsole area, and at least a portion of the first reflow material is present on the ground-facing outsole area of ​​the upper.

7. The upper of claim 6, wherein the at least a portion of the first reflow material is on at least 40% of the ground-facing outsole area of ​​the upper.

8. The upper of claim 6, comprising an outermost layer comprising at least a portion of the first reflow material, wherein the outermost layer comprises a first area and a second area, wherein the first area comprises an increased concentration of the first reflow material compared to the second area.

9. The upper of claim 8, wherein the first area comprises a ground-facing outsole area; and / or wherein the second area comprises a forefoot opening area and / or an ankle collar area.

10. A process for manufacturing an article, the article being an upper for an article of footwear, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber; receiving a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition m 1) Creep relaxation temperature T cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs ; placing at least a portion of the first element and at least a portion of the second element on a molding surface; When the at least a portion of the first element and the at least a portion of the second element are on the molding surface, the temperature of the entire article is raised to a temperature above the melting temperature T of the low processing temperature polymer composition. m and lower than 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs Temperature; and after raising the temperature of the entire article, while maintaining at least a portion of the upper on the molding surface, lowering the temperature of the entire upper to below the melting temperature T of the low processing temperature polymer composition. m temperature, thereby forming the upper; Wherein the upper includes a ground-facing outsole area, and at least a portion of the first element is present on the ground-facing outsole area.

11. An upper for an article of footwear, comprising: first reflow material; and a second element selected from a second forming member, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and resolidified product of a first element selected from a first formed part, a first film, a first yarn, a first fiber, a first textile or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers, wherein the low processing temperature polymer composition exhibits a melting temperature T from 80°C to 135°C m ; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature Tc that is each higher than that of the low processing temperature polymer composition. m 1) Creep relaxation temperature T at least 10°C greater cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs ; The temperature of the entire upper has been raised to a temperature higher than the melting temperature T of the low processing temperature polymer composition. m and lower than 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs temperature; and The upper includes a toe box area and a heel box area, and at least a portion of the first reflow material is present on the toe box area and / or the heel box area of ​​the upper.

12. The shoe upper of claim 11, wherein the shoe upper includes an outermost layer, the outermost layer including at least a portion of the first reflow material; wherein the outermost layer includes a first area and a second area, wherein the first area includes the first reflow material in an increased concentration compared to the second area.

13. The upper according to claim 12, wherein the second area includes a forefoot opening area and / or an ankle collar area.

14. The upper of claim 12, wherein the outermost layer includes a transition region positioned between the first region and the second region, wherein the transition region includes a reduced concentration of the low processing temperature polymer composition compared to the first region.

15. The upper of claim 14, wherein the transition region comprises an increased concentration of the low processing temperature polymer composition as compared to the second region.

16. A process for manufacturing an upper for an article of footwear, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber; receiving a second element selected from a second forming member, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers and exhibiting a melting temperature T from 80°C to 135°C m ; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymer composition exhibits a melting temperature Tc that is each lower than that of the low processing temperature polymer composition. m 1) Creep relaxation temperature T at least 10°C greater cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs ; placing at least a portion of the first element and at least a portion of the second element on a molding surface; When the at least a portion of the first element and the at least a portion of the second element are on the molding surface, the temperature of the entire upper is raised to a temperature above the melting temperature T of the low processing temperature polymer composition. m and lower than 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs and after raising the temperature of the entire upper, while maintaining at least a portion of the upper on the molding surface, lowering the temperature of the entire upper to below the melting temperature T of the low processing temperature polymer composition. m temperature, thereby forming the upper; The upper includes an outermost layer, the outermost layer includes at least a portion of the first element comprising the low processing temperature polymer composition, the outermost layer includes a first area and a second area, wherein the first area includes an increased concentration of the first element comprising the low processing temperature polymer composition compared to the second area, wherein the first area includes a toe box area and a heel area.

17. A combined upper and outsole for an article of footwear, comprising: a textile comprising a first textile region, a second textile region and a third textile region, wherein the textile forms at least a medial midfoot region, a lateral midfoot region and a ground-facing outsole region of the combined upper and outsole, wherein the first textile region is rigid or semi-rigid and forms at least a portion of the ground-facing outsole area of ​​the combined upper and outsole, and when the combined upper and outsole is present in an article of footwear, the first textile region forms at least a portion of the ground-facing outsole area of ​​the article of footwear; wherein the first textile region comprises a first reflow material, wherein the first reflow material is a melted and resolidified product of a first yarn; wherein the first reflow material comprises a low processing temperature polymer composition; the low processing temperature polymer composition comprises one or more first thermoplastic polymers and exhibits a melting temperature T of 135° C. or less m ; wherein the second textile area is flexible and / or tough and forms an ankle collar area, a tongue area and / or a throat area of ​​the combined upper and outsole, and when the combined upper and outsole are present in an article of footwear, the second textile area forms an ankle collar area, a tongue area and / or a throat area of ​​the article of footwear; and wherein the second textile region comprises a second yarn, the second yarn comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymer composition exhibits a melting temperature T greater than the low processing temperature polymer composition m At least one of the following: 1) creep relaxation temperature T cr ; 2) Heat deformation temperature T hd ; or 3) Vicat softening temperature T vs ; wherein the third textile area comprises at least a portion of a second yarn present in at least a first row of loops and a second row of loops, wherein at least a portion of the first row of loops of the second yarn and at least a portion of the second row of loops of the second yarn are connected by at least a portion of the first return material.

18. The combination upper and outsole of claim 17, wherein the at least a portion of the first reflow material is on at least 90% of the ground facing outsole area.

19. A combination upper and outsole according to claim 17, wherein the third textile area is positioned between the first textile area and the second textile area, the third textile area forms at least a portion of the medial mid-shoe area and / or the lateral mid-shoe area of ​​the combined upper and outsole, and when the combined upper and outsole is present in a footwear article, the third textile area forms at least a portion of the medial mid-shoe area and / or the lateral mid-shoe area of ​​the footwear article, and the third textile area is less rigid than the first textile area and the third textile area is more rigid than the second textile area.

20. The combination upper and outsole of claim 19, wherein the first textile zone is in the ground-facing outsole area and in the medial midfoot area and the lateral midfoot area.

21. The combination upper and outsole of claim 19, wherein the first textile zone is in the medial midfoot area or the lateral midfoot area or both.

22. An article of footwear comprising a textile, the textile comprising a first textile region, a second textile region, and a third textile region, the third textile region being positioned between the first textile region and the second textile region, wherein the first textile region is rigid or semi-rigid, the second textile region is flexible, and the third textile region is less rigid or semi-rigid than the first textile region and more rigid or semi-rigid than the second textile region; wherein the first textile region comprises a first reflow material, the first reflow material being a melted and resolidified product of a first element selected from a first yarn or a first fiber, the first reflow material comprising a low processing temperature polymer composition, wherein the low processing temperature polymer composition comprises one or more first thermoplastic polymers and exhibits a melting temperature T of 135° C. or less m ;and wherein the second textile region comprises a second element selected from a second yarn or a second fiber, wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers and exhibiting a melting temperature T of each lower than that of the low processing temperature polymer composition. m 1) Creep relaxation temperature T at least 10°C greater cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs , wherein the article of footwear includes a medial midfoot region, a lateral midfoot region, and a ground-facing outsole region, and at least a portion of the first reflow material is present on the ground-facing outsole region.

23. The article of footwear recited in claim 22, wherein the first textile region forms at least a portion of a ground-facing outsole area of ​​the article of footwear.

24. The article of footwear according to claim 22, wherein one or more of the first textile area, the second textile area, and the third textile area form at least a portion of a lateral midfoot region of the article of footwear, a medial midfoot region of the article of footwear, or both.

25. The article of footwear recited in claim 24, wherein the third textile zone forms at least a portion of a lateral midfoot region of the article of footwear, a medial midfoot region of the article of footwear, or both.

26. The article of footwear according to claim 24, wherein the second yarn or the second fiber is an axially dyed yarn or fiber.

27. A process for manufacturing an upper for an article of footwear, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber, and receiving a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; Placing at least a portion of the first element and at least a portion of the second element on a molding surface, the molding surface being the molding surface of the last, the placing comprising: firstly placing a majority of the first forming element on the molding surface, and then covering at least a portion of the majority of the first forming element on the molding surface of the last with at least a portion of the second element; wherein the first element comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition m 1) Creep relaxation temperature T cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs ; wherein receiving the first element comprises receiving a first formed element, the first formed element comprising two or more portions, the two or more portions being selected from a portion of a third film, a portion of a third textile, or both, wherein at least one of the third film and the third textile comprises a low processing temperature polymer composition comprising at least one third thermoplastic polymer, wherein the two or more portions are secured to one another in a configuration configured to fit over the last; When the at least a portion of the first element and the at least a portion of the second element are on the molding surface of the last, the temperature of the entire upper is raised to a temperature above the melting temperature T of the low processing temperature polymer composition. m and lower than 1) creep relaxation temperature T of the high processing temperature polymer composition cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs Temperature; After raising the temperature of the entire upper, while keeping at least a portion of the upper on the molding surface of the last, lowering the temperature of the entire upper to below the melting temperature T of the low processing temperature polymer composition. m temperature, thereby forming the upper.

28. The process of claim 27, wherein the low processing temperature polymer composition exhibits a melting temperature T of from 80°C to 135°C. m .

29. The process of claim 27, wherein the high processing temperature polymer composition exhibits a melting temperature T of each lower than that of the low processing temperature polymer composition. m 1) Creep relaxation temperature T at least 10°C greater cr ; 2) Heat deformation temperature T hd ; and 3) Vicat softening temperature T vs .

30. The process of claim 27, wherein the two or more portions of the first forming element are secured to one another using sutures.

31. The process of claim 30, wherein the suture comprises a low processing temperature polymer composition comprising at least one fourth thermoplastic polymer.

32. A knitted textile (300), comprising: a first textile region (302; 422; 436) comprising fibers and / or yarns comprising a low processing temperature polymer composition; a second textile region (304a, 304b) comprising a combination of fibers and / or yarns comprising the low processing temperature polymer composition and fibers and / or yarns comprising a high processing temperature polymer composition; and a third textile zone (306a, 306b) comprising fibers and / or yarns comprising the high processing temperature polymer composition, in The melting temperature of the low processing temperature polymer composition is lower than the melting temperature or decomposition temperature of the high processing temperature polymer composition, the second textile region (304a, 304b) comprising a plurality of sub-regions (305a, 305b, 305c, 305d; 424a, 424b, 424c, 424d; 438a, 438b, 438c, 438d) comprising different combinations and / or different positioning of fibers and / or yarns comprising the low processing temperature polymer composition and fibers and / or yarns comprising the high processing temperature polymer composition, the first textile region (302; 422; 436) comprising an increased concentration of fibers and / or yarns comprising the low processing temperature polymer composition as compared to the second textile region (304a), the second textile region (304a, 304b) comprising an increased concentration of fibers and / or yarns comprising the high processing temperature polymer composition as compared to the first textile region (302; 422; 436) and an increased concentration of fibers and / or yarns comprising the low processing temperature polymer composition as compared to the third textile region (304a, 304b), the third textile region (306a, 306b) comprising an increased concentration of fibers and / or yarns comprising the high processing temperature polymer composition as compared to the second textile region (304a, 304b), In the second textile region (304a), the sub-regions (305a-305d) have at least one staggered interface (306) that provides a staggered or non-linear transition between sub-regions of the knitted textile (300).

33. The knitted textile (300) according to claim 32, wherein the low processing temperature polymer composition exhibits a melting temperature of 135°C or less.

34. The knitted textile (300) according to claim 32 or 33, wherein In the portion (600) of the staggered interface (306), a first row (602) of coils is interconnected to a second row (604) of coils, and Both the first row (602) and the second row (604) include a first yarn (606) that can include the high processing temperature polymer composition and a second yarn (608) that can include the low processing temperature polymer composition.

35. The knitted textile (300) according to claim 34, wherein The second textile area (304a, 304b) is positioned on one side of the first textile area (302; 422; 436), and the third textile area (306a, 306b) is positioned on an opposite side of the second textile area (304, 304b).

36. The knitted textile (300) according to claim 34 or 35, wherein In the first horizontal row (602), the second yarn (608) extends from the first textile region (302) into the second textile region (304a) and toward the third textile region (306a) further than the second yarn (608) in the second horizontal row (604) extends from the first textile region (302) into the second textile region (304a) and toward the third textile region (306a).

37. The knitted textile (300) according to any one of claims 34 to 36, wherein In the second textile area (304a), the loops of the second yarn (608) in the first row (602) are interlaced with the loops of the second yarn (608) in the second row (604) at the first longitudinal row, and at the second longitudinal row (610), the loops of the second yarn (608) in the first row (602) are interlaced with the loops of the first yarn (606) in the second row (604).

38. The knitted textile (300) according to any one of claims 34 to 37, wherein In the second textile region (304a), the first yarn (606) in the first row (602) is interlaced with the first yarn (606) in the second row (604) at a third wale (612).

39. The knitted textile (300) according to any one of claims 34 to 38, wherein In at least a portion of the second textile area (304a), the first course (602) has a different number of loops of the first yarn (606) and / or the second yarn (608) than the second course (604).

40. The knitted textile (300) according to any one of claims 32 to 39, wherein In at least a portion of the second textile region (304a), adjacent wales have one or more loops of different yarns.

41. The knitted textile (300) according to any one of claims 32 to 40, wherein The first textile region (302) has at least 5 wt%, 10 wt%, or 25 wt% more fibers and / or yarns comprising the low processing temperature polymer composition than the second textile region (304a).

42. The knitted textile (300) according to any one of claims 32 to 41, wherein The second textile region (304a) has at least 5 wt%, 10 wt%, or 25 wt% more fibers and / or yarns comprising the high processing temperature polymer composition than the first textile region (302).

43. The knitted textile (300) according to any one of claims 32 to 42, wherein the high processing temperature polymer composition exhibits a melting temperature from 140°C to 500°C.

44. A method of forming a textile product, comprising: Thermoforming to melt or deform at least a portion of the low processing temperature polymer composition present in the knitted textile (300) of any one of claims 32 to 43.

45. The method of claim 44, wherein The thermoforming is performed within a temperature range that causes the low processing temperature polymer composition to melt or deform, while the high processing temperature polymer composition does not melt and / or deform.

46. ​​A textile (300) comprising first fibers and / or first yarns comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers; and second fibers and / or second yarns comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, The textile (300) comprises: a first textile region (302) comprising said first fibers and / or said first yarns comprising said low processing temperature polymer composition; a second textile region comprising the high processing temperature polymer composition; and a third textile region comprising a combination of said first fibers and / or said first yarns comprising said low processing temperature polymer composition and said second fibers and / or said second yarns comprising said high processing temperature polymer composition, wherein the third textile region comprises an increased concentration of the second fibers and / or the second yarns comprising the high processing temperature polymer composition as compared to the first textile region (302), and the third textile region comprises an increased concentration of the first fibers and / or the first yarns comprising the low processing temperature polymer composition as compared to the second textile region, and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition m At least one of the following: 1) creep relaxation temperature T cr ; 2) Heat deformation temperature T hd ; or 3) Vicat softening temperature T vs .

47. The textile (300) of claim 46, wherein the third textile region is positionable on either side of the first textile region (302), and the second textile regions are positionable on opposite sides of the third textile region, respectively.

48. A textile (300) according to claim 46 or claim 47, wherein the third textile area comprises a plurality of sub-areas (305a, 305b, 305c, 305d) of the third textile area, and the plurality of sub-areas may include different combinations and / or different positioning of the first fibers and / or the first yarns comprising the low processing temperature polymer composition and the second fibers and / or the second yarns comprising the high processing temperature polymer composition.

49. A textile (300) according to any one of claims 46-48, wherein the first textile region (302) comprises an increased concentration of the first fibers and / or the first yarns comprising the low processing temperature polymer composition compared to the second textile region and / or the third textile region; and / or wherein the second textile region comprises an increased concentration of the second fibers and / or the second yarns comprising the high processing temperature polymer composition compared to the first textile region (302) and / or the third textile region.

50. A textile (300) according to claim 49, wherein the first textile region (302) has at least 5 wt% more first fibers and / or first yarns comprising the low processing temperature polymer composition than the second textile region and / or the third textile region; and / or wherein the second textile region comprises at least 5 wt% more second fibers and / or second yarns comprising the high processing temperature polymer composition than the first textile region (302) and / or the third textile region.

51. A textile (300) according to any one of claims 46-50, wherein the third textile region comprises at least 5 wt% more first fibers and / or first yarns comprising the low processing temperature polymer composition than the second textile region, and the third textile region has at least 5 wt% more second fibers and / or second yarns comprising the high processing temperature polymer composition than the first textile region (302).

52. A textile (300) according to any one of claims 46-49, wherein the first textile region (302) includes the first fibers and / or the first yarns comprising the low processing temperature polymer composition, but does not include the second fibers and / or the second yarns comprising the high processing temperature polymer composition present in the second textile region.

53. The textile (300) according to any one of claims 46 to 52, wherein the low processing temperature polymer composition exhibits a melting temperature T of 135°C or less. m .

54. A method of manufacturing a textile article by thermoforming a textile (300) according to any one of claims 46 to 53, the method comprising: placing at least a portion of the textile (300) on a molding surface, While the textile (300) remains in contact with the molding surface, the temperature of the entire textile (300) is raised to a first temperature that is higher than the melting point of the low processing temperature polymer composition but lower than at least one of the following of the high processing temperature polymer composition: 1) the creep relaxation temperature T cr ; 2) Heat deformation temperature T hd ; or 3) Vicat softening temperature T vs , and then The temperature of the entire textile is lowered to the second temperature.

55. A textile article obtainable by the method of claim 54, comprising: first reflow material; and said second yarn or said second fiber; The first reflow material is a melted and resolidified product of the first yarn or the first fiber.

56. The textile article according to claim 55 comprises a melted fiber component (1120), wherein the melted fiber component (1120) is thermoformed from a first state as a plurality of first fibers comprising the low processing temperature polymer composition to a second state as the melted fiber component (1120), wherein the melted fiber component (1120) comprises a plurality of partially melted first fibers, a plurality of substantially completely melted first fibers, and a mixture thereof, and a plurality of second fibers comprising the high processing temperature polymer composition.

57. A textile article according to claim 56, wherein the molten fiber component (1120) and the plurality of second fibers at least partially form a structure having at least a first zone, a second zone and a third zone, wherein the second zone is positioned between the first zone and the third zone; the first zone includes a higher concentration of the plurality of molten first fibers than the second zone, and the third zone includes a higher concentration of the plurality of second fibers than the second zone.

58. A textile article according to claim 55, comprising a melted yarn component, which is thermoformed from a first state as the first yarn to a second state as the melted yarn component, the melted yarn component is formed by a yarn that has been at least partially melted and resolidified into a new structure that is different from its yarn structure; and the second yarn comprises a high processing temperature polymer composition.

59. A textile article according to claim 58, wherein the molten yarn component and the second yarn at least partially form a structure having at least a first zone, a second zone and a third zone, wherein the second zone is positioned between the first zone and the third zone, the first zone includes a higher concentration of the molten yarn component than the second zone, and the third zone includes a higher concentration of the second yarn than the second zone.

60. The textile article of claim 57 or claim 59, wherein the structure forms an outer surface of the article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

61. The textile article according to any one of claims 55 to 60, wherein the textile article is a component of an article of clothing (200) or an article of footwear (100) or an article of sports equipment.

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