Knitted textiles and shoe uppers and their manufacturing methods

Abstract

This application relates to a knitted textile and a shoe upper and a method for manufacturing the same. There is disclosed a wearable article having one or more textiles, the textile including a low processing temperature polymer composition and a high processing temperature polymer composition; and a method for manufacturing the wearable article. The low processing temperature polymer composition and the high processing temperature polymer composition can be selectively incorporated into the textile to provide one or more structural properties and / or other advantageous properties to the article. 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 search tool for retrieval purposes in a particular technical field and is not intended to limit the present disclosure.

Description

[0001] This application is a divisional application of the application with the filing date of November 9, 2017, application number 202110802431X, and invention title "Knitted Textiles and Shoe Upper and Manufacturing Method Thereof".

[0002] The application with the filing date of November 9, 2017, application number 202110802431X, and invention title "Knitted Textiles and Shoe Upper and Manufacturing Method Thereof" is a divisional application of the application with the filing date of November 9, 2017, application number 201711100304.5, and invention title "Knitted Textiles and Shoe Upper and Manufacturing Method Thereof".

[0003] Cross - reference to related applications

[0004] 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, the entire disclosures of which are incorporated herein by reference. Technical field

[0005] The present disclosure relates to articles, such as apparel articles, footwear articles, and sports equipment articles. More specifically, the present disclosure relates to articles comprising one or more materials, the one or more materials comprising 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 comprising a low - processing - temperature polymer composition and a high - processing - temperature polymer composition. Background of the invention

[0006] Traditionally, certain wearing articles, such as footwear articles, are made by cutting individual pieces of material and assembling them together. The individual pieces can be assembled by sewing and / or using adhesives. However, cutting and assembling multiple pieces of material is a wasteful, labor - intensive, and error - prone process, where such errors result in increased waste as well as increased manufacturing time and energy. Summary of the invention

[0007] One aspect of the present disclosure provides a knitted textile, the knitted textile comprising:

[0008] A first yarn comprising a low - processing - temperature polymer composition, the low - processing - temperature polymer composition comprising one or more first thermoplastic polymers; and

[0009] A second yarn comprising a high - processing - temperature polymer composition, the high - processing - temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high - processing - temperature polymer composition exhibits a melting temperature T higher than that of the low - processing - temperature polymer compositionm at least one of the following: 1) the creep relaxation temperature T cr ; 2) the heat distortion temperature T hd ; or 3) the Vicat softening temperature T vs ;

[0010] wherein the first yarn and the second yarn at least partially form a plurality of interconnected courses on the outer surface of the knitted textile, the outer surface comprising at least a first zone, a second zone, and a third zone, the second zone being located between the first zone and the third zone, the first zone including an increased concentration of the second yarn compared to the second zone, and the third zone including an increased concentration of the first yarn compared to the second zone.

[0011] In some embodiments, the knitted textile is a component of a footwear article, a component of a clothing article, or a component of a sports equipment article.

[0012] In some embodiments, the knitted textile is an upper for a footwear article; and wherein the third zone includes a region configured as a ground-facing outsole region, a region configured as a sole perimeter region, a region configured as a heel region, a region configured as a collar region, and combinations thereof.

[0013] In some embodiments, the knitted textile is an upper for a footwear article; and wherein the second zone includes a region configured as a sole perimeter region, a region configured as a heel region, a region configured as a collar region, a region configured as a medial midfoot region, a region configured as a lateral midfoot region, and combinations thereof.

[0014] In some embodiments, the first zone includes a region configured as a forefoot opening region, a region configured as an ankle collar region, or both.

[0015] In some embodiments, the first zone is substantially free of the first yarn.

[0016] In some embodiments, the first yarn exhibits a tenacity of from about 1 gram / denier to about 5 grams / denier, or exhibits an elongation of less than about 130%, or exhibits a shrinkage of less than about 60%, or any combination thereof.

[0017] In some embodiments, the one or more first thermoplastic polymers of the first yarn comprise one or more thermoplastic polymers selected from the group consisting of polyester, polyether, polyamide, polyurethane, and polyolefin.

[0018] In some embodiments, the one or more first thermoplastic polymers comprise a thermoplastic polyamide, a thermoplastic poly(ether block amide), or a thermoplastic polyurethane, and the low processing temperature polymer composition exhibits a melting temperature of from about 80 °C to about 135 °C, exhibits a glass transition temperature T of about 50 °C or lower g , exhibits a melt flow index of from about 0.1 g / 10 min to about 60 g / 10 min at 160 °C using a test weight of 2.16 kg, exhibits a melting enthalpy of at least 5 J / g, and exhibits a modulus of from about 1 MPa to about 500 MPa.

[0019] In some embodiments, the high processing temperature polymer composition exhibits a melting temperature T above 140 °C m .

[0020] In some embodiments, the second yarn is a package-dyed polyester yarn.

[0021] Another aspect of the present disclosure provides a method for manufacturing a knitted article, the method comprising:

[0022] providing a complete knitted textile comprising a first yarn and a second yarn, the first yarn comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers; 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 at least one of the following that is higher than the melting temperature T of the low processing temperature polymer composition: 1) creep relaxation temperature T m ; 2) heat distortion temperature T cr ; or 3) Vicat softening temperature T hd ; wherein the first yarn and the second yarn at least partially form a plurality of interconnected courses on the outer surface of the complete knitted textile, the outer surface comprising at least a first zone, a second zone, and a third zone, the second zone being located between the first zone and the third zone, the first zone comprising an increased concentration of the second yarn compared to the second zone, and the third zone comprising an increased concentration of the first yarn compared to the second zone; vs placing at least a portion of the complete knitted textile on a molded outer surface;

[0023] while at least a portion of the complete knitted textile is on the molded outer surface, increasing the temperature of the complete knitted textile to a temperature that is higher than the melting temperature T of the low processing temperature polymer composition

[0024] m ​and at least one of the following of the high - processing - temperature polymer composition: 1) the creep - relaxation temperature T cr ; 2) the heat - deflection temperature T hd ; or 3) the Vicat softening temperature T vs ; and

[0025] After increasing the temperature of the complete knitted textile, while at least a portion of the complete knitted textile remains on the molded outer surface, the temperature of the complete knitted textile is decreased to a temperature below the melting temperature T m of the low - processing - temperature polymer composition, thereby forming a knitted article.

[0026] In some embodiments, the molded outer surface is a shoe last for a footwear article.

[0027] In some embodiments, the complete knitted textile includes a knitted - textile inner surface and a knitted - textile outer surface; wherein at least a portion of the complete knitted textile on the shoe last has a knitted - textile inner surface in contact with the molded outer surface; and wherein placing at least a portion of the complete knitted textile on the shoe last further includes placing a protective cover in contact with at least a portion of the complete knitted textile on the shoe last; wherein at least a portion of the protective cover is in contact with the knitted - textile outer surface.

[0028] In some embodiments, the protective cover is formed of a silicone elastomer, and increasing the temperature of the complete knitted textile is increasing the temperature of the complete knitted textile to a temperature below the melting temperature or degradation temperature of the silicone elastomer.

[0029] In some embodiments, the protective cover further includes a protective - cover raised surface in contact with at least a portion of the knitted - textile outer surface.

[0030] In some embodiments, the method further includes placing a bag in contact with at least a portion of the protective cover after placing the protective cover in contact with at least a portion of the knitted - textile outer surface, and then compressing the inner surface of the bag against the outer surface of the protective cover.

[0031] Another aspect of the present disclosure provides a knitted article, the knitted article comprising:

[0032] A first reflow material, wherein the first reflow material is a melted and re - solidified product of a first yarn, and wherein the first reflow material comprises a low - processing - temperature polymer composition, the low - processing - temperature polymer composition comprising one or more first thermoplastic polymers; and

[0033] A second yarn comprising a high processing temperature polymer composition, the high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a melting temperature T higher than that of the low processing temperature polymer composition m of at least one of the following: 1) creep relaxation temperature T cr ; 2) heat distortion temperature T hd ; or 3) Vicat softening temperature T vs ;

[0034] wherein at least a portion of the second yarn is present in at least a first course and a second course, wherein at least a portion of the first course of the second yarn and at least a portion of the second course of the second yarn are joined by at least a portion of the first backflow material, and the knitted article has an outer surface comprising at least a first zone, a second zone, and a third zone, the second zone being located between the first zone and the third zone, the first zone comprising an increased concentration of the second yarn compared to the second zone, and the third zone comprising an increased concentration of the first backflow material compared to the second zone.

[0035] In some embodiments, the knitted article is a component of a footwear article, a component of a clothing article, or a component of a sports equipment article.

[0036] In some embodiments, the knitted article is a component of a footwear article, and at least a portion of the third zone is a ground-facing outsole region. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Other aspects of the present disclosure will be readily apparent after review of the detailed description in conjunction with the accompanying drawings.

[0038] Figure 1A is a top and side perspective view of a footwear article in accordance with aspects of the present invention, which illustrates primarily the locations of three different textile zones.

[0039] Figure 1B is in accordance with aspects of the present invention Figure 1A bottom and side perspective view of a footwear article.

[0040] Figure 1C is in accordance with aspects of the present invention Figure 1A top and side perspective view of an alternative aspect of a footwear article, which illustrates primarily the locations of three different textile zones.

[0041] Figure 2A is a side view of a clothing article in accordance with aspects of the present invention, which illustrates primarily an elbow patch.

[0042] Figure 2B According to various aspects of the present invention Figure 2A Close-up view of the elbow patch of an article of clothing illustrating the three different textile zones.

[0043] Figure 3 is a schematically depicted plan view of a textile having three types of textile regions according to aspects of the present invention.

[0044] FIG. 4A to FIG. 4E Describe the various aspects of the present invention Figure 3 Exemplary cross-sections of textile areas of various types of textiles.

[0045] FIG. 5A to FIG. 5J Describe the various aspects of the present invention that may exist in FIG. 4A to FIG. 4E An exemplary knitted structure in each section of the exemplary cross-section depicted in FIG.

[0046] Figure 6 is a schematic representation of two interconnected courses having different types of yarns and depicting an interlaced interface in accordance with aspects of the present invention.

[0047] Fig. 7A is a schematic representation of three interconnected courses in accordance with aspects of the present invention, wherein the middle course is formed from a different yarn than the outer courses.

[0048] Figure 7B is according to aspects of the present invention after exposure to a thermoforming process Fig. 7A Schematic representation of interconnected rows of loops and showing that the middle row of loops is converted to a molten yarn component after thermoforming, but the two outer rows of loops are not converted.

[0049] Figure 8 According to various aspects of the present invention Figure 7B Schematic representation of a cross-section of a melted yarn component and showing that a portion of the yarn from one of the external rows of stitches is encapsulated within the melted yarn component.

[0050] Fig.9A is a schematic representation of a cross-section of a portion of the interconnected rows of FIG. 7 showing one coil in the middle row of coils and one coil in the upper row of coils in accordance with aspects of the present invention.

[0051] Fig. 9B is after the interconnected rows of FIG. 7 have been exposed to a thermoforming process according to aspects of the present invention. Fig.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.

[0052] Fig. 10A Schematic representation of three interconnected courses of a type of yarn according to aspects of the present invention, where the anchoring yarn is in a float stitch and a tuck stitch.

[0053] Fig. 10B is according to aspects of the present invention Fig. 10A Schematic representation of interconnected courses, and shows that after thermoforming, a type of yarn forming the interconnected courses has been transformed into molten yarn components, where the anchoring yarn still appears as yarn.

[0054] Fig. 10C is according to aspects of the present invention Fig. 10B Schematic representation of a cross-section of the molten yarn components, which shows the anchoring yarn encapsulated within the molten yarn components.

[0055] Fig.11A is according to aspects of the present invention Figure 3 Schematic representation of a part of one of the textile areas of a textile according to aspects of the present invention, and shows areas of different types of fibers.

[0056] Fig. 11B is according to aspects of the present invention after exposure to a thermoforming process Fig.11A Schematic representation of a part, and shows that one type of fiber among multiple types of fibers has been transformed into a non-fibrous material, where fibers of another material are embedded within the non-fibrous material.

[0057] Fig. 11C is according to aspects of the present invention Fig. 11B Cross-section of the non-fibrous material, which shows two other fibers encapsulated within the non-fibrous material.

[0058] Fig.12 Side view of a schematic representation of a footwear article comprising a textile material according to aspects of the present invention, and shows a chassis, a heel support, and an insole for incorporation into the footwear article.

[0059] Fig.13 is according to aspects of the present invention Fig.12 Cross-section of the footwear article, which has a chassis, a heel support, and an insole positioned inside the footwear article.

[0060] Fig.14 Side view of a schematic representation of a footwear article comprising a textile material according to aspects of the present invention, which shows ground-engaging cleats added to the ground-facing outsole area of the footwear article.

[0061] Fig.15is a top and side perspective view according to aspects of the present invention, showing an upper for a footwear product placed on a shoe last.

[0062] Fig.16 is a top and side perspective view of the upper from Fig.15 on a shoe last according to aspects of the present invention, showing the upper at least surrounding the bottom portion of the shoe last.

[0063] Fig.17 is a cross - section of the upper from Fig.16 on a shoe last according to aspects of the present invention, showing the shoe last in contact with the inner surface of the upper.

[0064] Fig.18 is a top and side perspective view of the upper from Fig.16 on a shoe last according to aspects of the present invention, showing a protective cover surrounding the upper.

[0065] Fig.19 is a cross - section of the upper covered with a protective cover from Fig.18 on a shoe last according to aspects of the present invention, showing the protective cover in contact with the outer surface of the upper.

[0066] Fig. 20A is a side view of the upper from Fig.16 on a shoe last according to aspects of the present invention, showing a vacuum bag with the upper placed inside.

[0067] Fig. 20B is a side view of the upper inside the Fig. 20A vacuum bag according to aspects of the present invention, showing the vacuum bag pressing against the outer surface of the upper.

[0068] Fig.21 is a schematic representation of a thermoforming system having a heating zone and a cooling zone according to aspects of the present invention.

[0069] Fig. 22 is a flowchart of an exemplary process for manufacturing an upper for a shoe according to aspects of the present invention.

[0070] Fig.23 is a flowchart of another exemplary process for manufacturing an upper for a shoe according to aspects of the present invention.

[0071] Fig.24 is a flowchart of an exemplary process for making a knitted upper for a footwear product according to aspects of the present invention.

[0072] Fig.25 is a flowchart of an exemplary process for forming a knitted article according to aspects of the present invention.

[0073] Fig.26 FIG. 0 is a flow chart of an exemplary process for making an upper for a footwear article in accordance with aspects of the present invention.

[0074] Fig. 27 FIG. 5 is a flow chart of an exemplary process for making a sole for a footwear article in accordance with aspects of the present invention. Specific Embodiments

[0075] The present disclosure relates to textiles or combinations of textiles and other materials (e.g., formed components, membranes, second textiles, yarns, or fibers), where one or more of the textiles or other materials include a low processing temperature composition, and one or more of the textiles or other materials include a high processing temperature composition. In some aspects, a single textile includes both a low processing temperature composition and a high processing temperature composition. The present disclosure also relates to methods of thermoforming a textile, alone or in combination with one or more other materials, on a molding surface to re-shape the textile, attaching the one or more other materials to the textile using a reflow polymeric material, or both. 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, increasing the temperature of the entire textile to a first temperature and then decreasing the temperature of the entire textile to a second temperature. The first temperature is a temperature that is above the melting point of the low processing temperature composition but below at least one of the following of the high processing temperature polymeric composition: 1) the creep relaxation temperature T cr ; 2) the heat distortion temperature T hd ; or 3) the Vicat softening temperature T vsThus, using the disclosed process, portions of the textile and / or one or more materials that comprise the low processing temperature composition will melt, reflow, and then resolidify into a new shape or configuration, while portions that form the high processing temperature composition will retain their original shape or configuration. Forming first fibers and / or yarns from the low processing temperature composition and using these fibers and / or yarns to construct textiles such as woven textiles, knitted textiles, non-woven textiles, braided textiles, etc. are particularly effective and efficient ways to incorporate the low processing temperature composition in these thermoforming processes. For example, the use of the disclosed textiles and processes makes it possible to produce a thermoformed article comprising integrally formed regions using only a single textile and only a single thermoforming process, the article having properties ranging from conventional textiles to solid molded polymeric materials. It has been found that producing yarns and / or fibers that function well in the disclosed process while also producing a final article having the desired properties also requires the use of a low processing temperature composition that has a balance of several properties disclosed herein. Examples of polymers that can provide this property balance in the low processing temperature composition are also disclosed. In certain instances, low processing temperature compositions for making yarns suitable for use on commercial weaving or knitting equipment are also disclosed.

[0076] Accordingly, in various aspects, the present disclosure is directed to overcoming the disadvantages of various aspects of the prior art. In particular, one aspect of the present disclosure is to provide a knitted fabric that can be a component of a footwear article, a clothing article, or a sports equipment component that comprises a low temperature processing polymer composition and a high temperature processing polymer composition. In some aspects, the knitted fabric is a component of a footwear article such as an upper. The knitted fabric can be manufactured using the disclosed process, which comprises knitting a first row of loops consisting of a first yarn and a second yarn, the first yarn comprising a low temperature processing polymer composition, and the low temperature processing polymer composition comprising one or more first thermoplastic polymers, and the second yarn comprising a high temperature processing polymer composition, and the high temperature processing polymer composition comprising one or more second thermoplastic polymers.

[0077] The disclosed knitted fabric can be used to manufacture a knitted article comprising a first reflow material that is the product of melting and resolidifying on the first yarn, the first reflow material comprising a low temperature processing polymer composition, and the low temperature processing polymer composition comprising one or more first thermoplastic polymers; and a second yarn comprising a high temperature processing polymer composition, and the high temperature processing polymer composition comprising one or more second thermoplastic polymers. A process for making a knitted article is also disclosed herein. The knitted article can be a footwear article, a clothing article, or a sports equipment article.

[0078] In various aspects, the present disclosure relates to the composition of a knitted article: a first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, a second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits a creep relaxation temperature T cr higher than the melting temperature T m of the cryogenically treated polymer composition, and a first portion of the knitted article comprises a plurality of interconnected loops formed of at least the first yarn and the second yarn.

[0079] In one aspect, the present disclosure relates to the composition of a knitted article: a first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, a second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits a heat distortion temperature T hd higher than the melting temperature T m of the cryogenically treated polymer composition, and a first portion of the knitted article comprises a plurality of interconnected loops formed of at least the first yarn and the second yarn.

[0080] In one aspect, the present disclosure relates to the composition of a knitted article: a first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, a second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits a Vicat softening temperature T vs higher than the melting temperature T m of the cryogenically treated polymer composition, and a first portion of the knitted article comprises a plurality of interconnected loops formed of at least the first yarn and the second yarn.

[0081] In one aspect, the present disclosure relates to the composition of a knitted article: a first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, the cryogenically treated polymer composition exhibits a melting temperature T m of 135 °C or lower; a second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) a heat distortion temperature T hd ; 3) a Vicat softening temperature T vs in which at least one temperature is higher than the melting temperature T m of the cryogenically treated polymer composition, and a first portion of the knitted article comprises a plurality of interconnected loops formed of at least the first yarn and the second yarn.

[0082] In one aspect, the present disclosure relates to a process for manufacturing components of a manufactured article: providing a knitted article according to any one of aspects 1-117; combining the knitted article with one or more other components to form a footwear article, a clothing article, or a sports equipment article.

[0083] In one aspect, the present disclosure relates to a process for manufacturing a knitted article, the process comprising: knitting a first row of loops composed of a first yarn and a second yarn, the first yarn comprising a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprising one or more first thermoplastic polymers, the second yarn comprising a heat-treated polymer composition, and the heat-treated polymer composition comprising one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) a heat distortion temperature T hd ; 3) a Vicat softening temperature T vs in which at least one temperature is higher than the melting temperature T of the cryogenically treated polymer composition m ; knitting a second row of loops composed of the first yarn and the second yarn, and at least a part of the first row and a part of the second row form a plurality of interconnected loops.

[0084] In one aspect, the present disclosure relates to a process for manufacturing a knitted article, the process comprising: knitting a first row, the first row comprising a first yarn and a second yarn, wherein the first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, the second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) a heat distortion temperature T hd ; or 3) a Vicat softening temperature T vs in which at least one temperature is higher than the melting temperature T of the cryogenically treated polymer composition m ; knitting an anchor yarn into one or more loops of the first yarn in the first row of loops, wherein the anchor yarn comprises an anchor yarn composition, the anchor yarn composition comprises one or more polymers, and the elongation of the anchor yarn composition is lower than the elongation of the cryogenically treated polymer composition, the first row of loops is on the outer surface of the knitted article, and the outer surface at least comprises a first region, a second region, and a third region, wherein the second region is located between the first region and the third region, and the first yarn in the third region is denser than that in the second region.

[0085] In one aspect, the present disclosure relates to the composition of a knitted article: a first reflow material, wherein the first reflow material is a product obtained by melting and re-solidifying on a first yarn, the first reflow material comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers; and a second yarn, the second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers; wherein the heat-treated polymer composition exhibits a creep relaxation temperature T cr higher than the melting temperature T of the cryogenically treated polymer composition m ; at least a portion of the second yarn is at least located in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are at least connected to a portion of the first reflow material.

[0086] In one aspect, the present disclosure relates to the composition of a knitted article: a first reflow material, wherein the first reflow material is a product obtained by melting and re-solidifying on a first yarn, the first reflow material comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers; and a second yarn, the second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers; wherein the heat-treated polymer composition exhibits a heat distortion temperature T hd higher than the melting temperature T of the cryogenically treated polymer composition m ; at least a portion of the second yarn is at least located in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are at least connected to a portion of the first reflow material.

[0087] In one aspect, the present disclosure relates to the composition of a knitted article: a first reflow material, wherein the first reflow material is a product obtained by melting and re-solidifying on a first yarn, the first reflow material comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers; and a second yarn, the second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers; wherein the heat-treated polymer composition exhibits a Vicat softening temperature T vs higher than the melting temperature T of the cryogenically treated polymer composition m ; at least a portion of the second yarn is at least located in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are at least connected to a portion of the first reflow material.

[0088] In one aspect, the present disclosure relates to the composition of a knitted article: a first recycled material, wherein the first recycled material is the product of melting and re-solidifying on a first yarn, the first recycled material comprising a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprising one or more first thermoplastic polymers; the cryogenically treated polymer composition exhibits a melting temperature T m of 135 °C or lower; and a second yarn, the second yarn comprising a heat-treated polymer composition, and the heat-treated polymer composition comprising one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) a heat distortion temperature T hd ; or 3) a Vicat softening temperature T vs such that at least one of the temperatures is higher than the melting temperature T m of the cryogenically treated polymer composition; at least a portion of the second yarn is at least located in a first course of the loops and a second course of the loops, and at least a portion of the first course of the second yarn loops and at least a portion of the second course of the second yarn loops are at least connected to a portion of the first recycled material.

[0089] In various aspects, the present disclosure relates to a process for manufacturing an article composition: providing the disclosed knitted article; and then combining the knitted article with one or more other materials to form a footwear article, a clothing article, or a sports equipment article.

[0090] In various aspects, the present disclosure relates to a process for manufacturing a knitted article, the process comprising: receiving a complete knitted fabric, the knitted fabric comprising a first yarn and a second yarn, wherein the first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, and the second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) a heat distortion temperature T hd ; 3) a Vicat softening temperature T vs such that at least one of the temperatures is higher than the melting temperature T m of the cryogenically treated polymer composition; in a first portion of the knitted fabric, at least one of the first yarn and the second yarn can form a plurality of interconnected loops; placing at least a portion of the knitted fabric on a forming surface; when at least a portion of the knitted fabric is placed on the forming surface, raising the temperature of the entire knitted fabric to a temperature higher than the melting temperature T m of the cryogenically treated polymer composition and lower than the: 1) creep relaxation temperature T cr ; 2) heat distortion temperature T hd ; or 3) Vicat softening temperature T of the heat-treated polymer compositionvs any one of the temperatures; after the entire knitted fabric is heated up, when at least a part of the knitted fabric is still placed on the forming surface, the temperature of the entire knitted fabric is lowered, and the lowered temperature is lower than the melting temperature T of the cryogenically treated polymer composition m to form a knitted article.

[0091] In one aspect, the present disclosure relates to a process for manufacturing a knitted article, the process comprising: receiving a complete knitted fabric comprising a first yarn and a second yarn, wherein the first yarn comprises a cryogenically treated polymer composition, and the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, wherein the second yarn comprises a heat-treated polymer composition, and the heat-treated polymer composition comprises one or more second thermoplastic polymers, wherein the heat-treated polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) a heat distortion temperature T hd ; or 3) a Vicat softening temperature T vs in which at least one of the temperatures is higher than the melting temperature T of the cryogenically treated polymer composition m ; a first part of the knitted fabric comprises a first row of loops, the loops comprising the first yarn and the second yarn; knitting an anchor yarn into one or more loops of the first yarn in the first row of loops, wherein the anchor yarn comprises an anchor yarn composition, the anchor yarn composition comprises one or more polymers, and the elongation of the anchor yarn composition is lower than the elongation of the cryogenically treated polymer composition, the first row of loops is on the outer surface of the knitted article, and the outer surface comprises at least a first zone, a second zone and a third zone, wherein the second zone is located between the first zone and the third zone, and the first line of the third zone is denser than the second zone; placing at least a part of the knitted fabric on the forming surface; when at least a part of the knitted fabric is placed on the forming surface, raising the temperature of the entire knitted fabric, and the raised temperature is higher than the melting temperature T of the cryogenically treated polymer composition m and lower than any one of: 1) the creep relaxation temperature T cr ; 2) the heat distortion temperature T hd ; or 3) the Vicat softening temperature T vs of the heat-treated polymer composition; after the entire knitted fabric is heated up, when at least a part of the knitted fabric is still placed on the forming surface, lowering the temperature of the entire knitted fabric, and the lowered temperature is lower than the melting temperature T of the cryogenically treated polymer composition m to form a knitted article.

[0092] The present disclosure relates to materials and processes for making textile, sports equipment, and wearing articles (including footwear and apparel). It should be understood that the present disclosure contemplates a variety of sports equipment, including backpacks, equipment bags, hats, protective gear, and the like. It should be understood that the present disclosure contemplates a variety of wearing articles, including knitted articles. A non-limiting list of wearing articles contemplated by the present disclosure includes shoes, shirts, pants, socks, jackets or other outerwear, protective equipment, hats, and undergarments, such as bras. In some aspects, the wearing article is a footwear article. "Footwear article" is used to refer to an article intended to be worn on a human foot. For example, in some aspects, the footwear article can be a shoe. In some aspects, the disclosed materials and processes can be used to manufacture components used in wearing articles such as, for example, footwear articles. Exemplary components of a wearing article include, but are not limited to, a shoe upper for a footwear article.

[0093] Exemplary footwear articles are athletic shoes or sports shoes, including, but not limited to, running shoes, basketball shoes, soccer shoes, baseball shoes, football shoes, tennis shoes, rugby shoes, cross-trainers, walking shoes, hiking boots, golf shoes, sneakers, and the like. Alternatively, the footwear article can be a non-athletic shoe, including, but not limited to, dress shoes, slippers, casual shoes, sandals, and boots, including work boots. The shoe can enclose or can not enclose the entire foot of the wearer. For example, the shoe can be a sandal or other article that exposes most of the foot of the wearer. Thus, one of ordinary skill in the art can appreciate that the materials and processes disclosed herein are applicable to a wide variety of shoe types or styles other than the specific types or styles discussed in the following materials and depicted in the figures.

[0094] The disclosed textiles and articles can include yarns, fibers, or combinations of yarns and fibers that include a low processing temperature polymer composition (described below) and yarns, fibers, or combinations of yarns and fibers that include a high processing temperature polymer composition (also described below). The disclosed textiles and articles include at least two yarns that balance several material properties as described herein. Additionally, the yarns and fibers used in the disclosed materials and processes will be selected based on a variety of factors, including the type of shoe to be manufactured (e.g., whether it is an athletic footwear article or a non-athletic footwear article) and the typical use of the footwear article. For example, when considering the type of yarns and fibers to be used in an athletic footwear article, the type of sport for which the athletic footwear article is used and / or the conditions under which the athletic footwear article will be worn (e.g., indoor or outdoor) can be considered.

[0095] The disclosed articles can include formed parts, films, fibers, yarns, or combinations thereof that include a low processing temperature polymer composition (described below), and formed parts, films, fibers, yarns, or combinations thereof that include a high processing temperature polymer composition (also described below). The disclosed articles include at least two polymer compositions that balance several material properties as described herein. Additionally, the compositions and processes for forming these articles will be selected based on a variety of factors, including the type of article to be manufactured and the typical use of the article.

[0096] In various aspects, the disclosed formed parts, films, textiles, and articles include two different polymer compositions, where one of the polymer compositions can be melted or deformed in a thermoforming process performed within a first temperature range (referred to herein as the low processing temperature polymer composition), while the other polymer composition maintains its shape within the first temperature range (referred to herein as the high processing temperature polymer composition). It will be understood that the reference to "polymer composition" is intended to refer to a composition that includes at least one polymer. Optionally, additional ingredients such as pigments, dyes, fillers, processing aids, etc. can be present in the polymer composition. The low processing temperature composition includes one or more first thermoplastic polymers. The high processing temperature composition includes one or more second polymers. In some instances, the high processing temperature polymer composition is a thermoplastic composition and includes one or more second thermoplastic polymers. The polymer compositions of the present disclosure can be used to form formed parts, films, and / or fibers. The formed parts and / or films can then be incorporated into articles as described herein. The fibers can then 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 another aspect, the disclosed textiles and articles include a first film, fiber, or yarn that includes a low processing temperature polymer composition and a second film, fiber, or yarn that includes a high processing temperature polymer composition.

[0097] As mentioned above, the articles described herein can include materials such as formed parts, films, fibers, yarns, and / or textiles, where the articles are at least partially formed from a low processing temperature polymer composition and a high processing temperature polymer composition. In some instances, the materials are at least partially formed from a low processing temperature polymer composition and a high processing temperature polymer composition. As used herein, "low processing temperature polymer composition" and "high processing temperature polymer composition" are relative terms with respect to the creep relaxation temperature (T cr ), Vicat softening temperature (T vs ), heat deflection temperature (T hd ), and / or melting temperature (T m ) of each of these compositions. The creep relaxation temperature (Tcr ) The Vicat softening temperature (T vs ), heat distortion temperature (T hd ), and melting temperature (T m ) are understood to be lower than the decomposition temperature of the polymer composition at the high processing temperature. These parameters are described in further detail below. It should be understood that other properties and parameters may differ between the low processing temperature polymer composition and the high processing temperature polymer composition, as discussed in detail below. In various aspects, the low processing temperature polymer composition and / or the high processing temperature polymer composition, or both, may be present in a shaped part, film, textile, yarn, or fiber.

[0098] In various aspects, when the low processing temperature polymer composition and the high processing temperature polymer composition are thermoplastic compositions, the melting temperature (T m ) of the low processing temperature polymer composition is lower than at least one of the following properties of the high processing temperature polymer composition: (1) the creep relaxation temperature (T cr ); (2) the Vicat softening temperature (T vs ); (3) the heat distortion temperature (T hd ); or (4) the melting temperature (T m ). That is, for example, the low processing temperature polymer composition exhibits a melting temperature (T cr ) that is lower than the temperature of at least one of the creep relaxation temperature (T vs ), Vicat softening temperature (T hd ), heat distortion temperature (T m ), or melting temperature (T m ) of the high processing temperature polymer composition, and the melting temperature (T m ) is lower than the melting temperature (T m ) of the high processing temperature polymer composition.

[0099] In another aspect, the melting temperature (T m ) of the low processing temperature polymer composition is lower than the creep relaxation temperature (T cr ) of the high processing temperature polymer composition. In another aspect, the melting temperature (T m ) of the low processing temperature polymer composition is lower than the Vicat softening temperature (T vs ) of the high processing temperature polymer composition. In another aspect, the melting temperature (T m ) of the low processing temperature polymer composition is lower than the heat distortion temperature (T hd ) of the high processing temperature polymer composition. In another aspect, the melting temperature (T m ) of the low processing temperature polymer composition is lower than the melting temperature (T m ) of the high processing temperature polymer composition.

[0100] In various aspects, the melt temperature (T m ) of the high processing temperature polymer composition is greater than at least one of the following properties of the low processing temperature polymer composition: (1) the creep relaxation temperature (T cr ) ; (2) the Vicat softening temperature (T vs ) ; (3) the heat distortion temperature (T hd ) ; or (4) the melt temperature (T m ). That is, for example, the high processing temperature polymer composition exhibits a melt temperature (T cr ) that is greater than the creep relaxation temperature (T vs ), the Vicat softening temperature (T hd ), the heat distortion temperature (T m ), or the melt temperature (T m ) of the low processing temperature polymer composition, and the melt temperature (T m ) is lower than the melt temperature (T m ) of the low processing temperature polymer composition.

[0101] In another aspect, the melt temperature (T m ) of the high processing temperature polymer composition is greater than the creep relaxation temperature (T cr ) of the low processing temperature polymer composition. In another aspect, the melt temperature (T m ) of the high processing temperature polymer composition is greater than the Vicat softening temperature (T vs ) of the low processing temperature polymer composition. In another aspect, the melt temperature (T m ) of the high processing temperature polymer composition is greater than the heat distortion temperature (T hd ) of the low processing temperature polymer composition. In another aspect, the melt temperature (T m ) of the high processing temperature polymer composition is greater than the melt temperature (T m ) of the low processing temperature polymer composition.

[0102] In various aspects, the low processing temperature polymer composition and the high processing temperature polymer composition can be selectively incorporated into textiles or articles to provide one or more structural properties and / or other advantageous properties to the textiles or articles. In various aspects, the textiles can be thermoformed to impart such structural properties and / or other advantageous properties. The thermoforming can be performed within a temperature range that is lower than at least one of the following properties of the high processing temperature polymer composition: (1) the creep relaxation temperature (T cr ) ; (2) the Vicat softening temperature (T vs ) ; (3) the heat distortion temperature (T hd ) ; or (4) the melt temperature (T m)。The thermoforming can be performed within a temperature range below the creep relaxation temperature (T cr ) of the polymer composition at the high processing temperature. The thermoforming can be performed within a temperature range below the Vicat softening temperature (T vs ) of the polymer composition at the high processing temperature. The thermoforming can be performed within a temperature range below the heat distortion temperature (T hd ) of the polymer composition at the high processing temperature. The thermoforming can be performed within a temperature range below the melting temperature (T m ) of the polymer composition at the high processing temperature.

[0103] In various aspects, the low processing temperature polymer composition can be used to form fibers. As used herein, "fiber" should be understood to include filaments. Similarly, in various aspects, the high processing temperature polymer composition can be used to form fibers. In various aspects, the fiber can be a bicomponent fiber including a first portion formed from the low processing temperature polymer composition and a second portion formed from the high processing temperature polymer composition. For example, the low processing temperature polymer composition and the high processing temperature polymer composition can be coextruded to form a bicomponent fiber. Fibers can be extruded from the low processing temperature polymer composition and subsequently coated with the high processing temperature polymer composition. Alternatively, fibers can be extruded from the high processing temperature polymer composition and subsequently coated with the low processing temperature polymer composition. In another aspect, the fiber can be a multicomponent fiber including three or more polymer compositions comprising one or more low processing temperature polymer compositions and one or more high processing temperature polymer compositions.

[0104] In various aspects, the disclosed fibers can be used to prepare yarns. Short fibers or long fibers can be used to form the yarns. The yarns of the present disclosure include at least one of a low processing temperature polymer composition and a high processing temperature polymer composition. Examples 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 of the disclosed fibers, which include a low processing temperature polymer composition, a mixture of two or more low processing temperature polymer compositions, a high processing temperature polymer composition, a high processing temperature polymer composition or a mixture of more low 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 from a low processing temperature polymer composition. Alternatively, substantially all or most of the fibers of the yarn can be formed from a high processing temperature polymer composition. The yarn can include fibers formed from a low processing temperature polymer composition or fibers formed from a high processing temperature polymer composition, or both types of fibers. The yarn can include fibers formed from a low processing temperature polymer composition, wherein the yarn is coated with a high processing temperature polymer composition. Alternatively, the yarn can include fibers formed from a high processing temperature polymer composition, wherein the yarn is coated with a low processing temperature polymer composition.

[0105] In various aspects, the foregoing 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 another aspect, the textiles can be knitted textiles including one or more of the disclosed yarns. In another aspect, the textiles can be non-woven textiles including one or more of the disclosed fibers.

[0106] In various aspects, the low processing temperature polymer composition or the high processing temperature polymer composition or both can be used to prepare shaped parts. The shaped parts can be molded parts that can be manufactured by injection molding, compression molding, blow molding, rotational molding or other molding techniques known to those skilled in the art. In some aspects, the shaped parts can include a mixture of two or more low processing temperature polymer compositions. In alternative aspects, the shaped parts can include a mixture of two or more high processing temperature polymer compositions. In another aspect, the shaped parts can include one or more low processing temperature polymer compositions and one or more high processing temperature polymer compositions. For example, the shaped part can include two or more parts, wherein the first part is formed from a low processing temperature polymer composition and the second part is formed from a high processing temperature polymer composition. A two-shot molding process can be used to form the two or more parts.

[0107] In various aspects, a low processing temperature polymer composition or a high processing temperature polymer composition can be used to make a film. In some aspects, the film can include one or more low processing temperature polymer compositions. Alternatively, in some aspects, the film can include one or more high processing temperature polymer compositions. In another aspect, the film can include one or more low processing temperature polymer compositions and one or more high processing temperature polymer compositions. In various aspects, the film can be a multilayer film including one or more of the disclosed films, e.g., a bilayer film including a first layer comprising a low processing temperature polymer composition and a second layer comprising a high processing temperature polymer composition. The multilayer film can be formed by coextrusion or lamination.

[0108] In a conventional formation process of an article including a wearable article, a transition region from a first functional region to a second functional region can be achieved by a change in the material imparting the functionality. This transition region from a first material having a first functional description to a second material having a different functional description can introduce limitations to the final article. For example, in the case of a shoe, the transition region from the sole to the upper appears near the bite line of the shoe. This transition region can be referred to as a hard-soft transition region because the sole generally has a relatively rigid response to foot movement and the upper has a relatively non-rigid response to foot movement. Other such hard-soft transition regions can exist at other locations on the shoe, depending on the design and construction methods used. At this transition region, the wearer of the shoe may experience discomfort because the parts of the foot on one side of the transition region are allowed to move in a different manner (e.g., more freely) than the parts of the foot on the other side of the transition region. This sudden change in the allowed degree of freedom of movement of the wearer's foot (e.g., a hard-soft transition region) can affect the perceived performance and feel of the shoe. To limit the effect of the hard-soft transition region, manufacturers can insert multiple material layers or otherwise mechanically manipulate the transition region to mask the change. Each of these changes may insert complexity, additional processing steps, and / or materials, which may further affect the efficiency, cost, and weight of the shoe.

[0109] Accordingly, aspects contemplated herein allow for an integrally formed article portion having a transition zone from a first functional zone to a second functional zone, the transition zone being built into the zones and during the formation of the zones. For example, manipulation of materials and techniques, such as under knitting, can be implemented to allow for a gradient from the first functional zone to the second functional zone. Bringing this back to the hard-soft transition zone of a shoe, it is contemplated to form (e.g., knit) a first functional zone (e.g., sole zone) of the shoe using a first type of material (e.g., a low processing temperature polymer composition described below), and to form (e.g., knit) a second functional zone (e.g., upper portion) of the shoe using a different material (e.g., a high processing temperature polymer composition described below). Additionally or alternatively, a first type of stitch is used to knit the sole zone of the shoe, and a second type of stitch is used to knit the upper portion of the shoe. Further, in this example, the transition zone from the first functional zone (e.g., sole zone) to the second functional zone (e.g., upper zone) can include one or more transition regions where knitting techniques (e.g., stitch selection, layer manipulation) and / or materials are mixed in a defined manner to integrally form a more natural transition from the first functional zone to the second functional zone during the manufacture of the zones. This integral transition between the functional zones can positively impact, in exemplary aspects, the perceived performance and / or feel of the shoe by the wearer.

[0110] In one aspect, a textile is provided that includes a first plurality of fibers comprising a low processing temperature polymer composition. The textile further includes a second plurality of fibers comprising a high processing temperature polymer composition. The first plurality of fibers and the second plurality of fibers can be deposited to form separate regions of the textile. For example, the first plurality of fibers can form a first surface of the textile, and the second plurality of fibers can form a second surface of the textile opposite the first surface. Alternatively or additionally, the first plurality of fibers can form an intermediate portion of a first surface of the textile, and the second plurality of fibers can form a lateral portion of the first surface of the textile. The first plurality of fibers and the second plurality of fibers can 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, where the first zone includes an increased concentration of the second plurality of fibers compared to the second zone, and where the third zone includes an increased concentration of the first plurality of fibers compared to the second zone. In a particular instance, the textile is a non-woven textile. In some instances, the 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 instance, the textile is a component of an upper for a footwear article. The textile component can comprise at least 75 wt% of an upper for a footwear article.

[0111] In one aspect, there is provided a textile that includes a first yarn comprising a low processing temperature polymer composition. The textile further includes a second yarn comprising a high processing temperature polymer composition. The first and second yarns can be used to form separate regions of the textile. The first yarn and the second yarn can be included in 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 examples, the 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 example, the textile is a component of an upper for a footwear article. The textile component can comprise at least 75 wt% of the upper for the footwear article.

[0112] In one aspect, there is provided a woven textile that includes 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 regions of the woven textile article. For example, the first yarn can form substantially all or a portion of the warp yarns of the weave pattern of the woven textile article, and the second yarn can form substantially all or a portion of the weft yarns of the weave pattern 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 examples, 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 example, the woven textile is a component of an upper for a footwear article. The woven textile component can comprise at least 75 wt% of the upper for the footwear article.

[0113] In one aspect, a knitted textile is provided, the knitted textile comprising a first yarn comprising a low processing temperature polymer composition, the low processing temperature polymer composition comprising one or more first thermoplastic polymers. The knitted textile further comprises a second yarn comprising a high processing temperature polymer composition, the high processing temperature polymer composition comprising one or more second thermoplastic polymers. The first and second yarns 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, the second zone being positioned between the first zone and the third zone, wherein the first zone comprises an increased concentration of the second yarn compared to the second zone, and wherein the third zone comprises an increased concentration of the first yarn compared to the second zone. In some examples, the knitted textile is a component of an article of the present disclosure, such as an article of apparel or an article of footwear or an article of sports equipment. In a particular example, the knitted textile is a component of an upper for an article of footwear. The knitted textile component can comprise at least 75 weight percent of an upper for an article of footwear.

[0114] The knitted textile can be formed by a knitting process, such as flat knitting or circular knitting. In certain aspects, the knitted textile can have a substantially seamless configuration. In another aspect, the knitted textile can be a knitted article formed from a single-piece knitting construction. As used herein, a knitted article is defined as being formed from a "single-piece knitting construction" when formed as a single-piece element by a knitting process. That is, the knitting process substantially forms the various features and structures of the knitted article without the need for a large number of additional manufacturing steps or processes. Although portions of the knitted article can be joined to each other 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 a single-piece knitting construction because it is formed as a single-piece knitted element. In various aspects, the knitted article can further comprise other elements (e.g., a tongue, a label, a shoelace, a heel counter, a logo, a trademark, a tag) that can be added after the knitting process.

[0115] Knitted textiles can incorporate various types of stitches and yarns, as well as combinations of stitches and yarns. With respect to stitches, a 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 utilized, the 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, stretchability, thickness, breathability, and abrasion resistance. That is, different types of stitches can impart different properties to different areas of the knitted textile. With respect to yarns, a 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, for example, a yarn including a low processing temperature polymer composition in one area of the knitted textile and a yarn including a high processing temperature polymer composition in another area of the knitted textile. Depending on various design criteria, a knitted textile can incorporate yarns having different deniers, materials (e.g., cotton, elastane, polyester, rayon, wool, and nylon), and degrees of twist. Different types of yarns can affect the physical properties of the knitted textile, including aesthetics, stretchability, 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 of stitches and yarns, as well as combinations of stitches and yarns, the knitted article of each area can have specific properties that, by use in a footwear article, a clothing article, or a sports equipment article, enhance the comfort, durability, and performance of the knitted textile as needed.

[0116] The knitted textile can be prepared by a variety of suitable processes. By way of example, a flat knitting process can be utilized to manufacture the knitted textile. While flat knitting can provide a suitable process for forming the knitted textile, other knitting processes can also be utilized, such as wide tube circular knitting, narrow tube circular knitting jacquard, single jersey circular knitting jacquard, double jersey circular knitting jacquard, warp knitting, warp knitting raschel, and double needle bar raschel. In various aspects, the knitted textile can be subjected to post-treatment steps, for example, in order to remove a portion of the knitted textile, add components to the knitted textile, form a wool texture, and the like. In other aspects, the knitted textile can include various knit structures and / or include different knit sub-layers.

[0117] In certain aspects, the entire knitted article can be seam-free. A seam-free knitted article can be provided, for example, by circular knitting. A circular knitted article can allow for the provision of a three-dimensional preform without the need for sewing at designated locations. Accordingly, unwanted seams in the knitted article can be avoided, and the three-dimensional preformed knitted article can have a particularly good fit and additional aforementioned benefits of a seam-free structure.

[0118] However, it should be noted that the textiles and textile articles (including knitted articles) of the present disclosure can be utilized to fabricate composite elements. In some aspects, the composite element can include a first textile prepared as disclosed herein and a second textile or film or shaped component. That is, the composite element includes a first textile region and a second region selected from a region including a second textile, a region including a film, a region including a shaped component, or a combination thereof.

[0119] In one aspect, there is provided a textile including a first plurality of fibers, the first plurality of fibers including a low processing temperature polymer composition including 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 a sports equipment article. The textile article can be a component of a clothing article. The textile article can be a component of a footwear article. The textile article can be an upper portion for a footwear article.

[0120] In various aspects, the textile includes a second plurality of fibers including a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting at least one of the following that is greater than the melting temperature (T m ) of the low processing temperature polymer composition in the first plurality of fibers: (1) creep relaxation temperature (T cr ) ; (2) heat distortion temperature (T hd ) ; (3) Vicat softening temperature (T vs ) ; or (4) melting temperature (T m ).

[0121] In another aspect, the textile includes a second plurality of fibers including a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a creep relaxation temperature (T m ) that is greater than the melting temperature (T cr ) of the low processing temperature polymer composition in the first plurality of fibers.

[0122] In another aspect, the textile includes a second plurality of fibers including a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a heat distortion temperature (T m ) that is greater than the melting temperature (T hd ) of the low processing temperature polymer composition in the plurality of fibers.

[0123] In another aspect, the textile includes a second plurality of fibers including a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a Vicat softening temperature (T m ) that is greater than the melting temperature (T vs ) of the low processing temperature polymer composition in the first plurality of fibers.

[0124] In another aspect, the textile includes a second plurality of fibers comprising a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a melting temperature (T m ) greater than the melting temperature (T m ) of the low processing temperature polymer composition in the first plurality of fibers.

[0125] In another aspect, the textile includes a first yarn comprising a low processing temperature polymer composition, the low processing temperature polymer composition including 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 a footwear article.

[0126] In various aspects, the textile includes a second yarn comprising a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting at least one of the following that is greater than the melting temperature (T m ) of the low processing temperature polymer composition in the first yarn: (1) a creep relaxation temperature (T cr );(2) a heat distortion temperature (T hd );(3) a Vicat softening temperature (T vs );or (4) a melting temperature (T m ).

[0127] In another aspect, the textile includes a second yarn comprising a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a creep relaxation temperature (T m ) greater than the melting temperature (T cr ) of the low processing temperature polymer composition in the first yarn.

[0128] In another aspect, the textile includes a second yarn comprising a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a heat distortion temperature (T m ) greater than the melting temperature (T hd ) of the low processing temperature polymer composition in the yarn.

[0129] In another aspect, the textile includes a second yarn comprising a high processing temperature polymer composition, the high processing temperature polymer composition exhibiting a Vicat softening temperature (T m ) greater than the melting temperature (T vs ) of the low processing temperature polymer composition in the first yarn.

[0130] In another aspect, the textile includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T m ) greater than the melting temperature (T m ) of the low processing temperature polymer composition in the first yarn.

[0131] In certain aspects, a textile article is provided that includes a molten fiber component that is thermoformed from a first state as a first plurality of fibers to a second state as a molten fiber component (i.e., a component formed from a plurality of fibers, where at least a portion of the plurality of fibers has at least partially melted and resolidified into a new morphology different from their fibrous morphology). The first plurality of fibers includes a low processing temperature polymer composition. It will be understood that the molten fiber component can include structures such as, for example, partially molten first plurality of fibers, substantially completely molten first plurality of fibers, and mixtures thereof. The textile article can further include a second plurality of fibers comprising a high processing temperature polymer composition. Optionally, the molten 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, where the second zone is positioned between the first zone and the third zone. The first zone contains a higher concentration of the second plurality of fibers compared to the second zone, and the third zone contains a higher concentration of the molten plurality of fiber components compared to the second zone. In some instances, this structure can form the outer surface of the article, where the first zone, the second zone, and the third zone each form a part of the outer surface.

[0132] In one aspect, a textile article includes a first plurality of fibers that include a low processing temperature polymer composition that includes one or more thermoplastic polymers. The textile article can be a component of a clothing article. The textile article can be a non-woven textile article. The textile article can be a component of a sports equipment article. The textile article can be a component of a footwear article. The textile article can be an upper portion for a footwear article.

[0133] In various aspects, the textile article includes a second plurality of fibers comprising a high processing temperature polymer composition that exhibits at least one of the following that is greater than the melting temperature (T m ) of the low processing temperature polymer composition of the first plurality of fibers: (1) a creep relaxation temperature (T cr );(2) a heat distortion temperature (T hd );(3) a Vicat softening temperature (T vs );or (4) a melting temperature (T m), the first plurality of fibers transition from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0134] In another aspect, the textile article includes a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a creep relaxation temperature (T m ) greater than the melting temperature (T cr ) of the low processing temperature polymer composition of the first plurality of fibers, and the first plurality of fibers transition from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0135] In another aspect, the textile article includes a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a heat distortion temperature (T m ) greater than the melting temperature (T hd ) of the low processing temperature polymer composition of the first plurality of fibers, and the first plurality of fibers transition from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0136] In another aspect, the textile article includes a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a Vicat softening temperature (T m ) greater than the melting temperature (T vs ) of the low processing temperature polymer composition of the first plurality of fibers, and the first plurality of fibers transition from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0137] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T m ) greater than the melting temperature (T m ) of the low processing temperature polymer composition of the first plurality of fibers, and the first plurality of fibers transition from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0138] In some aspects, a textile article is provided that includes a molten yarn component that is thermoformed from a first state as a first yarn to a second state as a molten yarn component (i.e., a component formed from a yarn that has been at least partially melted and re-solidified into a new form different from its yarn form). The first yarn includes a low processing temperature polymer composition. It will be understood that the molten yarn component can include structures such as, for example, a partially melted first yarn, a substantially completely melted first yarn, and mixtures thereof. The knitted article can also include a second yarn that includes a high processing temperature polymer composition. Optionally, 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 contains a higher concentration of the second yarn compared to the second zone, and the third zone contains a higher concentration of the molten yarn component compared to the second zone. In some instances, 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.

[0139] In one aspect, a textile article includes a first yarn that includes a low processing temperature polymer composition that includes one or more thermoplastic polymers. The textile article can be a knitted article. The textile article can be a woven article. The textile article can be a component of a clothing article. The textile article can be a component of a footwear article. The textile article can be an upper portion for a footwear article. The textile article can be a knitted upper portion for a footwear article.

[0140] In various aspects, the textile article includes a second yarn that includes a high processing temperature polymer composition that exhibits at least one of the following that is greater than the melting temperature (T m ) of the low processing temperature polymer composition of the first yarn: (1) creep relaxation temperature (T cr ) ; (2) heat distortion temperature (T hd ) ; (3) Vicat softening temperature (T vs ) ; or (4) melting temperature (T m ), wherein the first yarn is transformed from a first state as a first yarn to a second state as a molten yarn component.

[0141] In another aspect, the textile article includes a second yarn that includes a high processing temperature polymer composition that exhibits a creep relaxation temperature (T m ) that is greater than the melting temperature (T cr) The first yarn transitions from a first state as the first yarn to a second state as a molten yarn component.

[0142] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a heat distortion temperature (T m ) greater than the melting temperature (T hd ) of the low processing temperature polymer composition in the first yarn, and the first yarn transitions from a first state as the first yarn to a second state as a molten yarn component.

[0143] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a Vicat softening temperature (T m ) greater than the melting temperature (T vs ) of the low processing temperature polymer composition in the first yarn, and the first yarn transitions from a first state as the first yarn to a second state as a molten yarn component.

[0144] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T m ) greater than the melting temperature (T m ) of the low processing temperature polymer composition in the first yarn, and the first yarn transitions from a first state as the first yarn to a second state as a molten yarn component.

[0145] In some aspects, the textile article is a knitted article including a plurality of interconnected courses. Each course of the plurality of interconnected courses includes a first yarn and a second yarn. The first yarn includes a low processing temperature polymer composition. The second yarn includes a high processing temperature polymer composition. The knitted article further includes at least one knitted layer including 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 course of the plurality of interconnected courses extends through the first zone, the second zone, and the third zone, wherein the third zone has an increased concentration of the first yarn compared to the second zone. In some instances, 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. Additionally, the knitted article includes an anchor yarn extending through at least a portion of the third zone. The anchor yarn includes a high processing temperature polymer composition, e.g., fibers formed from a high processing temperature polymer composition. The anchor yarn exhibits an elongation less than that of the first yarn.

[0146] In addition to textiles and articles including textiles, the present disclosure also relates to articles including a molten film component that is thermoformed from a first state as a film to a second state as a molten film (i.e., a film including a low processing temperature polymeric material, wherein at least a portion of the low processing temperature polymeric material of the film has melted and re-solidified on a substrate into a new morphology different from its film morphology). The article may further include a high processing temperature composition. Optionally, the molten film component and the high processing temperature 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 composition compared to the second zone, and the third zone includes a higher concentration of the molten film component compared to the second zone. In some instances, this structure may form an outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface.

[0147] In one aspect, an article includes a molten film component that includes a low processing temperature polymer composition including one or more thermoplastic polymers. The article may be a component of an apparel article. The article may be a component of a sports equipment article. The article may be a component of a footwear article. The article may be an upper portion for a footwear article.

[0148] In various aspects, the article includes a second element (e.g., a formed component, a film, a textile, a fiber, a yarn) including a high processing temperature polymer composition that exhibits at least one of the following that is greater than the melting temperature (T m ) of the low processing temperature polymer composition of the molten film component: (1) a creep relaxation temperature (T cr ); (2) a heat distortion temperature (T hd ); (3) a Vicat softening temperature (T vs ); or (4) a melting temperature (T m ), wherein the molten film component is transformed from a first state as a film to a second state as a molten film component.

[0149] In another aspect, the article includes a second element including a high processing temperature polymer composition that exhibits a creep relaxation temperature (T m ) that is greater than the melting temperature (T cr ) of the low processing temperature polymer composition of the molten film component, wherein the molten film component is transformed from a first state as a film to a second state as a molten film component.

[0150] In another aspect, the article includes a second element comprising a high processing temperature polymer composition that exhibits a heat distortion temperature (T m ) greater than the melting temperature (T hd ) of the low processing temperature polymer composition of the molten film component, where the molten film component transitions from a first state as a film to a second state as a molten film component.

[0151] In another aspect, the article includes a second element comprising a high processing temperature polymer composition that exhibits a Vicat softening temperature (T m ) greater than the melting temperature (T vs ) of the low processing temperature polymer composition of the molten film component, where the molten film component transitions from a first state as a film to a second state as a molten film component.

[0152] In another aspect, the textile article includes a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T m ) greater than the melting temperature (T m ) of the low processing temperature polymer composition of the first plurality of fibers, where the first plurality of fibers transition from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0153] The present disclosure also relates to an article including a first polymeric component comprising a molten zone that is thermoformed from a first state as a shaped component to a second state as a molten shaped component (i.e., the shaped component includes a low processing temperature polymeric material, where at least a portion of the low processing temperature polymeric material has melted and re-solidified into a new morphology different from its original shaped component morphology). The first component may also include a zone formed from a high processing temperature. Alternatively or additionally, the article may further include a second component comprising a high processing temperature polymer composition.

[0154] In one aspect, an article includes a first shaped component that includes a low processing temperature polymer composition that includes one or more thermoplastic polymers. The article may be a component of a clothing article. The article may be a component of a sports equipment article. The article may be a component of a footwear article. The article may be an upper portion for a footwear article. The article may be a sole element of a footwear article.

[0155] In various aspects, the article includes a second element (e.g., a shaped component, film, textile, fiber, yarn) comprising a high processing temperature polymer composition that exhibits a melting temperature (Tm )at least one of the following large values: (1) creep relaxation temperature (T cr ); (2) heat distortion temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), and the first formed component changes from the first state as a formed component to the second state as a melted formed component.

[0156] On the other hand, the article includes a second element comprising a high processing temperature polymer composition, and the high processing temperature polymer composition exhibits a creep relaxation temperature (T m ) that is greater than the melting temperature (T cr ) of the low processing temperature polymer composition of the first formed component, and the first formed component changes from the first state as the first formed component to the second state as a melted formed component.

[0157] On the other hand, the article includes a second element comprising a high processing temperature polymer composition, and the high processing temperature polymer composition exhibits a heat distortion temperature (T m ) that is greater than the melting temperature (T hd ) of the low processing temperature polymer composition of the first formed element, and the first formed element changes from the first state as a formed element to the second state as a melted formed component.

[0158] On the other hand, the article includes a second element comprising a high processing temperature polymer composition, and the high processing temperature polymer composition exhibits a Vicat softening temperature (T m ) that is greater than the melting temperature (T vs ) of the low processing temperature polymer composition of the first formed element, and the first formed element changes from the first state as the first formed element to the second state as a melted formed component.

[0159] On the other hand, the textile article includes a second element comprising a high processing temperature polymer composition, and the high processing temperature polymer composition exhibits a melting temperature (T m ) that is greater than the melting temperature (T m ) of the low processing temperature polymer composition of the first plurality of fibers, and the first plurality of fibers changes from the first state as the first formed component to the second state as a melted formed component.

[0160] In one aspect, a knitted upper for a footwear article is provided, the knitted upper including a first yarn comprising a low processing temperature polymer composition. The knitted upper for the footwear article further includes a second yarn comprising a high processing temperature polymer composition. The first and second yarns at least partially form a plurality of interconnected courses in at least one knitted layer of the knitted upper for the footwear article, the at least one knitted layer 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 an increased concentration of the second yarn as compared to the second zone, and wherein the third zone includes an increased concentration of the first yarn as compared to the second zone. In some examples, this structure can form an outer surface of the article, wherein the first zone, the second zone, and the third zone each form a part of the outer surface.

[0161] In certain aspects, a knitted upper for a footwear article is provided, the knitted upper including a molten yarn component comprising a low processing temperature polymer composition. The molten yarn component is thermoformed from a first state as a first yarn to a second state as a molten yarn component. The knitted upper for the footwear article further includes a second yarn comprising a high processing temperature polymer composition. The molten 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 zone and the third zone. The first zone includes a higher concentration of the second yarn as compared to the second zone, and the third zone includes a higher concentration of the molten yarn component as compared to the second zone. In some examples, this structure can form an outer surface of the article, wherein the first zone, the second zone, and the third zone each form a part of the outer surface.

[0162] In some aspects, a wearing article is a footwear article, the footwear article including (but not limited to) articles such as shoes. Footwear articles generally include an upper and a sole structure. The upper provides a covering for the foot, the covering comfortably receiving the foot and positioning the foot fixedly relative to the sole structure. Additionally, the upper generally provides protection for the foot. The sole structure can provide various support, cushioning, and shock absorption. The sole structure is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces (i.e., providing cushioning) during walking, running, and other locomotive activities, the sole structure can (for example) influence foot movement (e.g., by resisting pronation), impart stability, and provide traction. Thus, the upper and the sole structure cooperate to provide a comfortable structure suitable for a wide variety of locomotive activities.

[0163] Upper forming structure, the structure provides a covering for some or all of the wearer's foot and positions the foot relative to the sole structure of that shoe. The upper forms a cavity on the interior of the shoe for receiving the foot. The cavity has the general shape of the foot and provides access to the cavity at the ankle opening. In some aspects, the upper extends across the dorsal and toe regions of the foot, extends along the mid and sides of the foot, and extends around the heel region of the foot. The upper can have any design, shape, size, and / or color. For example, in some aspects, if the article is a basketball shoe, the upper can be a high-top upper configured to provide high support to the ankle. Alternatively, in some aspects, if the article is a running shoe, the upper can be a low-top upper.

[0164] The upper can also incorporate a lacing system to adjust the fit of the shoe and to permit entry of the foot into and removal of the foot from the cavity in the upper. The lacing system is often incorporated into the upper to selectively vary the size of the ankle opening and to permit the wearer to modify certain dimensions (notably the circumference) of the upper to accommodate feet of different sizes. Additionally, the upper can include a tongue that extends beneath the lacing system to enhance the comfort of the shoe (e.g., by modulating the pressure applied to the foot by the lacing adjustment), and the upper can also include a heel counter to limit or control the movement of the heel. Additionally, the upper can include a tongue that extends beneath the lacing system to enhance the adaptability and comfort of the shoe, and the upper can incorporate a heel counter.

[0165] In some aspects, the sole structure can include one or more components or layers that can individually or jointly provide several attributes to the footwear article, such as support, stiffness, flexibility, stability, cushioning, comfort, reduced weight, or other attributes. In some aspects, the sole structure can include layers referred to as an insole, a midsole, and an outsole. However, in some aspects, one or more of these components can be omitted. In certain aspects, the sole can optionally include a shank. In some aspects, the sole structure includes an outsole component that includes an outer major surface that can be exposed and in contact with the ground, and an inner major surface. In another aspect, the sole structure can further include a midsole component that can be attached to the upper along the entire length of the upper. When present, the midsole forms the intermediate layer of the sole structure and serves a variety of purposes, including controlling foot movement and attenuating impact forces.

[0166] The midsole that can be attached along the entire length of the upper to form an intermediate layer of the sole structure and is used for various purposes, including controlling foot movement and reducing impact force. Many midsole configurations are mainly formed of an elastic polymer foam material that extends over the entire length and width of the shoe, such as polyurethane (PU) or ethylene-vinyl acetate (EVA). The midsole can also incorporate plates, regulators, fluid-filled chambers, and / or other elements that further reduce force, affect foot movement, and / or impart stability, for example.

[0167] The outsole forms the element of the shoe that contacts the ground and is typically formed of a durable, wear-resistant material that includes texture or other features for enhancing traction. The outsole can be formed of a durable and wear-resistant material (such as rubber) that includes texture for enhancing traction. The outsole can optionally further include cleats.

[0168] In some aspects, the footwear article can further include an insole, which is a thin member that is positioned within the upper and adjacent to the plantar (bottom) surface of the foot to enhance shoe comfort, for example, by wicking away moisture by capillary action and providing a soft, comfortable feel. In some aspects, the insole can be formed of a foam material, such as polyurethane foam, foam rubber, or ethylene vinyl acetate. In certain aspects, the insole is not glued to the sole structure or otherwise attached to the sole structure. Alternatively, the insole can be attached to the sole structure.

[0169] In certain aspects, there is provided a knitted upper for a footwear article, the knitted upper for the footwear article including a plurality of interconnected courses. Each course of the plurality of interconnected courses includes a first yarn and a second yarn. The first yarn includes a low-processing-temperature polymer composition that includes one or more first thermoplastic polymers. The second yarn includes a high-processing-temperature polymer composition that includes one or more second thermoplastic polymers. The knitted upper for the footwear article further includes at least one knitted layer that includes at least a first zone, a second zone, and a third zone, where the second zone is positioned between the first zone and the third zone. Each course of the plurality of interconnected courses extends through the first zone, the second zone, and the third zone, where the third zone has an increased concentration of the first yarn compared to the second zone. Additionally, the knitted upper for the footwear article includes an anchor yarn that extends through at least a portion of the third zone. The anchor yarn includes an anchor yarn composition that includes one or more polymers. The anchor yarn exhibits an elongation rate that is less than the elongation rate of the first yarn.

[0170] Exemplary aspects of articles of sports equipment, articles of clothing, and textiles

[0171] As discussed above, certain aspects relate to one or more textiles that include fibers and / or yarns that include 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 a sports equipment article or a wearable article. In certain aspects, the disclosed textiles can form at least a portion of a component of a footwear article. In certain aspects, the disclosed textiles can form at least a portion of a component of a sports equipment article. For example, the disclosed textiles can form at least a portion of the upper of a shoe such as a sports shoe.

[0172] Turning now to the figures, and specifically to Figure 1A and Figure 1B , footwear article 100 is depicted as an exemplary wearable article. While Figure 1A and Figure 1B depict footwear article 100, it should be understood that the present disclosure also contemplates other wearable articles. Figure 1A and Figure 1B depict footwear article 100, it should be understood that the present disclosure also contemplates other wearable articles. Figure 1A and Figure 1B The footwear article 100 of Figure 1A Figure 1A and Figure 1B can generally include a ground-facing sole region 110, an ankle collar region 112, a lateral midfoot region 114a and a medial midfoot region 114b, a slip-on region 116, and a heel region 118. Additionally, the footwear article 100 can include a plurality of eyelets 120, an upper region 122, a tongue region 124, and a throat region 126. As shown in Figure 1A

[0173] In Figure 1A and Figure 1B depicted, the footwear article 100 can include at least one textile 102 that at least partially forms a portion of the footwear article 100. The textile 102 of the footwear article 100 can include at least three separate textile zones that identify specific functional regions of the footwear article 100, e.g., zones 104, 106, and 108. In certain aspects, these specific functional regions are at least partially associated with incorporating specific textile media in different amounts, techniques, and combinations into these textile zones (illustrated as zones 104, 106, and 108 in Figure 1A Figure 1A and Figure 1B ). It should be understood that while the textile 102 includes three specific functional regions, more than three functional regions are also contemplated.

[0174] In some aspects, the textile zone 104 can exhibit a rigid or semi-rigid functionality suitable for use as the ground-facing sole 110 of the footwear article 100. Thus, in some aspects, the textile zone 104 can be positioned to encompass at least a portion of the ground-facing sole 110 of the footwear article 100. In some aspects, the targeted incorporation of a low processing temperature polymer composition into the textile zone 104 of the textile 102 can at least partially provide a rigid or semi-rigid functionality for use as the ground-facing sole 110 after thermoforming. As used herein, "thermoforming" refers to a process that can include the melting and / or deformation of a low processing temperature polymer composition and / or one or more thermoplastic polymers and the subsequent cooling of the melted and / or deformed material to form a panel or film that can be rigid or semi-rigid. The thermoforming process is discussed in detail below.

[0175] In addition, in various aspects, another textile zone, such as textile zone 108, can exhibit flexibility and / or flexibility to accommodate movement from the wearer. In some aspects, the textile zone 108 can encompass the ankle collar region 112, the tongue region 124, and / or the throat region 126 of the footwear article 100. In various aspects, the textile zone 108 can include a high processing temperature polymer composition.

[0176] In some aspects, another textile, such as zone 106, can be positioned between textile zones 104 and 108. In some aspects, the textile zone 106 can encompass at least a portion of the lateral midfoot region 114a and / or the medial midfoot region 114b on the footwear article 100. In some aspects, the textile zone 106 can include a combination of a low processing temperature polymer composition from the textile zone 104 and a high processing temperature polymer composition from the textile zone 108. In these aspects, this combination of textiles present in the textile zone 106 allows the textile zone 106 to act as a transition zone between the rigid or semi-rigid functionality of the textile zone 104 and the flexible and flexible functionality of the textile zone 108, thus achieving a smoother transition from the rigidity to the flexibility of the textile 102.

[0177] In addition, in these aspects, the textile zone 106 can exhibit a rigidity or semi-rigidity that is less than that of the textile zone 104 but greater than that of the textile zone 108. Moreover, in the same or alternative aspects, the textile zone 106 can exhibit a flexibility that is less than that of the textile zone 108 but greater than that of the textile zone 104.

[0178] Alternatively or additionally, the three textile zones 104, 106, and 108 can be at least partially located within the midfoot region, such as within the lateral midfoot region 114a and / or the medial midfoot region 114b.

[0179] In certain aspects of textile zone 106, the combination of the low processing temperature polymer composition present in textile zone 104 and the high processing temperature polymer composition present in textile zone 108 can impart one or more structural properties to footwear article 100 when exposed to a thermoforming process, such as semi-rigid support in the lateral midfoot region 114a and / or the medial midfoot region 114b, and / or impart a three-dimensional shape or structure to one or more portions of footwear article 100.

[0180] In certain aspects, as can be seen in Figure 1A , textile zone 106 extends away from textile zone 104 towards eyelet 120. In these aspects, the combination of the textile medium comprising the low processing temperature polymer composition and the textile medium comprising the high processing temperature polymer composition can allow the transfer of forces transmitted from eyelet 120 or other lacing mechanisms into this combination of textile media present in the lateral midfoot region 114a and / or the medial midfoot region 114b. In certain aspects, in order to successfully transfer the forces transmitted from eyelet 120, textile zone 104 and / or the low processing temperature polymer composition present in textile zone 104 can terminate at region 128, which is at a distance of 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 or at least about 5 stitches below eyelet 120 when textile 102 is a knitted textile formed on a commercial knitting machine. In these aspects, the flexible and bendable characteristics of the high processing temperature polymer composition present in region 108 adjacent to eyelet 120 can facilitate the transfer of forces transmitted from eyelet 120 to textile zone 106 and / or the low processing temperature polymer composition present in the lateral midfoot region 114a and / or the medial midfoot region 114b.

[0181] In the aspects depicted in Figure 1A and Figure 1B , textile zone 106 is positioned in the collar region 116 and the heel region 118. In these aspects, 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. Additionally, the thermoformed material can provide abrasion resistance in the collar region 116 and / or the heel region 118. In alternative aspects, textile zone 104 can form at least a portion of the collar region 116 and / or the heel region 118 to achieve increased rigidity or increased abrasion resistance because textile zone 104 contains a greater amount of the low processing temperature polymer composition or an alternative positioning of the low processing temperature polymer composition (e.g., external knitted surface) compared to textile zone 106.

[0182] Figure 1CDepict alternative aspects of the footwear article 100a. In these aspects, the footwear article 100a can generally include at least three types of textile regions: textile region 104a, textile region 106a, and textile region 108a. In certain aspects, the textile regions 104a, 106a, and 108a can respectively have the same properties and parameters as the textile regions 104, 106, and 108 of the footwear article 100 discussed above with reference to Figure 1A The textile regions 104, 106, and 108 of the footwear article 100 have the same properties and parameters.

[0183] In Figure 1C In the aspects depicted in, portions of the textile region 104a, e.g., portions 104b and 104c, can extend upward from the outsole region through the midfoot region 115A and toward the plurality of eyelets 120a. In these aspects, the rigidity or semi-rigidity functionality provided by portions 104b and 104c that extend from the outsole region through the midfoot region 115A to the plurality of eyelets 120a can provide increased wearer stability in the midfoot region 115A. Additionally, in various aspects, forces applied through one or more of the plurality of eyelets 120a can be at least partially transferred to the rigid or semi-rigid portions 104b and 104c that extend through the midfoot region 115A and to the rigid or semi-rigid textile region 104a present in the outsole region, thereby providing increased support and comfort to the wearer.

[0184] In certain aspects, in addition to the thermoformed material providing structure, rigidity, strength, and / or support to one or more regions of the wearable article, the thermoformed material can provide a waterproof or water-resistant surface.

[0185] Figure 2A And Figure 2B Depict the shirt 200 as an exemplary apparel article. The shirt 200 depicted in Figure 2A And Figure 2B Includes at least one textile 202 that at least partially forms a part of the shirt 200. As best seen in Figure 2B The textile 202 can include three separate textile regions 204, 206a-d, and 208 that can identify specific functional regions of the 200. In certain aspects, these specific functional regions are at least partially associated with incorporating specific textile media into these textile regions 204, 206a-d, and 208 in different amounts and combinations.

[0186] In some aspects, the textile region 204 can include enhanced regions, such as an exterior film or patch 210, which can provide abrasion resistance to, for example, the elbow region 212 of the shirt 200. In these aspects, targeted and integral incorporation of a low processing temperature polymer composition into the textile region 204 can at least partially form the patch 210 when the textile 202 is thermoformed by melting or deforming the low processing temperature polymer composition and subsequently cooling and solidifying the molten material to form the patch 210.

[0187] In various aspects, the textile region 208 can exhibit flexibility and / or bendability similar to that of conventional shirt materials. In these aspects, the textile region 208 can comprise or consist only of a high processing temperature polymer composition. Additionally, in some aspects, the textile region 206 can at least partially provide a transition region within the textile 202 from the rigid or semi-rigid patch 210 present in the textile region 204 to the flexible and bendable portion present in the textile region 208. In these aspects, the textile regions 206a-d can comprise a combination of the low processing temperature polymer composition present in the textile region 204 and the high processing temperature polymer composition present in the textile region 208. Although not shown in Figure 2A and Figure 2B , the textile regions 206b-d also provide a transition region to, for example, the flexible and bendable material present in the textile region 208.

[0188] In some aspects, similar to the textile region 106 of the textile 102 discussed above with reference to Figure 1A and Figure 1B , this combination of the low processing temperature polymer composition from the textile region 204 and the high processing temperature polymer composition from the textile region 208 can provide a seamless or integrated transition region from the patch 210 to the flexible and bendable portion present in the textile region 208 of the shirt 200.

[0189] Although this exemplary description of the textile regions 204, 206a-d, and 208 in Figure 2A and Figure 2B relates to the elbow region of the garment 200, it should be understood that the textile regions 204, 206a-d, and 208 and the associated properties can apply to other regions of the shirt or other garments (such as the knees, thighs, hips, chest), and / or the lower back region of the garment, or regions that require reinforcement, such as regions adjacent to fasteners (e.g., zippers, buttons, snaps, drawstrings, etc.).

[0190] Now turning to Figure 3, provides a plan view of an exemplary textile 300. It should be understood that the 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.

[0191] Similar to Figure 1A and Figure 1B textile 102 and Figure 2A and Figure 2B textile 202, Figure 3 textile 300 includes three types of textile regions. By way of example, 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. In Figure 3 textile 300, textile regions 304a and 304b may be located on either side of textile region 302, while textile regions 306a and 306b may be located on opposite sides of textile regions 304 and 304b, respectively.

[0192] In some aspects, the fibers and / or yarns comprising the low processing temperature polymer composition present in textile region 302 may impart structural or functional properties to textile 300 that can be used to form a wearable article when exposed to a thermoforming process. By way of example, textile region 302 may represent the Figure 1A and Figure 1B textile region 104 of textile 102. In various aspects, the fibers and / or yarns comprising the high processing temperature polymer composition present in 306a and 306b may impart to textile 300 (e.g., in Figure 1A and Figure 1BThe textile regions 108 of the footwear article 100 depicted therein impart flexibility or bendability. Additionally, in various aspects, the textile regions 304a and 304b can include the following combinations to provide structural support and a three-dimensional structure for a particular wearable article: fibers and / or yarns including a low processing temperature polymer composition present in the textile region 302 and fibers and / or yarns including a high processing temperature polymer composition present in the textile regions 306a and 306b. Further, as discussed above, in certain aspects, this combination of fibers and / or yarns including a low processing temperature polymer composition and fibers and / or yarns including a high processing temperature polymer composition in the textile regions 304a and 304b can provide an integrated transition between the rigid thermoformed material in the textile region 302 and the flexible and bendable high processing temperature polymer composition in the textile regions 306a and 306b.

[0193] In one or more aspects, the textile regions 304a and 304b can include a plurality of sub-regions, such as sub-regions 305a, 305b, 305c, and 305d of the textile region 304a, which can include different combinations and / or different orientations of fibers and / or yarns including a low processing temperature polymer composition and fibers and / or yarns including a high processing temperature polymer composition. In certain aspects, the sub-region 305a can include fibers and / or yarns including a low processing temperature polymer composition, but does not include fibers and / or yarns including a high processing temperature polymer composition present in the textile regions 306a and / or 306b. In the same or alternative aspects, the sub-region 305d can include fibers and / or yarns including a high processing temperature polymer composition, but does not include fibers and / or yarns including a low processing temperature polymer composition present in the textile region 302.

[0194] It should be understood that while only the sub-regions of the textile region 304a may be further described herein, these descriptions apply to the sub-regions present in the textile region 304b. Additionally, it should be understood that if only the textile region 304a and / or 306a are further discussed in certain descriptions, then these descriptions also apply to the textile regions 304b and 306b, respectively.

[0195] In certain aspects, based on the relative orientation of fibers and / or yarns including a low processing temperature polymer composition and fibers and / or yarns including a high processing temperature polymer composition in the textile regions 302, 304a, and 306a, the textile 300 can have different concentrations of the low processing temperature polymer composition and / or the high processing temperature polymer composition in these textile regions 302, 304a, 306a.

[0196] As used herein, the term "concentration" refers to a cluster or aggregation in a specific volume. Thus, the term concentration includes measurements of a specified volume (e.g., cm 3) the amount of material in (e.g., weight in grams). For example, in a knitted textile, a first portion of a single knitted layer of the textile can have an increased concentration of a first yarn by having more stitches (e.g., plain stitches, tuck stitches, and / or float stitches) than an equal-sized second portion of the textile. In another example, in a non-woven textile, if a first portion of the textile is formed to have more of a first fiber (e.g., weight in grams) than an equal-sized second portion, then the first portion can have an increased concentration of the first fiber.

[0197] In various aspects, textile zone 302 can include fibers and / or yarns comprising a low processing temperature polymer composition having an increased concentration compared to textile zones 304a and / or 306a. For example, in these aspects, textile zone 302 can have at least 5 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile zones 304a and / or 306a. In another aspect, textile zone 302 can have at least 10 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile zones 304a and / or 306a. In one aspect, textile zone 302 can have at least 25 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile zones 304a and / or 306a.

[0198] In the same or alternative aspects, textile zone 304a can include fibers and / or yarns comprising a low processing temperature polymer composition having an increased concentration compared to textile zone 306a. For example, in these aspects, textile zone 304a can have at least 5 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile zone 306a. In another aspect, textile zone 304a can have at least 10 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile zone 306a. In one aspect, textile zone 304a can have at least 25 wt% more fibers and / or yarns comprising a low processing temperature polymer composition compared to textile zone 306a.

[0199] In various aspects, textile zone 306a can include fibers and / or yarns comprising a high processing temperature polymer composition at an increased concentration compared to textile zones 302 and 304a. For example, in these aspects, textile zone 306a can have at least 5 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile zone 302 and / or 304a. In another aspect, textile zone 306a can have at least 10 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile zone 302 and / or 304a. In one aspect, textile zone 306a can have at least 25 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile zone 302 and / or 304a.

[0200] In certain aspects, textile zone 304a can include fibers and / or yarns comprising a high processing temperature polymer composition at an increased concentration compared to textile zone 302. For example, in these aspects, textile zone 304a can have at least 5 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile zone 302. In another aspect, textile zone 304a can have at least 10 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile zone 302. In one aspect, textile zone 304a can have at least 25 wt% more fibers and / or yarns comprising a high processing temperature polymer composition compared to textile zone 302.

[0201] FIG. 4A to FIG. 4D Exemplary cross-sections of textile zones 302, 304a, and 306a of textile 300 are schematically depicted. Generally, Figure 4A A cross-section exemplary of textile zone 306a is depicted and, in certain aspects, further illustrates how this portion of textile zone 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 zone 302. Figure 4B A cross-section exemplary of textile zone 302 is depicted and, in various aspects, also illustrates how this portion of textile zone 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 zone 306a. Figure 4C and Figure 4D Two cross-sections exemplary of textile zone 304a are depicted and further illustrate how 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 zone 304a.

[0202] Now, from the perspective of textile 300 as a knitted textile, the description will be made in FIG. 4A to FIG. 4D The cross-sections depicted herein. The various processes for forming the knitted textile and the types of yarns that can be used are discussed in detail below. It is contemplated that a variety of knitting techniques can be implemented to achieve the described results. For example, in some aspects, purl stitches can be used in place of "plain stitches" to achieve comparable results with different aesthetics and / or textures. For simplicity herein, "plain stitches" will be discussed, but it is contemplated that functionally equivalent replacements can be used. Similarly, "tuck stitch" may be discussed in certain aspects, but it is also contemplated that alternative stitch techniques can be implemented to achieve comparable results. Although relatively simple knitted structures are depicted and discussed, numerous warp-knitted and weft-knitted structures can be formed by (e.g.) transverse knitting, wide-tube circular knitting, narrow-tube circular knitting jacquard, single-sided circular knitting jacquard, double-sided circular knitting jacquard, double-bar raschel, warp-knitted jacquard, and warp knitting.

[0203] It should be understood that FIG. 4A to FIG. 4D the cross-sections depicted herein are schematic, and each cross-section is organized into individual segments to highlight the potential knitted structures that may be present. First, the potential knitted structures that may be present in the individual segments of these cross-sections are described.

[0204] FIG. 5A to FIG. 5J Depict exemplary potential knitted structures that may be present in the individual segments of the cross-section depicted in 4A to 4D herein. Figure 5A Depict the plain stitch (or sometimes referred to as jersey stitch) structure 502 formed by the back needle bed 504. It should be understood that, according to the traditional stitch diagram, the rows of small circles associated with the back needle bed 504 represent the needles of the back needle bed 504 (e.g., needle 505). Additionally, the same is true for the front needle bed, e.g., the front needle bed 508 depicted in Figure 5B herein; that is, the rows of small circles associated with the front needle bed 508 represent the needles in the front needle bed 508 (e.g., needle 507).

[0205] Figure 5B Depict the plain stitch structure 506 formed by the front needle bed 508. Figure 5C Depict a float stitch and tuck stitch structure 510, which has a tuck stitch formed by the front needle bed 512 and the back needle bed 514. Figure 5D Depict another float stitch and tuck stitch structure 516, which has a tuck stitch formed by the front needle bed 518 and the back needle bed 520. Figure 5E Depict a float stitch structure 522. Fig. 5F Depict a plain stitch and tuck stitch structure 524, which has a plain stitch 524a formed by the return needle bed 528 and a tuck stitch 524b formed by the front needle bed 526. Figure 5G Depict a plain stitch and float stitch structure 530, where the plain stitch is formed on the front needle bed 532. Figure 5HDepict the under - stitch and float stitch organization structure 534, where the under - stitch is formed on the back needle bed 536. Fig.5I Depict the tuck and float knitting structure 538, where the tuck stitch organization is formed by the front needle bed 540. Figure 5J Depict the tuck and float knitting structure 542, where the tuck stitch organization is formed by the back needle bed 544.

[0206] Now return to the cross - sections 4A - 4D of the textile 300. Generally speaking, the cross - sections depicted in 4A - 4D are similarly structured due to the main structure of the knitted textile. For example, in all aspects, there is a tubular knitted structure that includes a knitted structure mainly formed by the back needle bed (e.g., the knitted structure 502 depicted in Figure 5A and a knitted structure mainly formed on the front needle bed (e.g., the knitted structure 506 depicted in Figure 5B ). In addition, in these aspects, this tubular knitted structure is connected via one or more tuck stitch organizations and float stitch organization structures, where the tuck stitch organizations are formed by the back needle bed and the front needle bed (e.g., the tuck stitch organization and float stitch organization structures 510 and 516 depicted in Figure 5C and Figure 5D respectively).

[0207] Schematically depict this connected tubular knitted structure with three horizontal rows prominent in the cross - sections depicted in 4A - 4D. For example, Figure 4A Depict the cross - section 402 of the textile area 306a containing a Figure 3 textile area containing a polymer composition with a high processing temperature.

[0208] Figure 4A The cross - section 402 of Figure 5A schematically depicts a top section 404, a middle section 406, and a bottom section 408. The top section 404 and the bottom section 408 represent the knitted structures for forming the tubular knitted structure, while the middle section 406 represents the tuck stitch organization and float stitch organization structures for connecting the tubular knitted structures together. Thus, in some aspects, the top section 404 can include one or more of the knitted structures 502 and 524 depicted in Fig. 5F and Figure 5B respectively. The bottom section 408 can include the knitted structure 506 depicted in Figure 5C and Figure 5D respectively. The middle section 406 can include one or more of the knitted structures 510 and 516 depicted in

[0209] Figure 4B Depict the cross - section 410 of the textile area 302 containing a yarn including a polymer composition with a low processing temperature. The cross - section 410 includes a top section 412, a middle section 414, and a bottom section 416, which can include those described above with respect to Figure 4AThe same knitting structure identified by the top section 404, middle section 406, and bottom section 408 of the cross-section 402.

[0210] In some aspects, it may be necessary to swell the low-treatment temperature polymer composition in the textile area 302 to provide the desired thickness and rigidity to the thermoformed textile area 302, for example, to form the ground-facing sole of a footwear article. In these aspects, the textile area 302 may include repeating stitch steps to increase the concentration of yarns including the low-treatment temperature polymer composition relative to other textile areas (e.g., textile areas 304a and / or 306a). In some aspects, the repeating stitch steps may be provided by including, for example, multiple stitch structures in any or all of the top section 412, middle section 414, and bottom section 416 of the cross-section 410. In one example, multiple overlapping tuck and float stitch structures (e.g., the structures depicted in Figure 5C , Figure 5D , Fig.5I and Figure 5J ) may be provided in the middle section 414 of the cross-section 410.

[0211] In some aspects, in areas of the textile 300 that include a large amount of yarns including the low-treatment temperature polymer composition (e.g., textile area 302), anchor yarns 413 may be provided in the textile 300 to help restrain the flow of the melted low-treatment temperature polymer composition and / or provide a certain flexibility to the thermoformed material. In the cross-section 410 depicted in Figure 4B , the anchor yarns 413 are depicted as being present in the middle section 414 between the top section 412 and the bottom section 416, respectively. In these aspects, this positioning of the anchor yarns 413 may result in the anchor yarns 413 being embedded or encapsulated by the low-treatment temperature polymer composition after thermoforming of the textile 300.

[0212] Although the anchor yarns 413 in Figure 4B are depicted as straight lines, it should be understood that this is a schematic representation of the anchor yarns 413 and is not intended to specify any particular type of knitting structure. For example, the anchor yarns 413 may exist in the textile 300 as many different types of knitting structures, such as in Figure 5E and Figure 5GOne or more of the structures depicted in -J. In some aspects, the stitch selection of the anchoring yarn 413 can depend on the desired resistance to elongation of the material through which the anchoring yarn 413 extends. For example, an anchoring yarn stitch that floats five stitches between tuck stitches or plain stitches will provide greater resistance to stretching of the material through which the anchoring yarn 413 extends than an anchoring yarn stitch that only floats two or three stitches between tuck stitches or plain stitches. In this example, the different resistances to elongation between the floating lengths are due to non-linear portions (e.g., stitch loops) that are more easily elongated than linear segments, which results in different amounts of resistance to elongation.

[0213] In some aspects, when the anchoring yarn 413 is present as Figure 5G one or more of the knitting structures depicted in -J, the anchoring 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 is also present as Figure 5A and Figure 5B one or more of the knitting structures of. Additionally, in some aspects, the anchoring yarn 413 can extend 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, and the yarn comprising the low processing temperature polymer composition can also be used to form at least a portion of the tuck stitches and / or plain stitches. In these aspects, using the yarn comprising the low processing temperature polymer composition and the anchoring yarn to at least partially form the length between tuck stitches or plain stitches, the anchoring yarn 413 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. In the same or alternative aspects, the anchoring yarn 413 can be knotted at loops spaced within 50% or 25% of the gauge of the knitting machine used to form at least a portion of the textile 300, which is represented by the number of needles of the common needle bed, e.g., tuck stitches or plain stitches.

[0214] Figure 4C and Figure 4D depict cross-sections of the textile region 304a and portions of the textile regions 302 and 306a. For example, Figure 4C the cross-section 418 of contains a portion 422 corresponding to the textile region 302 and a portion 420 corresponding to the textile region 306a. The portions 424a, 424b, 424c, and 424d correspond to the sub-regions 305a, 305b, 305c, and 305d of the textile region 304a of the textile 300, respectively. Schematically simplified FIG. 4C to FIG. 4Ecross-section; however, one or more regions and / or portions of the expected cross-section may include a variety of fibers and / or yarns in different configurations and concentrations. For example, the textile region 424c in the intermediate section 428 may include both fibers and / or yarns containing a low processing temperature polymer composition and fibers and / or yarns containing a high processing temperature polymer composition, but in a configuration / concentration different from that in the textile regions 424b and / or 424d of the intermediate section 428. In other words, various construction techniques allow for the combination of fibers and / or yarns in a given section and textile region through variations in methods of combining, including, attaching, depositing, or applying fibers and / or yarns (e.g., stitch selection), and these variations in methods allow for variations in the fiber and / or yarn concentration at the section level and / or textile region level.

[0215] Figure 4C The cross-section 418 of Figure 4A and Figure 4B contains the same general tubular knitting structure of the same type as discussed above with respect to the cross-sections 402 and 410 of Figure 4A respectively. Thus, the cross-section 418 contains a top section 426, an intermediate section 428, and a bottom section 430. The top section 426, the intermediate section 428, and the bottom section 430 may respectively contain the same knitting structures as discussed above with reference to the top section 404, the intermediate section 406, and the bottom section 408 of the cross-section 402 of

[0216] In Figure 4C the cross-section 418, the portions 422 and 424a contain knitting structures made using yarns including a low processing temperature polymer composition, while the portions 420, 424d, and 424c contain knitting structures made using yarns including a high processing temperature polymer composition. However, as provided above, it is expected that combinations of fibers and / or yarns based on different stitch techniques may be implemented in the respective portions to achieve a transition from one major material to another.

[0217] Portion 424b comprises a tubular knitted structure made from yarns comprising a high processing temperature polymer composition; however, the knitted structure formed by the front and back needle beds and the back needle bed (using yarns comprising a high processing temperature polymer composition) is joined via floats and tucks (or equivalent effective needle steps) from yarns comprising a low processing temperature polymer composition. This portion 424b illustrates how the low processing temperature polymer composition can physically join two outer knitted layers via the facings or membranes of the thermoformed material when the textile 300 is subjected to thermoforming. In these respects, a wearable article having this type of tubular knitted structure that has been thermoformed and joined via an integral thermoforming material will primarily comprise typical knitted yarn layers joined together via a thermoformed film on opposite outer surfaces of the textile. This structure can be utilized to provide the wearable article with waterproof / water resistant or other weather resistant properties while still maintaining the aesthetics and feel of a typical knitted article.

[0218] As with Figure 4C cross-section 418 of Figure 4D cross-section 432 of

[0219] Figure 4D The top region 440, middle region 442, and bottom region 444 of cross-section 432 of Figure 4A can respectively comprise the same knitted structures discussed above with reference to the top section 404, middle section 406, and bottom section 408 of cross-section 402 of

[0220] In an exemplary aspect, Figure 4D portions 434 and 438d of cross-section 432 comprise a knitted structure that comprises yarns comprising a high processing temperature polymer composition, while portions 436, 438a, and 438b comprise a knitted structure made using yarns comprising a low processing temperature polymer composition. However, as also provided above, it is contemplated that primary (but not exclusive) material selections can be made. For example, in portion 438b, yarns comprising a high processing temperature polymer composition can be present in the middle region 442 to assist in the transition of materials. The concentration of yarns comprising a high processing temperature polymer composition in portion 438b can be less than the concentration present in portion 438c of the same middle region 442. For example, portion 438b can have at least 5 wt%, 10 wt%, or 25 wt% less of the yarns comprising a high processing temperature polymer composition than portion 438c of the same middle region 442.

[0221] Portion 438c includes a tubular structure using yarns including a low processing temperature polymer composition, which is joined via floats and tucks from yarns including a high processing temperature polymer composition. In these aspects, after thermoforming, this portion 438c can encapsulate the yarns including the high processing temperature polymer composition within the fascia of the melted and cooled thermoformed material. In certain aspects, such a structure can provide a degree of flexibility to an otherwise rigid thermoformed material.

[0222] For example, Figure 4E depicts a cross-section 446 that is the same as cross-section 432 of Figure 4D , except that an anchor yarn 448 has been added to at least a portion of the region that includes yarns including a low processing temperature polymer composition. In certain aspects, the anchor yarn 448 can have any or all of the properties discussed above with respect to Figure 4B the anchor yarn 413 of Figure 5E and Figure 5G -J. For example, the anchor yarn can be incorporated into a textile using one or more of the knitting structures depicted in

[0223] It can be seen in Figure 4E that the anchor yarn 448 extends from a portion 450 corresponding to the cross-section 446 of the textile region 302 and into portions 452a and 452b corresponding to sub-regions 305a and 305b of the textile region 304a. Additionally, in these aspects, Figure 4E it is illustrated that yarns including a low processing temperature polymer composition are also present (e.g., as having a presence in Figure 5A and Figure 5Bin at least a portion of the textile that is the same as the anchoring yarn 448 among one or more of the knitted structures). Thus, in some aspects, the anchoring yarn 448 can extend as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of the yarn including the low processing temperature polymer composition. Additionally, in some aspects, the anchoring yarn 448 can extend as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of the yarn including the low processing temperature polymer composition and can also be used to form at least a portion of the tuck stitch and / or the lower needle using the yarn including the low processing temperature polymer composition. In these aspects, between using the yarn including the low processing temperature polymer composition and the anchoring yarn 448 to at least partially form the tuck stitch or the lower needle, the anchoring yarn 448 can extend across at least two, at least three, at least four, or at least five adjacent loops of the yarn including the low processing temperature polymer composition. In the same or alternative aspects, the anchoring yarn 448 can be knotted at loops that are within 50% or within 25% of the amount of the gauge of the knitting machine used to form at least a portion of the textile 300, separated by the number of needles, e.g., the tuck stitch or the lower needle.

[0224] As discussed above, in one or more aspects, the anchoring yarn 448 can extend from the textile zone 302 toward the textile zone 306a into the textile zone 304a. In these aspects, the anchoring yarn 448 may not extend as far from the textile zone 302 toward the textile zone 306a into the textile zone 304a as the yarn including the low processing temperature polymer composition extends into the zone 304a toward the textile zone 306a because there is less need to restrain flow and / or provide flexibility to the thermoformed material during thermoforming since the yarn including the high processing temperature polymer composition from the zone 306a is also present in the textile zone 304a.

[0225] For example, in Figure 4E cross-section 446, the anchoring yarn extends from portion 450 (corresponding to a portion of the textile zone 302) and extends into portion 452b (corresponding to the sub-region 305b of the textile 300). Additionally, cross-section 446 illustrates that the top segment 456 and the bottom segment 460 of cross-section 446 show the yarn including the low processing temperature polymer composition extending from portion 450 toward portion 454 (corresponding to the textile zone 406a) into portion 452c, which extends further than the anchoring yarn 448 in the same direction. However, in the middle segment 458, in portions 452c and 452d, there are yarns including the high processing temperature polymer composition, which can provide flexibility to the thermoformed textile and / or restrain flow during thermoforming.

[0226] As discussed above, in certain aspects, when the textile 300 is a knitted textile, it will be at FIG. 4A to FIG. 4E The cross-section of the textile depicted is shown as having a top section, a bottom section, and an intermediate section, where the top and bottom sections can form a tubular knitted structure having a top knitted layer and a bottom knitted layer (and where the tuck stitches or other connecting stitches present in the intermediate section can also form part of a tubular or general knitted structure). In these respects, each of the top and bottom outer knitted layers can include a plurality of interconnected courses.

[0227] In addition, in Figure 3 the textile 300, it can be seen that in region 304a, sub-regions 305a-d have at least one staggered interface, e.g., the staggered interface 306. The staggered interface, e.g., the staggered interface 306, provides a staggered or non-linear transition between sub-regions of the textile 300 along the width w of the textile. In these respects, when the textile 300 is thermoformed, these staggered interfaces provide a finer integration transition between the rigid regions formed by the low-processing temperature polymer composition in the textile zone 302 and the flexible and bendable regions formed by the yarns including the high-processing temperature polymer composition in the textile zone 306a. In various aspects, this finer integration transition provided at least in part by the staggered interface can increase the durability or tear strength of the thermoformed textile 300, as compared to similar textiles having a linear abrupt transition between a monolithic rigid material and a flexible material.

[0228] In the case where the textile 300 is a knitted textile, the staggered interface 306 can depict how different courses of the yarns on the top or bottom outer knitted layer can have different amounts of coils (or general stitch selections) of yarns including the low-processing temperature polymer composition and / or yarns including the high-processing temperature polymer composition. Since the textile can have multiple layers (e.g., top, intermediate, and bottom), the staggered interface can be found in any combination of the layers and is not limited to the exposed or depicted surface. Alternatively, as provided herein and as expected, a transition zone from a first primary material (e.g., fibers and / or yarns including the high-processing temperature polymer composition) to a second primary material (e.g., fibers and / or yarns including the low-processing temperature polymer composition) forms the textile, and the transition zone can appear only at the intermediate layer or at the combination of the intermediate layer and one or more outer layers. It should be understood that for the following discussion of the knitted layers, it is assumed that when Figure 3 the textile 300 is a knitted textile, the view of the textile 300 depicts the top layer. Additionally, the same description equally applies to the bottom knitted layer.

[0229] Figure 6 An exemplary portion 600 of the top layer of the textile 300 is schematically depicted, which shows a part of the staggered interface 306. In Figure 6As can be seen, part 600, the first horizontal row 602 of the coil is interconnected to the second horizontal row 604 of the coil. It should be understood that although only two interconnected horizontal rows are depicted in Figure 6 , more than two horizontal rows can be interconnected in the top knitted layer of the textile 300. As used herein, "interconnected" when referring to interconnected horizontal rows means how at least a portion of the coils in the first coil horizontal row are tied to at least a portion of the coils in the second coil horizontal row. In Figure 6 , an exemplary aspect of the interconnected horizontal rows is depicted, where individual coils from the second horizontal row 604 are interloped with individual coils from the first horizontal row 602. As used herein, "interloped" means how the coils from one horizontal row can surround the coils of another horizontal row, for example, in a purl stitch, and also means how one coil can cause another section of yarn to pass through the coil (or through the coil and around the yarn forming the coil) during, for example, a hemming process to form a second coil.

[0230] As can be seen in part 600 of the textile 300, the first horizontal row 602 and the second horizontal row 604 comprise two types of yarns: a first yarn 606 that can comprise a high processing temperature polymer composition and a second yarn 608 that can comprise a low processing temperature polymer composition. Although only two horizontal rows are depicted in part 600, it should be understood that the top knitted layer of the textile 300 can comprise any number of horizontal rows. In various aspects, each of the horizontal rows present in the top knitted layer of the textile 300 can comprise two or more types of yarns, as Figure 6 is depicted.

[0231] In Figure 6 , as can be seen, each horizontal row, for example, the first horizontal row 602 and the second horizontal row 604, can extend from the textile area 302 to the textile area 306a (in various aspects, each of the horizontal rows can extend from the textile area 306a to the textile area 306b). In certain aspects, in Figure 6 , as can be seen, the second yarn 608 in the first horizontal row 602 and the second horizontal row 604 can extend from the textile area 302 into the textile 304a. In the same or alternative aspects, the first yarn 606 can extend from the textile area 304a to the textile area 306a. It should be understood that although the schematic part 600 of the textile 300 depicts each coil as having only a single yarn, more than one yarn can be present at one or more coils (for example, another yarn can form a tuck stitch with the coils of Figure 6 part 600), as FIG. 4A to FIG. 4E is depicted in the cross-section of

[0232] As discussed above, portion 600 of the outer knit layer of textile 300 illustrates at least a portion of the interleaved interface 306. In some aspects, the interleaved interface 306 (and any other interleaved interface) can be formed by yarns of the same type in multiple courses that extend different distances from one area (or sub-area) into the next area or sub-area. For example, as seen in Figure 6 in the first course 602, the second yarn 608 extends further from textile zone 302 towards textile zone 306a into textile zone 304a than the second yarn extends from textile zone 302 towards textile zone 306a into textile zone 304a. In these aspects, the different distances that the second yarn 608 extends into textile zone 304a result in different amounts of loops of the second yarn 608 in each of the first course 602 and the second course 604, which can change the concentration of the yarn in a given area / sub-area. Thus, in these aspects, within textile zone 304a, the loops of the second yarn 608 in the first course 602 can interloop with the loops of the second yarn 608 in the first course 602 at the first wale 608, while at the second wale 610, the second yarn 608 of the first course 602 can interloop into the loops of the first yarn 604 in the first course 602. In the same or alternative aspects, within textile zone 304a, the first yarn 604 in the first course 602 can interloop with the first yarn 604 in the second course 604 at the third wale 612.

[0233] In one or more aspects, an interleaved interface, e.g., interleaved interface 306, can cause adjacent courses of multiple courses in textile 300 to have different numbers of loops of yarns comprising a low processing temperature polymer composition and yarns comprising a high processing temperature polymer composition. For example, as seen in Figure 6 in portion 600 of the upper knit layer of textile 300 depicted in, in at least a portion of textile zone 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. Additionally, in the same or alternative aspects, within at least a portion of textile zone 304a, adjacent wales can have one or more loops of different yarns. For example, as illustrated in Figure 6 in portion 600 of the upper knit layer of textile 300 in, wale 610 comprises loops of both the first yarn 606 and the second yarn 608, while wale 612 comprises loops of the first yarn 606.

[0234] As discussed above, the textiles described herein that may include fibers and / or yarns comprising a low processing temperature polymer composition may be thermoformed to impart certain structural properties to a wearable article. Additionally, 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 then solidify.

[0235] Fig. 7A Schematically depicts a portion 700 of a textile zone 304a of an upper knit layer of a Figure 3 textile 300 prior to a thermoforming process. Portion 700 includes a first row 702 and a second row 704 that have a first yarn 708 comprising a high processing temperature polymer composition. The portion also includes a third row 706 of a second yarn 710 comprising a low processing temperature polymer composition. In this regard, the third row 706 of loops of the second yarn 710 may be interconnected (e.g., interloped) to the first row 702 and the second row 707 having the first yarn 708.

[0236] Figure 7B Depicts portion 700 after exposure to a thermoforming process. By comparison Fig. 7A and Figure 7B it can be seen that the second yarn 710 comprising the low processing temperature polymer composition has been thermoformed from 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 solidifies into the molten yarn component 712 by completing the thermoforming process.

[0237] In various aspects, in Fig. 7A and Figure 7B it can be seen that the thermoforming process has also transformed Figure 3 at least a portion of the knit structure of portion 700 of the upper knit layer of the Fig. 7A textile 300. By way of example, the rows 702, 704, and 706 depicted in Figure 7B have been transformed such that at least in part due to the transformation of the yarn 710 in the second row 706 into the molten yarn component 712, portion 700 no longer includes an interloped row of loops of a yarn comprising a low processing temperature polymer composition and a yarn comprising a high processing temperature polymer composition. In Figure 3 it can be seen that while the thermoforming process may eliminate Figure 3This portion 700 of the upper knit layer of textile 300 can fix the positions of courses 702 and 704 to each other, in contrast to when courses 702 and 704 are interconnected via course 706 prior to thermoforming. Furthermore, in these aspects, the top portions 714 of the loops of first course 702 can still freely interconnect with other courses of yarn, thereby allowing the level of stiffness and / or three-dimensional shaping provided by textile area 304a to be adjusted.

[0238] Figure 8 Describe along the Figure 7B The section line 8 shown in FIG. Figure 3 A cross section of a portion 700 of an upper knitted layer of textile 300. Figure 8 7, at least a portion of the first yarn 708 can be encapsulated within the molten yarn component 712. Depending on the conditions used during the thermoforming process, the molten 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.

[0239] In Figure 7B and Figure 8 As can be seen in the aspects depicted in FIG, 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 speckles within the first yarn 708) that does not leach out after exposure to the thermoforming process. For example, in Figure 7B and Figure 8 As can be seen in the figure, there is no visible leaching of dye 716 from the first yarn 708 into adjacent regions (e.g., adjacent regions 718) of the melted yarn component 712. In some aspects, at least about 80 weight percent, at least about 90 weight percent, at least about 95 weight percent, or at least 99 weight percent of the dye 716 remains within the first yarn 708 or remains within the first yarn 708. Figure 3 The thermoformed portion 700 of the upper knitted layer of the textile 300 is formed in the thermoformed portion 700. In the same or alternative aspects, after thermoforming, there is no visible leaching of the dye into the Figure 3 Portion 700 of the upper knit layer of textile 300 is incorporated into any additional materials associated with the final article of wear.

[0240] Fig.9A and Fig. 9B Describe one aspect, Figure 3 The portion 700 of the upper knitted layer of the textile 300 is exposed to a thermoforming process, but only causes deformation of the low processing temperature polymer composition in the second yarn 710 without eliminating Fig. 7AAt least a portion of the interconnected horizontal rows 702, 704, and 706. As used herein, "deformation" in the context of the thermoforming process of a knitted textile refers to changing the structure of the yarn such that the yarn does not melt and flow in a manner that substantially eliminates the knitted structure of the textile (e.g., eliminating one or more interconnected loops or interloping horizontal rows).

[0241] Fig.9A Depicting a portion 700 of the upper knitted layer of textile 300 along cut line 9A-B prior to the thermoforming process, and Figure 3 A cross-section of the portion 700 of the upper knitted layer of textile 300, and Fig. 9B Depicting the same cross-section after the thermoforming process. As can be seen in Fig. 9B the second yarn 710 in the third horizontal row 706 has a changed yarn structure 710a after being exposed to the thermoforming process, while the structure of the first yarn 708 has not been changed. In this regard, the second yarn 710 in the third horizontal row 706 remains interloped with the first horizontal row 702 and the second horizontal row 704, and maintains Figure 3 the overall knitted structure of the portion 700 of the upper knitted layer of textile 300.

[0242] In some aspects, this changed yarn structure 710a can result in mechanical coupling or physical bonding of the second yarn 710 to another yarn (e.g., the first yarn 706) (or another portion of the second yarn 710). In some aspects, during the thermoforming process, the yarn 710 may have been exposed to a temperature that is higher than the glass transition temperature T of the low processing temperature polymer composition g but not higher than the melting temperature of the low processing temperature polymer composition. In these aspects, when the second yarn 710 is exposed to this elevated temperature, the second yarn can soften and become flexible but not melt, thereby allowing the yarn to be slightly molded around at least a portion of an adjacent yarn (e.g., the first yarn 706), and after cooling, this changed yarn structure can be mechanically locked in place to physically bond to the adjacent yarn.

[0243] FIG. 10A to FIG. 10C Depicting a portion 1000 of the upper knitted layer of the textile zone 302 of textile 300 before and after thermoforming Figure 3 of textile 300. Fig. 10A Depicting three horizontal rows 1010, 1012, 1014 of yarns containing a low processing temperature polymer composition. Fig. 10A Further depicting the anchor yarn 1016 extending as a float stitch 1016a and a tuck stitch 1016b.

[0244] Fig. 10B Depicting the same portion 1000 of the upper knitted layer of the textile zone 302 of textile 300 after being exposed to the thermoforming process. In Figure 3 the textile 300. Fig. 10B As can be seen, the interloping courses 1010, 1012, and 1014 of the yarns have been transformed into molten yarn components 1018. Additionally, in Fig. 10B and Fig. 10C (which is a cross-section along the cut line 10C of Fig. 10B ), it can be seen that the anchor yarn 1016 has maintained its yarn structure and is now encapsulated within the molten yarn component 1018. It should be understood that although the anchor yarn 1016 is depicted as being encapsulated within the molten yarn component 1018 in Fig. 10B , it is also contemplated that the anchor yarn 1016 can be at least partially embedded within the molten yarn component 1018 such that at least a portion of the anchor yarn 1016 is not completely covered by the molten yarn component 1018.

[0245] As discussed above, in some aspects, the textiles described herein can include knitted textiles, e.g., portions of the knitted textiles depicted in FIG. 4A to FIG. 10C . A knitted upper for a footwear article is an exemplary knitted textile. In these aspects, at least a portion of the knitted upper of the footwear article and, in some aspects, substantially the entirety of the upper can be formed of a knitted textile. The knitted textile can alternatively or additionally form another element of the footwear article, such as a midsole or a ground-facing outsole. The knitted textile can have a first side that forms the inner surface of the upper (e.g., facing the aperture of the footwear article) and a second side that forms the outer surface of the upper. The upper including the knitted textile can substantially surround the aperture such that when the footwear article is in use, it substantially encloses a person's foot. The first side and the second side of the knitted textile can exhibit different properties (e.g., the first side can provide abrasion resistance and comfort, while the second side can be relatively rigid and provide water resistance).

[0246] In various aspects, the knitted textile can be formed as an integral single-piece element during a knitting process (e.g., a weft knitting process (e.g., using 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 substantially form the knitted structure of the knitted textile without significant post-knitting processes or steps. Alternatively, two or more portions of the knitted textile can be formed separately and subsequently attached. In some embodiments, the knitted textile can be shaped after the knitting process to form and retain 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 label) at a seam and / or attaching one portion of the knitted component to another portion of the knitted component by sewing, by using an adhesive, or by another suitable attachment process.

[0247] Forming an upper with a knitted textile can provide advantageous properties to the upper, including (but not limited to) a specific degree of elasticity (e.g., expressed in terms of Young's modulus), breathability, flexibility, strength, moisture absorption, weight, and abrasion resistance. These properties can be achieved by selecting a specific single-layer or multi-layer knitted structure (e.g., ribbed knitted structure, single-sided knitted structure, or double-sided knitted structure); varying the size and tension of the knitted structure; using one or more yarns formed from a specific material (e.g., polyester material, monofilament material, or elastic material such as spandex); selecting a yarn of a specific size (e.g., fineness); or a combination thereof.

[0248] The knitted textile can also provide desirable aesthetic properties by incorporating yarns with different colors or other visual properties arranged in a specific pattern. The yarns and / or knitted structure of the knitted textile can vary at different locations such that the knitted component has two or more parts with different properties (e.g., the part forming the throat region of the upper can be relatively elastic while another part can be relatively inelastic). In some aspects, the 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).

[0249] In some aspects, the knitted textile can include one or more yarns or strands that are at least partially embedded or otherwise inserted into the knitted structure of the knitted textile during or after the knitting process, herein referred to as "tensile strands". The tensile strands can be substantially inelastic so as to have a substantially fixed length. The tensile strands can extend through multiple rows of the knitted textile or through channels within the knitted textile and can limit the stretching of the knitted textile in at least one direction. For example, the tensile strands can extend generally from the bite line of the upper to the throat region of the upper to limit the stretching of the upper in the lateral direction. The tensile strands can form one or more lace holes for receiving laces and / or can extend around at least a portion of the lace holes formed in the knitted structure of the knitted textile.

[0250] In alternative aspects, the textiles described herein can include non-woven textiles. The non-woven textiles described herein can be produced by any conventional method, such as any conventional mechanical, chemical, or thermal method for binding fibers together, including needle entangling or water entangling.

[0251] FIG. 11A to FIG. 11C Depicting aspects Figure 3 wherein the textile 300 is a non-woven textile and undergoes a thermoforming process. Fig.11A is Figure 3 a schematic depiction of a portion 1100 of the textile region 304a of the textile 300. Fig.11A As can be seen, the portion includes a first grouping 1110 of first fibers 1116 including a high processing temperature polymer composition, a second grouping 1112 of the first fibers 1116, and a third grouping 1114 of second fibers 1118 including a low processing temperature polymer composition. It should be understood that the portion 1100 of the textile 300 is schematic, and the placement and spacing of the first fibers 1116 and the second fibers 1118 can vary in the textile.

[0252] Although not depicted in FIG. 11A to FIG. 11C In aspects in which the textile 300 is a nonwoven textile, one or more interfaces between different portions of different fibers can also include one or more interlaced interfaces, e.g., the interlaced interface 306. In these aspects, the interlaced interface 306 can depict how the transition between regions or sub-regions having different concentrations of fibers including a low processing temperature polymer composition and / or different concentrations of fibers including a high processing temperature polymer composition does not occur linearly along Figure 3 the width w of the textile 300.

[0253] Returning now to FIG. 11A to FIG. 11C and Fig. 11C , specifically, in aspects in which the thermoforming process causes the low processing temperature polymer composition in the second fibers 1118 to melt and flow, the second fibers 1118 have been transformed into a non-fibrous material 1120, while the first fibers 1116 have not been transformed and thus remain in fibrous form. In these aspects, the non-fibrous material 1120 can join the first grouping 1110 of the first fibers 1116 to the second grouping 1112 of the first fibers 1116. Fig. 11C Shows a cross-section along the cut line 11C, which in some aspects shows 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.

[0254] Although not depicted in the figures, in some aspects, after exposure to the thermoforming process, the second fibers 1118 can not melt and flow, but instead can deform and change shape. The deformation of the fiber or yarn is depicted in Fig.9A and Fig. 9B . Similar to the deformation of the fiber or yarn discussed above with respect to Fig.9A and Fig. 9B , in some aspects, the second fiber can deform and be molded onto another first or second fiber (or the same fiber) and mechanically coupled or physically bonded to the fiber.

[0255] Method for manufacturing

[0256] Some conventional thermoforming processes involve selectively thermoforming only a portion of a product, for example, by masking portions of the product that are not desired to be exposed to the thermoforming process or by using a tool that contacts or covers only a portion of the product. However, such conventional methods result in time- and energy-intensive manufacturing methods because multiple steps are required to mask and expose portions of the product before and after the thermoforming process, or multiple sets of tools are required. Other conventional thermoforming processes involve thermoforming product components before assembling them into a product. This conventional process is also a time- and resource-intensive process because multiple steps and machines are required to individually form the product components before assembling the product. Additionally, a product formed from several individual components creates multiple seams where the individual components are joined, thus providing weaknesses in the product, a less natural feel for the wearer, and / or actual discomfort or harm to the wearer.

[0257] The manufacturing methods disclosed herein address one or more of the foregoing problems. The manufacturing methods disclosed herein utilize one or more of the formed components, membranes, textiles, yarns, and fibers disclosed herein, wherein the one or more formed components, membranes, textiles, yarns, and fibers include at least one low processing temperature polymer composition as disclosed herein. The manufacturing methods disclosed herein also utilize one or more of the formed components, membranes, textiles, yarns, and fibers disclosed herein, wherein the one or more formed components, membranes, textiles, yarns, and fibers include at least one high processing temperature polymer composition as disclosed herein. The disclosed manufacturing method includes a thermoforming step in which the low processing temperature polymer composition is softened or melted without melting or softening the high processing temperature polymer composition. Thermoforming is carried out in a temperature range below at least one of the following properties of the high processing temperature polymer composition: (1) creep relaxation temperature (Tcr); (2) Vicat softening temperature (Tvs); (3) heat distortion temperature (Thd); or (4) melting temperature (Tm). Thermoforming can be carried out in a temperature range below the creep relaxation temperature (Tcr) of the high processing temperature polymer composition. Thermoforming can be carried out in a temperature range below the Vicat softening temperature (Tvs) of the high processing temperature polymer composition. Thermoforming can be carried out in a temperature range below the heat distortion temperature (Thd) of the high processing temperature polymer composition. Thermoforming can be carried out in a temperature range below the melting temperature (Tm) of the high processing temperature polymer composition.

[0258] For example, in some aspects, as further discussed 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, the article can include a textile that includes a low processing temperature polymer composition and a high processing temperature polymer composition, such as a textile including at least multiple fibers or yarns, and including the low processing temperature polymer composition in at least a portion of the textile. In another aspect, the article can include a first formed component, film, textile, yarn, or multiple fibers that includes a low processing temperature polymer composition; and a second formed component, film, textile, yarn, or multiple fibers that includes a high processing temperature polymer composition, such as a knitted upper of a footwear article that includes the high processing temperature polymer composition; and a film that includes the low processing temperature polymer composition. In a further aspect, the article can include the polymerization of components, at least a portion of which includes a low processing temperature polymer composition and a high processing temperature polymer composition, on which the disclosed thermoforming process has been applied.

[0259] Since in several aspects such structural features are built into the article depending on their location in the article of the low processing temperature polymer composition and the high processing temperature polymer composition, after thermoforming, these structural features immediately become integrated with each other, thus allowing 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 has been noted, the manufacturing methods (and the advantages associated with these processes) are not limited to the use of textiles disclosed herein. For example, the process of forming structural features in the disclosed article can utilize a film including a low processing temperature polymer composition, and a textile including a high processing temperature polymer composition, and this process is also contemplated as a process for programming structural features into the disclosed article. Alternatively, the process for effectively programming structural features into the disclosed article can utilize a formed component including a low processing temperature polymer composition, and a textile including a high processing temperature polymer composition.

[0260] Additionally, this selective incorporation of the low-processing-temperature polymer composition and the high-processing-temperature polymer composition into the article provides a streamlined manufacturing method. For example, in some aspects, an entire article can be formed by arranging components and exposing the arranged components to a thermoforming process, wherein components comprising the low-processing-temperature polymer composition melt, flow, and re-solidify into more rigid structural features, while 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 that the manufacturer does not want to melt, flow, and re-solidify, resulting in a manufacturing method that is more efficient in terms of time and energy. Additionally, in some cases, using the articles described herein in the manufacturing methods described herein also allows for the provision of several different structures or other advantageous features in the article without having to assemble individual components into the final article, as 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.

[0261] In various aspects, the thermoforming process occurs at a temperature at which the yarn or fiber has been dyed thereunder (e.g., including the temperature at which the yarn or fiber comprising the high-processing-temperature polymer composition has been dyed thereunder), such that during the thermoforming process, such dyes do not filter out of the yarn or fiber and into the surrounding low-processing-temperature polymer composition. Thus, in order 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 the second yarn or fiber (e.g., the second yarn or fiber comprising the high-processing-temperature polymer composition).

[0262] Additionally, the compositions having this range of melting temperatures (i.e., melting temperatures lower than the temperature at which the second yarn or fiber comprising the high-processing-temperature polymer composition has been dyed) creates another problem because so many of the low-processing-temperature polymer compositions evaluated do not produce yarns that are suitable for use in commercial knitting equipment, as the yarns significantly shrink when exposed to the temperatures at which commercial knitting equipment typically operates.

[0263] In certain instances, the low-processing-temperature polymer compositions described herein have melting characteristics and an acceptable level of shrinkage when present in the yarn and used in commercial knitting equipment. For example, in some aspects, the low-processing-temperature polymer composition can exhibit a melting temperature Tm of 135 °C or less.

[0264] In some aspects, the articles and textiles described herein can be thermoformed within a temperature range that causes the low processing temperature polymer composition to melt or deform (and subsequently cure), while the high processing temperature polymer composition does not melt and / or deform, thus maintaining the structure of elements (such as yarns or fibers) comprising the high processing temperature polymer composition. In such aspects, this thermoforming process can produce a more rigid structural component (such as a sole portion of a shoe) that is integrally attached to a less rigid portion of the article or textile, such as an upper portion of a shoe, which has yarns or fibers comprising the high processing temperature polymer composition.

[0265] Accordingly, in one aspect, a method for manufacturing an article is provided. The article can be a component of a footwear article, a component of a clothing article, or a component of a sports equipment article. For example, a component of a sports equipment article can be a hat, a component of a bag, a component of a ball, and a component of protective equipment. The method includes receiving an article that includes a first forming component, a first film, a first textile, a first yarn, or a first fiber; and a second forming component, a second film, a second textile, a second yarn, or a second fiber. The first forming component, the first film, the first textile, the first yarn, or the first fiber includes a low processing temperature polymer composition that includes one or more first thermoplastics, wherein the second forming component. The second film, the second textile, the second yarn, or the second fiber includes a high processing temperature polymer composition that includes one or more second thermoplastics, and wherein the high processing temperature polymer composition exhibits at least one of the following: 1) a creep relaxation temperature Tcr; 2) a heat distortion temperature Thd; or 3) a Vicat softening temperature Tvs, which is greater than the melting temperature Tm of the low processing temperature polymer composition. The method further includes placing at least a portion of the article on a molding surface. Additionally, the method includes: when at least a portion of the article is on the molding surface, increasing the temperature of the entire article to a temperature that is above the melting temperature Tm of the low processing temperature polymer composition and below at least one of the following: 1) the creep relaxation temperature Tcr; 2) the heat distortion temperature Thd; or 3) the Vicat softening temperature Tvs of the high processing temperature polymer composition. After increasing the temperature of the entire article, when at least a portion of the article is still on the molding surface, decreasing the temperature of the entire article to a temperature that is below the melting temperature Tm of the low processing temperature polymer composition, thereby forming a thermoformed article.

[0266] In another aspect, a method for making an upper for a footwear article is provided. The method includes knitting a first row that includes interlacing a first yarn and a second yarn. The first yarn includes a low processing temperature polymer composition that includes one or more first thermoplastic polymers. The second yarn includes a high processing temperature polymer composition that includes one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat distortion temperature (Thd); or (4) a melting temperature (Tm) that is greater than the melting temperature (Tm) of the low processing temperature polymer composition. 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 alternative aspects, 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.

[0267] In a further aspect, a method for manufacturing an upper for a shoe is provided. The method includes receiving an upper that includes a first yarn and a second yarn. The first yarn includes a low processing temperature polymer composition that includes one or more first thermoplastic polymers. The second yarn includes a high processing temperature polymer composition that includes one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat distortion temperature (Thd); or (4) a melting temperature (Tm) that is greater than the melting temperature (Tm) of the low processing temperature polymer composition. In a first portion of the upper, at least one of the first yarn and the second yarn forms a plurality of interconnected loops. The method further includes placing the upper on a shoe last. Additionally, the method includes heating the entire upper to a temperature that is above the melting temperature (Tm) of the low processing temperature polymer composition and below at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat distortion temperature (Thd); or (4) the melting temperature (Tm) of the high processing temperature polymer composition while the entire upper is on the shoe last. After heating the entire upper, while the entire upper is on the shoe last, cooling the entire upper to a temperature below the melting temperature Tm of the first yarn composition to form a thermoformed upper.

[0268] In yet another aspect, a method for manufacturing a shoe upper is provided. The method includes receiving a shoe upper that includes: one or more first fibers, yarns, membranes, or shaped components that include a low processing temperature polymer composition; and one or more second fibers, yarns, membranes, or shaped components that include a high processing temperature polymer composition. Each of the one or more first fibers, yarns, membranes, or shaped components includes a low processing temperature polymer composition that includes one or more first thermoplastic polymers. Each of the one or more second fibers, yarns, membranes, or shaped components includes a high processing temperature polymer composition that includes one or more second thermoplastic polymers. The high processing temperature polymer composition of the one or more second fibers exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat distortion temperature (Thd); or (4) a melting temperature (Tm) that is greater than the melting temperature (Tm) of the low processing temperature polymer composition of the one or more first fibers. The shoe upper includes a sole region facing the ground, and at least a portion of the one or more first fibers is present on the sole region facing the ground. The method further includes placing the shoe upper on a shoe last such that at least a portion of the sole region facing the ground covers at least a portion of the bottom of the shoe last. The method also includes heating the entire shoe upper to a temperature that is higher than the melting temperature Tm of the low processing temperature polymer composition of the one or more first fibers and lower than at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat distortion temperature (Thd); or (4) the melting temperature (Tm) of the high processing temperature polymer composition of the one or more second fibers while the entire shoe upper is on the shoe last. After heating the entire shoe upper, while the entire shoe upper is on the shoe last, cooling the entire shoe upper to a temperature below the melting temperature (Tm) of the low processing temperature polymer composition of the one or more first fibers, thereby forming a thermoformed shoe upper.

[0269] In yet another aspect, a method for making a knitted upper for a footwear or sock product is provided. The method includes knitting a first row that includes loops of a first yarn and a second yarn. The first yarn includes a low processing temperature polymer composition that includes one or more first thermoplastic polymers. The second yarn includes a high processing temperature polymer composition that includes one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat deflection temperature (Thd); or (4) a melting temperature (Tm) that is greater than the melting temperature (Tm) of the low processing temperature polymer composition. The method further includes knitting a second row that includes loops of the first yarn and the second yarn. At least a portion of the first row and at least a portion of the second row form a plurality of interconnected loops.

[0270] The method steps, methods, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless explicitly identified as an order of performance. Additional or alternative steps may be used.

[0271] Exemplary preheating and thermoforming processes

[0272] As discussed above, in certain aspects, the articles and textiles described above, such as Figure 3 textile 300, may form at least a portion of a wearable article (such as a footwear or sock product). In such aspects, the textile may form the upper of the footwear or sock product, where the upper includes a sole portion facing the ground.

[0273] In certain aspects, the article or textile may be combined with additional materials that form the upper of the footwear or sock product. For example, in one or more aspects, the textile may be combined or laminated with one or more of an ankle collar lining, ankle collar foam, upper lining, or upper foam layer. In certain aspects, one or more of these additional materials may be secured to the textile, such as by knitting, knotting, or bonding, prior to thermoforming the textile.

[0274] In certain aspects, to provide additional comfort and / or support to a wearer of a footwear or sock product formed at least in part from the textiles described herein, an internal support device or insole may be provided. Fig.12 and 13 depicts a footwear or sock product 1200 that includes an insole 1210. Footwear or sock product 1200 includes a textile 1212 that forms an upper 1214 having a sole portion 1216 facing the ground. In certain aspects, as can be best seen in Fig.13 which Fig.13Depicts a cross-section of a footwear article 1200, where a sole plate 1210 is located within an inner portion 1218 of the footwear article 1200 and contacts an inner surface 1220 of a textile 1212. In some aspects, the sole plate 1210 may comprise a polymeric material, such as a high processing temperature polymeric material, such as a polyether block amide, which has a melting or deformation temperature above the temperature range within which a thermoforming process is carried out therein, such that the polymeric material is able to not melt or deform during the thermoforming processes described herein.

[0275] In various aspects, for heel support of a wearer, a heel support brace 1222 may be located on an inner portion 1218 of the upper 1214, or on an outer portion of the upper 1214, or may form part of the upper 1214. In several aspects, similar to the sole plate 1210, the heel support brace 1222 may comprise a polymeric material, such as a high processing temperature polymeric material, such as a polyether block amide that is able to not melt or deform when exposed to a thermoforming process. In several aspects, similar to the sole plate 1210, the heel support brace 1222 may comprise a portion formed from a low processing temperature polymer composition and a portion formed from a high processing temperature polymer composition.

[0276] In some aspects, an insole 1224 may be located above the sole plate 1210 within the interior 1218 of the footwear article 1200. In such aspects, the insole 1224 may comprise conventional insole materials, such as one or more foam or memory foam layers and a textile layer. It should be understood that while the sole plate 1210, the heel support brace 1222, and the insole 1224 are depicted as additional materials for forming the upper of the footwear article, other materials, such as plates, overlays, and / or side structures, may also be added.

[0277] In various aspects, prior to thermoforming, the heel support brace 1222 and the sole plate 1210 may be located within the interior 1218 of the footwear article 1200. In some aspects, after the thermoforming process is completed, an insole may be applied.

[0278] In some aspects, such as Fig.14 those depicted in, ground engaging cleats 1410 may be applied to the footwear article 1400. In several aspects, the footwear article 1400 may comprise the same features as the footwear article 1200 referenced above Fig.12 and 13 described. As in Fig.14As can be seen, ground-engaging cleats 1410 can be applied to the ground-facing outsole region 1412 of the footwear article 1400 to provide increased stability and traction. In some aspects, the ground-engaging cleats 1410 can be applied to the ground-facing outsole region 1412 after the thermoforming process is completed. In other aspects, as part of the thermoforming process, the ground-engaging cleats 1410 can be applied to the ground-facing outsole region 1412.

[0279] In various aspects, prior to thermoforming the footwear article, any of the textiles and additional materials discussed above can be braided, woven, knitted, or preformed into a generally boot-like shape of an upper having a ground-facing outsole portion, such as Fig.15 as depicted in the upper 1500 of. In such aspects, the upper 1500 can also include a sole plate or a heel support located on the interior 1510 of the upper 1500, such as the sole plate 1210 and the heel support 1222 discussed above with respect to Fig.12 discussed.

[0280] To prepare the upper 1500 for the thermoforming process, the upper 1500 is placed on a shoe last 1520 such that the shoe last 1520 enters the interior 1510 of the upper 1500. In some aspects, the shoe last 1520 can be formed of a polymeric material (such as a high processing temperature polymer composition). In certain aspects, the shoe last 1520 can be formed of a polymeric material (such as a silicone polymer) having a melting temperature Tm or a degradation temperature greater than 250 °C or greater than 300 °C. The shoe last 1520 can be made of other types of materials as long as such materials do not deform or melt during the thermoforming process or otherwise affect the thermoforming of the upper. Fig.16 Depicts the upper 1500 located on the shoe last 1520. As in Fig.16 As can be seen, the upper 1500 wraps around the shoe last 1520 to cover the bottom portion 1522 of the shoe last 1520, the forefoot portion 1524 of the shoe last 1520, and the heel portion 1526 of the shoe last 1520. In such aspects, the ground-facing outsole portion 1512 of the upper covers the bottom portion 1524 of the shoe last 1520. Although Fig.15 and 16The upper 1500 is described as having a sock-like structure that wraps around and covers the bottom portion 1522, the forefoot portion 1524, and the heel portion 1526 of the shoe last 1520, but in other respects, the upper 1500 may only partially wrap around the shoe last 1520. Similarly, in other respects, the upper 1500 may cover only the bottom portion 1522 of the shoe last 1520, only the forefoot portion 1524 of the shoe last 1520, only the heel portion 1526 of the shoe last 1520, or a combination thereof. In still other respects, the upper 1500 may cover only a portion of the bottom portion 1522 of the shoe last 1520, a portion of the forefoot portion 1524 of the shoe last 1520, a portion of the heel portion 1526 of the shoe last 1520, or a combination thereof.

[0281] Fig.17 Shows a cross-section of the upper 1500 located on the shoe last 1520 along the cut line 17. The cross-section 1700 reveals the shoe last 1500 contacting the inner surface 1540 of the upper 1500. The cross-section 1700 also reveals the presence of two types of materials in the upper 1500. For example, the cross-section 1700 reveals three types of textile zones of the textile forming the upper 1500. As visible in Fig.17 the textile zone 1710 associated with the ground-facing outsole portion 1512 of the upper covers the bottom portion 1524 of the shoe last 1520. In such respects, when the upper is a knitted textile forming a knitted upper, at least a portion of the yarn comprising the low processing temperature polymer composition covers at least a portion of the bottom portion 1524 of the shoe last 1520.

[0282] In addition, the textile zone 1714 covers the forefoot portion 1524 of the shoe last 1520, while the textile zone 1712 covers the midfoot region 1528 of the shoe last 1520. In certain aspects, the textile zones 1710, 1712, and 1714 may respectively have any or all of the properties discussed above with reference to Figure 3 the textile zones 302, 304a, 306a.

[0283] In certain aspects, a first layer may be placed on a molding surface (such as a shoe last) prior to the article (such as a footwear article or a component of a footwear article). For example, a first layer (such as a lining) may optionally be placed over the molding surface (such as a shoe last). For example, referring to Fig.17To further demonstrate one aspect of the first layer, the first layer may optionally be placed on a molding surface (such as a shoe last) before the article and the lining can be placed over the shoe last 1520 such that the forefoot region of the lining covers the forefoot region 1524. Thus, the upper including the textile regions 1710, 1712, and 1714 is then placed such that it covers at least a portion of the lining. Thus, at least a portion of the yarn including the low processing temperature polymer composition is covering at least a portion of the lining. It should be understood that in some aspects, the textile regions 1710, 1712, and 1714 may each or all have any of the properties discussed above with reference to Figure 3 the textile regions 302, 304a, 306a.

[0284] In a further aspect, an outer layer may optionally be located on at least a portion of the article, which is on the molding surface and is covering at least a portion of the article. The outer layer (which may be a film) may optionally be placed over at least a portion of the article (such as the upper) that is on the molding surface (such as a shoe last). By way of example, referring to Fig.17 To further demonstrate one aspect, the outer layer may optionally be placed over at least a portion of the upper that is already on the shoe last such that the textile region 1710 associated with the ground-facing sole portion 1512 of the upper covers the bottom portion 1524 of the shoe last 1520. Thus, at least a portion of the upper, including the textile regions 1710, 1712, and 1714, may be covered by at least a portion of the outer layer. Thus, at least a portion of the yarn including the low processing temperature polymer composition is in contact with at least a portion of the outer layer. It should be understood that in some aspects, the textile regions 1710, 1712, and 1714 may each or all have any of the properties discussed above with reference to Figure 3 the textile regions 302, 304a, 306a. The outer layer may be utilized in combination with the first layer as described in the preceding paragraphs.

[0285] In some aspects, a shaping component, such as a heel counter or a sockliner, may optionally be placed on the outer surface 1530 of the upper 1500. Alternatively, a shaping component, such as a heel counter or a sockliner, may optionally be placed on the inner surface 1540 of the upper 1500. It should be understood that the placement of the shaping component (whether on the outer surface 1530 or the inner surface 1540 of the upper 1500) is completed before the application of the protective sheath, vacuum, or protective sheath and vacuum bag, as described below.

[0286] In some 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 melted low processing temperature polymer composition. In such aspects, a protective sheath may be applied over the upper that is on the shoe last. By way of example, as Fig.18 and 19As can be seen, the protective sheath 1800 is located above the upper 1500 positioned on the shoe last 1520. In some aspects, the protective sheath 1800 can be formed of a polymeric material such as a high processing temperature polymer composition. In certain aspects, the protective sheath 1800 can be formed of an elastomeric polymeric material (such as a silicone polymer) having a melting temperature Tm or degradation temperature greater than 250 °C or greater than 300 °C. The protective sheath 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 affect the thermoforming of the upper. In several aspects, the protective sheath 1800 can apply a compressive force to the outer surface 1530 of the upper 1500, which can help to restrict the flow of the molten low processing temperature polymer composition. Additionally, in such aspects, a vacuum can be drawn on the combination of the shoe last 1520, the upper 1500 positioned on the shoe last, and the protective sheath positioned on the upper 1500. For example, a vacuum bag can be compressed on the outside of the protective sheath 1800 to apply a compressive force to the protective sheath 1800 to ensure flush contact of the sheath 1800 with the outer surface 1530 of the upper 1500. Vacuum bags are discussed in detail below.

[0287] In some aspects, the protective sheath 1800 can be utilized to provide a pattern or marking on the outer surface of the upper 1500. For example, the inner surface 1810 of the protective sheath 1800 can include a marking or pattern that, during the thermoforming process, due to the melting and cooling of the low processing temperature polymer composition in the upper 1500 and the compressive force applied to the upper 1500 by the protective sheath 1800 (and optionally, the vacuum bag), can be embossed or imprinted on the outer surface 1530 of the upper 1500. In such aspects, since the protective sheath 1800 can cover the entire upper 1500, it is possible for the protective sheath 1800 to emboss or imprint a pattern on any portion of the outer surface 1530 of the upper 1500 that contains the low processing temperature polymer composition.

[0288] In some aspects, it may be desirable to use both the protective sheath and the vacuum bag together, optionally. In such aspects, the protective sheath can be applied above the upper positioned on the shoe last. For example, as Fig.18 and 19 As can be seen, the protective sheath 1800 is located above the upper 1500 positioned on the shoe last 1520. As disclosed above, the protective sheath 1800 can be formed of an elastomeric polymeric material (such as a silicone polymer) having a melting temperature Tm or degradation temperature greater than 250 °C or greater than 300 °C. Thus, the protective sheath 1800 is located 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 a compressive force to the protective sheath or the vacuum bag as discussed in the present invention can be used to apply a compressive force to both the protective sheath and the vacuum bag when used together.

[0289] In some aspects, such as compared to the same upper thermoformed under similar conditions without using the sheath 1800, using the sheath 1800 alone and when used under vacuum can effectively reduce the number of air bubbles trapped in the low processing temperature polymeric material during the thermoforming process.

[0290] In Figures 15 to 19 In the aspects depicted in, the shoe last 1520 is formed of a rigid material. Additionally, in these aspects, when the shoe last 1520 is made of a rigid material, the compressive force applied via the sheath 1800 (and / or vacuum bag) creates a force or pressure differential between the inner surface 1540 and the outer surface 1530 of the upper 1500 (since the rigid shoe last 1520 at least partially resists this compressive force, which causes the 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 low processing temperature polymeric composition during melting, and / or provide relief or patterning of the outer surface 1530 of the upper 1500.

[0291] In some aspects, the upper 1500 can be positioned on the shoe last 1520 (when formed of a rigid material), and the outer surface 1530 of the upper 1500 (with or without the sheath 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 shoe last 1520, and a negative pressure can be applied between the inner surface 1540 of the upper 1500 and the shoe last 1520 to compress the upper 1500 onto the rigid shoe last 1520.

[0292] In several aspects, the pressure differential across the inner surface 1540 and the outer surface 1530 of the upper 1500 can also help form the three-dimensional structure of the footwear product during the thermoforming process. That is, in such aspects, as the low processing temperature polymeric composition melts, the molten material and the upper 1500 are forced against the rigid shoe last 1520, which, upon cooling, results in the upper 1500 taking the shape of the shoe last 1520.

[0293] In alternative aspects, this force or pressure differential between the inner surface 1540 and the outer surface 1530 of the upper 1500 can be achieved in another way. For example, in some aspects, the shoe last 1520 can be an expandable shoe last 1520 that can apply an outward force to the inner surface 1540 of the upper 1500. In such aspects, to achieve the pressure differential, the outer surface 1530 of the upper 1500 can contact a certain type of material that will at least partially resist the outward force applied by the expansion of the shoe last 1520.

[0294] As discussed above, a vacuum bag can be applied to the upper 1500 positioned on the shoe last 1520, with or without the sheath 1800. Fig. 20ADepict the upper 1500 located on the shoe last 1520 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.

[0295] In Fig. 20A the aspect depicted, the vacuum bag 2010 can include a valve 2012 for reducing the pressure inside the vacuum bag 2010. For example, the pressure between the outer surface 1530 of the upper 1500 (or the outer surface of the protective cover 1800 on the upper 1500) and the interior 2014 of the vacuum bag 2010 can be reduced, which will compress the vacuum bag onto the outer surface 1530 of the upper 1500 (or the outer surface of the protective cover 1800 on the upper 1500). Fig. 20B Depict the vacuum bag 2010 compressed onto the outer surface 1530 of the upper 1500 (or the outer 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 pressure differential discussed above with reference to Figures 15 to 19 that discussed.

[0296] Fig.21 Depict the thermoforming system 2100. Fig.21 The thermoforming system 2100 of Fig. 20A and 20B can include the upper 1500 located on the shoe last 1520, where the vacuum bag 2010 is compressed onto the upper 1500, as discussed above with respect to

[0297] As discussed above, the thermoforming process includes increasing the temperature of a textile material (e.g., the upper 1500) to a temperature that can cause at least a portion of the low processing temperature polymer composition present in the upper 1500 to melt and flow or deform. Additionally, the thermoforming process includes subsequently reducing the temperature of the upper 1500 to solidify the melted low processing temperature polymer composition into a desired shape, such as a footwear product.

[0298] The thermoforming system 2100 includes a heating zone 2110 that can be configured to heat the entire upper 1500. In some aspects, the heating zone 2110 heats the entire upper 1500 to a temperature above the melting temperature Tm of the low processing temperature polymer composition present in the upper 1500.

[0299] In various aspects, it will be understood that, although heating used in thermoforming has been specifically discussed with respect to applications having an upper 1500, this is only an exemplary aspect of the heating and thermoforming of the disclosed articles and methods. That is, the present invention contemplates heating with any of the disclosed heating methods used to provide a heating zone in a thermoforming system and process to thermoform any of the disclosed articles, the articles including a first forming component, a first film, a first textile, a first yarn, or a first fiber; and a second forming component, a second film, a second textile, a second yarn, or a second fiber, which is located on a molding surface, where the entirety is at least partially covered with a vacuum bag, a protective cover, or a combination of a protective cover and a vacuum, and then heated to a temperature above the Tm of a low processing temperature composition. The first forming component, the first film, the first textile, the first yarn, or the first fiber includes a low processing temperature composition.

[0300] In several aspects, heating the entire upper 1500 can provide a more efficient streamlined thermoforming process. For example, because forming components, films, textiles, fibers, and / or yarns including a low processing temperature polymer composition and forming components, films, textiles, fibers, and / or yarns including a 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 (e.g., by masking a portion of the upper or applying heat only to a portion of the upper) because the high processing temperature polymer composition can resist undergoing any deformation or melting under conditions where the low processing temperature polymer composition can be thermoformed. Optionally, however, additional heat treatment steps can be performed on the thermoformed articles of the present invention. For example, one or more surfaces of the thermoformed article can be subjected to an additional thermoforming process, such as to thermally attach a splint to the ground-facing surface of a footwear article prepared using the thermoforming process described herein.

[0301] As discussed above, it is desirable that the thermoforming process not deform or alter forming components, films, textiles, fibers, and / or yarns including a high processing temperature polymer composition. In such aspects, the heating zone 2110 can heat the entire upper 1500 to a temperature below at least one of the creep relaxation temperature Tcr, the heat distortion temperature Thd, or the Vicat softening temperature Tvs of the high processing temperature polymer composition or fibers and / or yarns including the high processing temperature polymer composition.

[0302] In one or more aspects, the heating zone 2110 can increase the temperature of the entire upper 1500 to a temperature from about 90°C to about 240°C. In several aspects, the heating zone 2110 can increase the temperature of the entire upper 1500 to a temperature from about 90°C to about 200°C. In one aspect, the heating zone 2110 can increase the temperature of the entire upper 1500 to a temperature from about 110°C to about 180°C.

[0303] In some aspects, the temperature of the entire upper 1500 can increase in about 10 seconds to about 5 minutes. In several aspects, the temperature of the entire upper 1500 can increase in about 30 seconds to about 5 minutes. In one aspect, the temperature of the entire upper 1500 can be increased in about 30 seconds to about 3 minutes.

[0304] In one or more aspects, the heating zone 2110 can expose the entire upper 1500 to a temperature ranging from about 90°C to about 240°C. In several aspects, the heating zone 2110 exposes the entire upper 1500 to a temperature ranging from about 90°C to about 200°C. In one aspect, the heating zone 2110 can expose the entire upper 1500 to a temperature ranging from about 110°C to about 180°C.

[0305] In some aspects, the entire upper 1500 can be exposed to one or more of the temperatures or ranges of the heating zone 2110 described above in about 10 seconds to about 5 minutes. In several aspects, the entire upper 1500 can be exposed to one or more of the temperatures or ranges of the heating zone 2110 described above from about 30 seconds to about 5 minutes. In one aspect, the entire upper 1500 can be exposed to one or more of the temperatures or ranges of the heating zone 2110 described above from about 30 seconds to about 3 minutes.

[0306] In some aspects, the heating zone 2110 can expose the entire upper 1500 to a pressure ranging from about 50 kPa to about 300 kPa. In several aspects, the heating zone 2110 can expose the entire upper 1500 to a pressure ranging from about 50 kPa to about 250 kPa. In one aspect, the heating zone 2110 can expose the entire upper 1500 to a pressure ranging from about 100 kPa to about 300 kPa.

[0307] In some aspects, before undergoing a cooling step, under the above conditions, the entire upper 1500 can be continuously exposed to the heating zone 2110 multiple times. For example, in some aspects, before undergoing a cooling step, under the above conditions, the entire upper 1500 can be continuously exposed to the heating zone 2110 2 to 10 times. In alternative instances, in some aspects, before undergoing a cooling step, under the above conditions, the entire upper 1500 can be continuously exposed to the heating zone 2110 twice.

[0308] In various aspects, after increasing the temperature of the entire upper 1500, the temperature of the entire upper 1500 is reduced to a temperature below the melting temperature Tm of the low - processing temperature polymer composition for a duration sufficient to cure the low - processing temperature polymer composition. For example, a heat source (including but not limited to conventional heaters such as convective heating, conventional ovens, air - circulation ovens or forced - air ovens, steam, directed microwave heating, ultraviolet radiation, infrared heating, and combinations of any of the foregoing) can be used for heating. The heat source can further include multiple heat sources, such as multiple similar sources, e.g., multiple heating coils or infrared emitters. Alternatively, the multiple heat sources can include multiple one or more different heat sources, such as multiple heating coils and multiple infrared emitters that can be used simultaneously or sequentially, or in a mode where only one of the multiple heat sources is used at any given time.

[0309] In some aspects, heating can be performed such that heat is transferred from another material or object to the entire upper 1500. For example, a molding surface (such as a shoe last) can be directly heated itself, e.g., via a configuration as a resistive heating element. In an alternative aspect, the molding surface (such as a shoe last) can be pre - heated to a desired temperature immediately before positioning the upper, textile, or article thereon. In the foregoing aspects, the molding surface itself can act as a heating zone for transferring heat to the entire upper.

[0310] In some aspects, radio - frequency heating (e.g., microwave radiation) can be used to heat the heating zone such that the radio - frequency heats the composition (e.g., the low - processing temperature composition) via interaction with a radio - frequency field of the composition that is part of the upper, textile, or article.

[0311] Additionally, in certain aspects, the entire upper 1500 can be exposed to the heating zone 2110 by moving the entire upper 1500 into the heating zone 2110, or by moving the heating zone 2110 to where the upper 1500 is located and then removing it after the heating step. Conventional transportation systems can be used to automate or semi - automate the movement of the upper 1500 and / or the heating zone 2110.

[0312] In certain aspects, after heating the entire upper 1500, the entire upper 1500 is cooled to a temperature below the melting temperature Tm of the low - processing temperature polymer composition. In such aspects, the entire upper 1500 can be exposed to the reduced temperature in the cooling zone 2112 by moving into the cooling zone 2112 or by moving the cooling zone 2112 to the upper 1500. The cooling zone 2112 can expose the entire upper 1500 to a pressure of approximately 0 kPa.

[0313] In one or more aspects, when in the cooling zone 2112, the entire upper 1500 can be exposed to a temperature of from about -25°C to about 25°C. In several aspects, when in the cooling zone 2112, the entire upper 1500 can be exposed to a temperature of from about -10°C to about 25°C. In one aspect, when in the cooling zone 2112, the entire upper 1500 can be exposed to a temperature of from about -10°C to about 10°C.

[0314] In certain aspects, the entire upper 1500 can be exposed to one or more of the temperatures or ranges of the cooling zone 2112 discussed above within about 10 seconds to about 5 minutes. In several aspects, the entire upper 1500 can be exposed to one or more of the temperatures or ranges of the cooling zone 2112 discussed above within about 10 seconds to about 3 minutes. In one aspect, the entire upper 1500 can be exposed to one or more of the temperatures or ranges of the cooling zone 2112 discussed above within about 10 seconds to about 2.5 minutes.

[0315] In certain aspects, once the upper 1500 has been cooled, as described above, the vacuum bag 2010 and the protective cover 1800 can be removed. In such aspects, any additional components can now be applied to the upper 1500, such as Fig.14 the ground-engaging cleats 1410.

[0316] Fig. 22 Depicts an exemplary method 2200 for manufacturing an upper of a shoe. Method 2200 can include the step 2210 of receiving an upper that includes 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.

[0317] According to Fig. 22 and the exemplary method 2200 of the present invention, generally, the low processing temperature polymer composition can be in the form of fibers (e.g., fibers consisting essentially of the low processing temperature polymer composition). The low processing temperature polymer composition can be present in the received upper in the form of yarns (e.g., yarns including the low processing temperature polymer composition, yarns formed entirely of fibers including the low processing temperature polymer composition, yarns partially formed of fibers including the low processing temperature polymer composition). Additionally or alternatively, the low processing temperature polymer composition can be in a form that is not part of a yarn structure. For example, the fibers can include 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 be in the form of textiles (including knitted, woven, non-woven textiles), films, sheets, or molded articles (e.g., injection molded articles). The low processing temperature polymer composition can also be in the form of foam materials.

[0318] Although certain aspects of the present invention have been illustrated with details regarding footwear products or uppers, within the scope of the present invention, the illustrated aspects are generally understood to be applicable to other disclosed aspects. For example, any of the disclosed low processing temperature compositions can be utilized to form, fabricate, or manufacture shaped components, films, textiles, or other articles and used in the methods disclosed herein. Similarly, any of the disclosed high processing temperature compositions can be utilized to form, fabricate, or manufacture shaped components, films, textiles, or other articles and used in the methods disclosed herein. Thus, any such shaped component, film, textile, or other article comprising a low processing temperature composition can optionally be contacted with a shaped component, film, textile, or other article comprising a high processing temperature composition and located on a molding surface. In some aspects, the molding surface can be a mold, a mold shell, or a shoe last. A protective cover and / or a vacuum bag can be located on the molding surface, applying a compressive force to the molding surface and providing a heating zone to the molding surface, as described in the present invention.

[0319] In some aspects, a second material formed from a high processing temperature polymer composition can exhibit at least one of a creep relaxation temperature Tcr, a heat deflection temperature Thd, or a Vicat softening temperature Tvs that is greater than the melting temperature Tm of a low processing temperature polymer composition. A material formed from a low processing temperature polymer composition can include any one or all of the properties of the low processing temperature polymer composition described above. A second material formed from a high processing temperature polymer composition can include any one or all of the properties of the high processing temperature polymer composition described above. A second material formed from a high processing temperature polymer composition can exist in the form of fibers (e.g., fibers consisting essentially of a high processing temperature polymer composition). A high processing temperature polymer composition can be present in a received upper in the form of a yarn (e.g., a yarn comprising a high processing temperature polymer composition, a yarn formed entirely of fibers comprising a high processing temperature polymer composition, a yarn formed partially of fibers comprising a high processing temperature polymer composition). Additionally or alternatively, a high processing temperature polymer composition can exist in a form that is not part of a yarn structure. For example, the fibers can include a high processing temperature polymer composition or can consist essentially of a high processing temperature polymer composition. A high processing temperature polymer composition can also exist in the form of a textile (including knitted, woven, non-woven textiles), a film, a sheet, or a molded article (e.g., an injection molded article). A high processing temperature polymer composition can also exist in the form of a foam material. In some aspects, the upper can include any one or all of the properties of the upper 1500 referenced above Figures 15 to 21 In addition, any of the textiles described above can be used, such as Figure 3 the textile 300, to form the upper.

[0320] While low processing temperature polymer compositions and high processing temperature polymer compositions may exist as separate materials or components of the received upper (e.g., in separate fibers, yarns, textiles, films, etc.), they may also exist in the same component (e.g., a yarn comprising fibers formed from a low processing temperature polymer composition and separate fibers formed from a high processing temperature polymer composition; a textile comprising a yarn formed from a low processing temperature polymer composition and separate yarns formed from a high processing temperature polymer composition). In other words, in the received upper, the low processing temperature polymer composition and the high processing temperature polymer composition exist in materials or components that are separate and at least different from each other at the fiber level.

[0321] 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 , 7A or the plurality of interconnected loops depicted in 9.

[0322] In step 2220 of method 2200, the upper is placed on a shoe last, such as Figures 15 to 17 the shoe last depicted in. In various aspects, the shoe last may be formed of a rigid material or may be an expandable shoe last. Additionally, as described above, the upper may have a sole plate, a heel support, or other components inserted into the upper before being placed on the shoe last.

[0323] In step 2230 of method 2200, when on the shoe last, the temperature of the entire upper is increased (e.g., heated) to a temperature above the melting temperature Tm of the first yarn composition and below at least one of the creep relaxation temperature Tcr, the heat distortion temperature Thd, or the Vicat softening temperature Tvs of the second yarn composition. In various aspects, the thermal forming system 2100 described above with respect to Fig.21 may be used to heat the entire upper. Any one or all of the parameters of the thermal forming system described above with respect to Fig.21 may be used to heat the upper.

[0324] In step 2240 of method 2200, when the upper is still on the shoe last, after heating, the temperature of the entire upper is decreased to a temperature below the melting temperature Tm of the low processing temperature polymer composition. For example, when the entire upper is on the shoe last, the entire upper may be cooled to form the thermally formed upper. In various aspects, the thermal forming system 2100 described above with respect to Fig.21 may be used to cool the entire upper. Any one or all of the parameters of the thermal forming system described above with respect to Fig.21cool the upper using any one or all of the parameters described for the thermoforming system.

[0325] When a first material or component comprising a low processing temperature polymer composition has been deformed and its original structure has been modified or melted and solidified into a new physical structure, after thermoforming the received upper, as the thermoforming is carried out at a temperature that is at or above the melting temperature Tm of the low processing temperature polymer composition but less than the creep relaxation temperature Tcr or heat distortion temperature Thd or Vicat softening temperature Tvs of the high processing temperature polymer composition, a second material or component (fibers, yarns, textiles, sheets, molded articles, etc.) comprising the high processing temperature polymer composition retains its original physical structure (e.g., fibers, yarns, textiles, etc.).

[0326] Fig.23 Depict an exemplary method 2300 for manufacturing an upper of a shoe. Method 2300 may include a 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 thermoplastics, and the high processing temperature polymer composition may comprise one or more second thermoplastics. In some aspects, the first and second thermoplastics may comprise any one or all of the parameters discussed above with respect to thermoplastics. In certain aspects, the upper may comprise any one or all of the properties of the upper 1500 described above. Additionally, any one of the textiles described above may be used, such as Figures 15 to 21 any one or all of the properties of the upper described above. Additionally, any one of the textiles described above may be used, such as Figure 3 the textile 300, to form the upper.

[0327] In some aspects, the high processing temperature polymer composition may exhibit at least one of a creep relaxation temperature Tcr, a heat distortion temperature Thd, or a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymer composition. The low processing temperature polymer composition may comprise any one or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition may comprise any one or all of the properties of the high processing temperature polymer composition described above. Additionally, the first and second yarns may exhibit any one or all of the properties and parameters discussed above.

[0328] 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 coils, such as Figure 6 、 7A or the plurality of interconnected coils depicted in 9.

[0329] In step 2320 of method 2300, place the upper on a shoe last, such as Figures 15 to 17onto the shoe last depicted therein. In various aspects, the shoe last can be formed of a rigid material or can be an expandable shoe last. Additionally, as described above, the upper can have a sole plate, a heel support, or other components inserted into the upper before being placed on the shoe last.

[0330] In step 2330 of method 2300, while on the shoe last, the entire upper is heated to a temperature that is higher than the melting temperature Tm of the low - processing - temperature polymer composition and lower than at least one of the creep relaxation temperature Tcr, the heat distortion temperature Thd, or the Vicat softening temperature Tvs of the high - processing - temperature polymer composition. In various aspects, as described above with respect to Fig.21 it is described that the thermoforming system 2100 can be used to heat the entire upper. Any one or all of the parameters described above with respect to Fig.21 the thermoforming system can be used to heat the upper.

[0331] In step 2340 of method 2300, after heating the entire upper, while on the shoe last, the entire upper is cooled to form a thermoformed upper. In various aspects, the thermoforming system 2100 described above with respect to Fig.21 can be used to cool the entire upper. Any one or all of the parameters described above with respect to Fig.21 the thermoforming system can be used to cool the upper.

[0332] Fig.24 Depicts method 2400 for manufacturing an upper for a shoe. Method 2400 can include step 2410 of receiving an upper that includes one or more first fibers and one or more second fibers. The one or more first fibers can include a low - processing - temperature polymer composition that includes one or more first thermoplastic polymers. The low - processing - temperature polymer composition can have any one or all of the properties discussed above with respect to the low - processing - temperature polymer composition. The one or more second fibers include a high - processing - temperature polymer composition that includes one or more second thermoplastic polymers. The high - processing - temperature polymer composition can have any one or all of the properties discussed above with respect to the high - processing - temperature polymer composition. In several aspects, the first and second thermoplastic polymers can include any one or all of the parameters discussed above with respect to the thermoplastic polymers. Additionally, in several aspects, the first and second fibers can include any one or all of the properties discussed above with respect to the fibers.

[0333] In one aspect, the high - processing - temperature polymer composition exhibits at least one of the following: a creep relaxation temperature Tcr, a heat distortion temperature Thd, or a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low - processing - temperature polymer composition of the one or more first fibers.

[0334] In some aspects, the upper may include a sole region facing the ground, wherein at least a portion of the first fibers is present in the sole region facing the ground.

[0335] Method 2400 may include step 2420 of placing the upper on a shoe last such that at least a portion of the sole region facing the ground at least covers the bottom portion of the shoe last, as depicted, for example, Figures 15 to 17 in. In various aspects, the shoe last may be formed of a rigid material or may be an expandable shoe last. Additionally, as described above, the upper may have a sole plate and / or a heel support inserted into the upper before being placed on the shoe last.

[0336] Method 2400 may further include step 2430 of heating the entire upper to a temperature above the melting temperature Tm of the low-processing temperature polymer composition and below at least one of the creep relaxation temperature Tcr, the heat distortion temperature Thd, or the Vicat softening temperature Tvs of the high-processing temperature polymer composition when on the shoe last. In various aspects, as described above with respect to Fig.21 it may be possible to use the thermoforming system 2100 to heat the entire upper. Any one or all of the parameters described above with respect to the thermoforming system Fig.21 may be used to heat the upper.

[0337] In step 2440 of method 2400, after heating the entire upper, the entire upper is cooled when on the shoe last to form a thermoformed upper. In various aspects, it may be possible to use the thermoforming system 2100 described above with respect to Fig.21 to cool the entire upper. Any one or all of the parameters described above with respect to the thermoforming system Fig.21 may be used to cool the upper.

[0338] Fig.25 Method 2500 for manufacturing a knitted upper for a footwear product is depicted. Method 2500 includes step 2510 of knitting a first row, the first row including loops of a first yarn and a second yarn. In several aspects, the first yarn includes a low-processing temperature polymer composition and the second yarn includes a high-processing temperature polymer composition. The low-processing temperature polymer composition may include one or more first thermoplastic polymers, and the high-processing temperature polymer composition may include one or more second thermoplastic polymers. In several aspects, the first and second thermoplastic polymers may include any one or all of the parameters discussed above with respect to thermoplastic polymers. In some aspects, the upper may include any one or all of the properties of the upper 1500 described above with reference to Figures 15 to 21 above.

[0339] In some aspects, the high processing temperature polymer composition may exhibit at least one of a creep relaxation temperature Tcr, a heat deflection temperature Thd, or a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymer composition. The low processing temperature polymer composition may comprise any one or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition may comprise any one or all of the properties of the high processing temperature polymer composition described above. Additionally, the first and second yarns may exhibit any one or all of the properties and parameters discussed above.

[0340] Method 2500 may further comprise the step 2520 of knitting a second course of loops comprising a first yarn and a second yarn. In some aspects, any commercial knitting technique as described above may be used to knit the first and second courses. In some 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 loops depicted in.

[0341] Figure 26 Method 2600 for depicting the formation of a knitted article is depicted. Method 2600 may comprise the step 2610 of knitting a first course of loops comprising a first yarn and a second yarn. In some 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 some aspects, the first and second thermoplastic polymers may comprise any one or all of the parameters discussed above with respect to thermoplastic polymers.

[0342] In some aspects, the high processing temperature polymer composition may exhibit at least one of a creep relaxation temperature Tcr, a heat deflection temperature Thd, or a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymer composition. The low processing temperature polymer composition may comprise any one or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition may comprise any one or all of the properties of the high processing temperature polymer composition described above. Additionally, the first and second yarns may exhibit any one or all of the properties and parameters discussed above.

[0343] Step 2620 of method 2600 comprises 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 rate that is less than the elongation rate of the low processing temperature polymer composition. In some aspects, the anchor yarn may have the above reference Figure 4B , 4E, any one or all of the properties of the anchor yarns discussed in 10A and 10B.

[0344] In several aspects, the first course of loops can be present on the outer surface of the knitted shoe upper. In such aspects, the outer surface of the knitted shoe upper can include a first zone, a second zone, and a third zone, where the second zone is located between the first zone and the third zone. Additionally, in such aspects, the third zone has an increased concentration of the first yarn compared to the second zone. The first zone, the second zone, and the third zone can each include any one or all of the properties of the textile zones 306a, 304a, and 302 of the textile 300 discussed above with reference to Figure 3 any one or all of the properties of the textile 300 discussed above with reference to

[0345] Figure 27 Describes a method 2700 for making a shoe upper for a footwear product. Step 2710 of method 2700 includes forming a ground-facing outsole region that includes a first group of one or more first fibers. In such aspects, the one or more first fibers can include a low processing temperature polymer composition that includes one or more first thermoplastic polymers.

[0346] Method 2700 can include step 2720 of forming a second region that includes one or more second fibers and a second group of one or more first fibers. In such aspects, the one or more second fibers include a high processing temperature polymer composition that includes one or more second thermoplastic fibers. The high processing temperature polymer composition exhibits at least one of the following: creep relaxation temperature Tcr; heat distortion temperature Thd; or Vicat softening temperature Tvs, which is greater than the melting temperature Tm of the low processing temperature polymer composition of the one or more first fibers. The first and second fibers, the low and high processing temperature polymer compositions, and the first and second thermoplastic polymers can each include any one or all of the corresponding properties discussed above.

[0347] Textiles, Yarns, and Fibers

[0348] As discussed above, the fibers, yarns, textiles, membranes, and shaped parts described herein can include the selective incorporation of low processing temperature polymer compositions and / or the selective incorporation of high processing temperature polymer compositions. In several aspects, such low processing temperature polymer compositions can be present in the form of fibers of the low processing temperature polymer composition. In several aspects, the fibers including the low processing temperature polymer composition are essentially free of the high processing temperature polymer composition. In other aspects, the fibers including the low processing temperature polymer composition consist essentially of the low processing temperature polymer composition. According to the present invention, these fibers can be used to form yarns, which in turn can be used to form textiles, including knitted, woven, or braided textiles. According to the present invention, these fibers can also be used to form non-woven textiles.

[0349] Similarly, the high processing temperature polymer compositions described above may be present in the form of fibers of the high processing temperature polymer compositions. In some aspects, the fibers comprising the high processing temperature polymer compositions are substantially free of the low processing temperature polymer compositions. In other aspects, the fibers comprising the high processing temperature polymer compositions consist essentially of the high processing temperature polymer compositions. According to the present invention, these fibers can be used to form yarns, which in turn can be used to form textiles, including knitted, woven or braided textiles. According to the present invention, these fibers can also be used to form non-woven textiles.

[0350] In some aspects, the fibers and / or yarns comprising the low processing temperature polymer compositions may further comprise the high processing temperature polymer compositions. For example, the fibers can be bicomponent fibers having the low processing temperature polymer compositions present on at least a portion of the outer surface of the fibers. For example, the low and high processing temperature polymer compositions can have a side-by-side structure, or can have a core and sheath structure, where the low processing temperature polymer compositions are present in the sheath. In certain aspects, the low processing temperature polymer compositions, the high processing temperature polymer compositions, or both can further comprise one or more conventional additives found in yarns or fibers comprising polymeric materials. While the foregoing may only describe the properties and parameters of the yarns or yarn compositions, it should be understood that such properties and parameters also apply to the fibers or fiber compositions, unless otherwise noted.

[0351] In certain aspects, one or more of the yarns can be monofilament yarns or multifilament yarns. In certain aspects, the yarns can be spun. In various aspects, conventional techniques (including but not limited to melt spinning, solution spinning or electrospinning) can be used to form one or more of the yarns.

[0352] In certain aspects, the fibers described herein can be fibers of different sizes, including fibers that are not suitable for being spun into commercial yarns. The yarns described herein include yarns suitable for use in commercial knitting machines, as well as yarns that are not individually suitable for use in commercial knitting machines.

[0353] In certain aspects, the yarns and / or fibers described herein can be used to provide specific functionality. For example, in certain aspects, the yarns comprising the low processing temperature polymer compositions can be thermoformed to form a film having waterproof or water-resistant properties. In such aspects, the film on the outer surface of the article is provided by utilizing the low processing temperature polymeric material yarns and / or fibers on the outer portion of the textile, including the knitted structure forming the textile.

[0354] As discussed above, in some aspects, one or more of the yarns and / or fibers may be dyed, for example, for aesthetic purposes. In various aspects, conventional dyeing techniques (e.g., beam dyeing or solution dyeing) may be used to dye the yarns and / or fibers. Generally, beam dyeing is a process performed on already formed yarns and / or fibers, while solution dyeing dyes the fibers before they are formed into yarns. In some aspects, yarns or fibers comprising a high processing temperature polymer composition may be dyed. In some aspects, yarns or fibers comprising a low processing temperature polymer composition are not dyed and may be formed from a polymer composition that is essentially pigment- or dye-free, which may include regions that result in a low processing temperature polymer composition that is transparent or nearly transparent (e.g., non-yarn or non-fiber materials after thermoforming).

[0355] In some aspects, yarns comprising a low processing temperature polymer composition may exhibit tenacity from about 1 gram / denier to about 5 grams / denier. In one or more aspects, yarns comprising a low processing temperature polymer composition may exhibit tenacity from about 1.5 grams / denier to about 4.5 grams / denier. In one aspect, yarns comprising a low processing temperature polymer composition may exhibit tenacity from about 2 grams / denier to about 4.5 grams / denier. As used herein, "tenacity" refers to a property of a fiber or yarn and is determined using the corresponding test methods and sampling procedures described below in the Property Analysis and Characterization Procedures section.

[0356] In various aspects, yarns comprising a low processing temperature polymer composition may exhibit elongation from about 10% to about 130%. In one or more aspects, yarns comprising a low processing temperature polymer composition may exhibit elongation from about 20% to about 130%. In one aspect, yarns comprising a low processing temperature polymer composition may exhibit elongation from about 40% to about 130%. As used herein, the term "elongation" refers to a property of a fiber or yarn and the corresponding test methods described below in the Property Analysis and Characterization section.

[0357] As discussed above, in some aspects, it may be desirable to utilize yarns suitable for use on commercial knitting equipment. The independent shrinkage of a yarn at 50 °C is a property that can predict a yarn's suitability for use on commercial knitting machines. In some aspects, when heated from 20 °C to 50 °C, a yarn comprising a low processing temperature polymer composition can exhibit an independent shrinkage of from about 0% to about 60%. In one or more aspects, when heated from 20 °C to 50 °C, a yarn comprising a low processing temperature polymer composition can exhibit an independent shrinkage of from about 0% to about 30%. In one aspect, when heated from 20 °C to 50 °C, a yarn comprising a low processing temperature polymer composition can exhibit an independent shrinkage of from about 0% to about 20%. As used herein, the term "independent shrinkage" refers to a property of the yarn and the corresponding test method described below in the section on property analysis and characterization.

[0358] In one or more aspects, the independent shrinkage of a yarn at 70 °C can be a useful indicator of the yarn's ability to be exposed to certain environmental conditions without any substantial change in the physical structure of the yarn. In some aspects, when heated from 20 °C to 70 °C, a yarn comprising a low processing temperature polymer composition can exhibit an independent shrinkage of from about 0% to about 60%. In one or more aspects, when heated from 20 °C to 70 °C, a yarn comprising a low processing temperature polymer composition can exhibit an independent shrinkage of from about 0% to about 30%. In one aspect, when heated from 20 °C to 70 °C, a yarn comprising a low processing temperature polymer composition can exhibit an independent shrinkage of from about % to about 20%.

[0359] In one or more aspects, a yarn comprising a low processing temperature polymer composition can exhibit a modulus of from about 1 MPa to about 500 MPa. In some aspects, a yarn comprising a low processing temperature polymer composition can exhibit a modulus of from about 5 MPa to about 150 MPa. In one aspect, a yarn comprising a low processing temperature polymer composition can exhibit a modulus of from about 20 MPa to about 130 MPa. In another aspect, a yarn comprising a low processing temperature polymer composition can exhibit a modulus of from about 30 MPa to about 120 MPa. In yet another aspect, a yarn comprising a low processing temperature polymer composition can exhibit a modulus of from about 40 MPa to about 110 MPa. As used herein, the term "modulus" refers to the corresponding test method described below in the section on property analysis and characterization.

[0360] In one or more aspects, when in the form of a veneer, the low processing temperature polymer composition can exhibit a modulus from about 1 MPa to about 500 MPa. In certain aspects, in the form of a veneer, the low processing temperature polymer composition can exhibit a modulus from about 5 MPa to about 150 MPa. In one aspect, in the form of a veneer, the low processing temperature polymer composition can exhibit a modulus from about 20 MPa to about 130 MPa. In another aspect, in the form of a veneer, the low processing temperature polymer composition can exhibit a modulus from about 30 MPa to about 120 MPa. In yet another aspect, in the form of a veneer, the low processing temperature polymer composition can exhibit a modulus from about 40 MPa to about 110 MPa.

[0361] In one or more aspects, when a yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature Tm of the low processing temperature polymer composition and then to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., the molten yarn component) can exhibit a modulus from about 1 Mpa to about 500 MPa when tested at about 20 °C and a pressure of 1 ATM. In several aspects, when a yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature Tm of the low processing temperature polymer composition and then to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., the molten yarn component) can exhibit a modulus from about 5 Mpa to about 150 MPa when tested at about 20 °C and a pressure of 1. In one or more aspects, when a yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature Tm of the low processing temperature polymer composition and then to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., the molten yarn component) can exhibit a modulus from about 20 Mpa to about 130 MPa when tested at about 20 °C and a pressure of 1 ATM. In one or more aspects, when a yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature Tm of the low processing temperature polymer composition and then to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., the molten yarn component) can exhibit a modulus from about 30 MPa to about 120 MPa when tested at about 20 °C and a pressure of 1 ATM. In one or more aspects, when a yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature Tm of the low processing temperature polymer composition and then to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., the molten yarn component) can exhibit a modulus from about 40 MPa to about 110 MPa when tested at about 20 °C and a pressure of 1 ATM.

[0362] 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 Tm of the low processing temperature polymer composition and then reached a temperature below the melting temperature Tm of the low processing temperature polymer composition, when tested at about 20 °C and a pressure of 1 ATM, the resulting thermoformed material (or melted yarn component) exhibits a cold ross flex from about 5,000 cycles to about 500,000 cycles. In one or more 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 Tm of the low processing temperature polymer composition and then reached a temperature below the melting temperature Tm of the low processing temperature polymer composition, when tested at about 20 °C and a pressure of 1 ATM, the resulting thermoformed material (or melted yarn component) exhibits a cold ross flex from about 10,000 cycles to about 300,000 cycles. In certain 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 Tm of the low processing temperature polymer composition and then reached a temperature below the melting temperature Tm of the low processing temperature polymer composition, when tested at about 20 °C and a pressure of 1 ATM, the resulting thermoformed material (or melted 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 section on property analysis and characterization procedures.

[0363] In some aspects, as discussed in detail below, an anchor yarn can be used to help restrict the flow of a molten material (e.g., a low processing temperature polymer composition) during a thermoforming process and / or impart a certain flexibility to the thermoformed material. In such aspects, the anchor yarn can exhibit an elongation less than that of the low processing temperature polymer composition (e.g., a yarn comprising the low processing temperature polymer composition or a molten yarn component produced by thermoforming such a yarn). For example, in some aspects, the anchor yarn can exhibit an elongation that is at least 10% less than the elongation of a 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 a 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 the low processing temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising the 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 the low processing temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising the low processing temperature polymer composition. Exemplary anchor yarns include polyamide yarns, polyolefin yarns, and polyester yarns, including yarns having a tenacity from about 5 grams per denier to about 10 grams per denier.

[0364] 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 high processing temperature polymer composition of the anchor yarn can be thermoplastic polymers. In some 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 of a second yarn used in 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 of a second yarn used in a textile comprising the anchor yarn.

[0365] As discussed above, in some respects, the low processing temperature polymer compositions and the high processing temperature polymer compositions have different properties. In various aspects, when a thermoforming process is performed at a temperature below the creep relaxation temperature, heat distortion 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 then cool and solidify into a structure different from that before the thermoforming process (e.g., thermoforming from a yarn into a molten yarn component), while the high processing temperature polymer composition cannot deform or melt during this process and can maintain its structure (e.g., as a yarn). In such aspects, the molten yarn component formed from the low processing temperature polymer composition during the thermoforming process can be integrally connected to an unchanged structure (e.g., a yarn or fiber), which can provide a three-dimensional structure and / or other properties targeted at a specific point on a wearable article.

[0366] In various aspects, one or more of the disclosed yarns can be coated yarns. In another aspect, the coated yarn can be any suitable yarn on which a coating including a thermoplastic coating composition has been formed.

[0367] In some aspects, the thermoplastic coating composition includes a low processing temperature polymer composition and optionally one or more additives. In another aspect, the thermoplastic coating composition includes a low processing temperature polymer composition that includes a thermoplastic polyurethane and optionally one or more additives. In another aspect, the thermoplastic coating composition includes a low processing temperature polymer composition that includes a thermoplastic poly(ether block amide) and optionally one or more additives.

[0368] In some aspects, the thermoplastic coating composition includes a high processing temperature polymer composition and optionally one or more additives. In another aspect, the thermoplastic coating composition includes a high processing temperature polymer composition that includes a thermoplastic polyurethane and optionally one or more additives. In another aspect, the thermoplastic coating composition includes a high processing temperature polymer composition that includes a thermoplastic poly(ether block amide) and optionally one or more additives.

[0369] In some aspects, the coated yarn can be a monofilament or multifilament yarn. The yarn can be based on natural or man-made fibers, which include polyester, high-tenacity polyester, polyamide yarn, metal yarn, stretch yarn, carbon yarn, glass yarn, polyethylene 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 including one or more of the foregoing yarns.

[0370] In some aspects, the thermoplastic coating composition includes TPU. In some aspects, the TPU can be any such material described in the present invention, for example, TPU prepared by polymerizing aromatic isocyanates or aliphatic isocyanates with polyether polyols or polycaprolactones using short-chain glycols (e.g., 1,4-butanediol) as chain extenders, or mixtures of different types of the disclosed TPU. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0371] In various aspects, the thermoplastic coating composition can further include additives, such as but not limited to thickeners, processing aids, dyes, or colorants. In another aspect, the additives are not optional and include at least one thickener. In another aspect, the additives are not optional and include at least one processing aid. In yet another aspect, the additives are not optional and include at least one thickener and at least one processing aid. In certain aspects, the thickener can include inorganic materials, such as silica, talc, or calcium carbonate (CaCO3).

[0372] 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 CaCO3. The thickener is at least partially used to increase the viscosity of the thermoplastic coating composition. In another aspect, the thickener used in the disclosed thermoplastic coating composition can be an alloy with a resin, such as a styrene-butadiene-styrene (SBS) block copolymer, a styrene-ethylene / butene-styrene (SEBS) resin, a polyoxymethylene resin (POM), or a styrene-acrylonitrile resin (SAN), which can impart compatibility with the thermoplastic polyurethane.

[0373] In certain aspects, the thermoplastic coating composition can include a processing aid to improve productivity. In another aspect, the processing aid can be lignite wax or a fatty acid ester (C5-C9) with pentaerythritol. Other processing aids are known to those skilled in the art and can also be used in the disclosed thermoplastic composition. An exemplary commercially available processing aid is ESTANE 58277 (Lubrizol).

[0374] In certain aspects, a coated yarn having a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound of the coated yarn. In another aspect, the TPU compound for coating the yarn can be prepared by controlling the content of the raw materials to have the desired hardness. In yet another aspect, depending on the thickness of the yarn made of polyester, nylon, spandex, etc., the thickness of the coated yarn can be reduced.

[0375] In some aspects, a coated yarn is prepared by combining a thermoplastic coating composition comprising a thermoplastic polymer (e.g., thermoplastic polyurethane) in a conventional extruder, optionally further comprising one or more additives, and then applying the combined thermoplastic polyurethane coating composition to the surface of the yarn. In another aspect, a method for preparing a coated yarn comprises the steps of: 1) preparing shaped thermoplastic pellets; and 2) producing a 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 commercial sources.

[0376] The step of preparing the shaped thermoplastic pellets can include the steps of: 1) mixing a thermoplastic polymer with various additives (e.g., thickeners and / or processing aids) and feeding the mixture into the hopper of a conventional compounding extruder; 2) melting, kneading, and combining the mixture in the barrel of the compounding extruder at suitable temperatures and pressures; 3) cutting the combined thermoplastic coating composition as it exits through the die of the compounding extruder to form pellets in cooling water; and 4) drying the shaped thermoplastic polyurethane pellets at a suitable temperature for a period of time and aging the dried pellets at a suitable temperature for a suitable period of time.

[0377] In certain instances, the step of preparing the shaped thermoplastic pellets at least includes the steps of: 1) mixing thermoplastic polyurethane with various additives (e.g., thickeners and / or processing aids) and feeding the mixture into the hopper of a conventional compounding extruder; 2) combining the mixture in the barrel of the compounding extruder at a temperature of about 150 to 250 °C and a pressure of about 50 to 150 kgf; 3) cutting the combined thermoplastic polyurethane as it exits through the die of the compounding extruder to form pellets in cooling water; and 4) drying the shaped thermoplastic polyurethane pellets at a temperature of 60 to 80 °C for about 4 to 6 hours and aging the dried pellets at a temperature of 30 to 50 °C for about 7 days or more.

[0378] In some aspects, the step of producing a coated yarn can include the steps of: 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 hopper of a 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 suitable temperatures and pressures; 3) applying the combined thermoplastic polymer and masterbatch to the surface of the yarn passing through the adapter and die to produce a coated yarn; and 4) winding the coated yarn around a bobbin using a winder.

[0379] Specifically, the steps of producing the coated yarn may include the following steps: 1) mixing the shaped thermoplastic polyurethane pellets with a masterbatch corresponding to the desired color and feeding the mixture into the hopper of a yarn coating extruder; 2) melting the mixture of the shaped thermoplastic polyurethane pellets and the masterbatch in the cylinder of the yarn coating extruder at a temperature of about 150 to 250 °C and a pressure of about 50 to 150 kgf; 3) coating the combined TPU and masterbatch on the surface of the yarn (made of polyester, nylon, spandex, etc.) passing through the joint and the cube to produce the coated yarn; and 4) winding the coated yarn around a bobbin using a winder.

[0380] Exemplary non-limiting examples of suitable commercially available coated yarns are Dream-Sil, which is a TPU-coated yarn available from Sambu Fine Chemicals (Korea).

[0381] As discussed above, an anchor yarn can be used to assist in restricting the flow of the molten material (low processing temperature polymer composition) during the thermoforming process and / or to impart some 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 that includes one or more third thermoplastic polymers such that the anchor yarn composition exhibits a creep relaxation temperature T cr , Vicat softening temperature T vs , heat distortion temperature T hd or melting temperature T m of at least one of which the melting temperature T m is greater than the melting temperature T m of the low processing temperature polymer composition. In certain aspects, the anchor yarn composition may have a specific range associated with these properties as discussed above with respect to the high processing temperature polymer composition. In certain aspects, the anchor yarn may be formed from a high processing temperature polymer composition and may thus include any of the thermoplastic polymers discussed above with reference to the high processing temperature polymer composition.

[0382] In various aspects, when determined according to ASTM m D3418-97, the fiber or yarn comprises a polyamide or polyether block amide low processing temperature polymer composition having a melting temperature (T m ) of about 90 °C to 120 °C. On the other hand, when determined according to ASTM m D3418-97, the melting temperature (T m ) of the polyamide or polyether block amide is approximately 93 °C to 99 °C. Additionally, when determined according to ASTM mWhen measured according to D3418-97, the melting temperature (T m ) of the polyamide or polyether block amide is about 112 °C to 118 °C. In some aspects, when measured according to ASTM m D3418-97, the melting temperature (T m ) of the polyamide or polyether block amide is about 90 °C, 91 °C, 92 °C, 93 °C, 94 °C, 95 °C, 96 °C, 97 °C, 98 °C, 99 °C, 100 °C, 101 °C, 102 °C, 103 °C, 104 °C, 105 °C, 106 °C, 107 °C, 108 °C, 109 °C, 110 °C, 111 °C, 112 °C, 113 °C, 114 °C, 115 °C, 116 °C, 117 °C, 118 °C, 119 °C, 120 °C, or any value within the range of melting temperature (T m ) composed of the above values, or a combination of the above melting temperature (T m ) values.

[0383] In all aspects, when measured according to ASTM m D3418-97, the fiber or yarn contains a polyamide or polyether block amide low-temperature treated polymer composition with a glass transition temperature (T g ) of about -20 °C to 30 °C. On the other hand, when measured according to ASTM m D3418-97, the glass transition temperature (T g ) of the polyamide or polyether block amide is about -13 °C to -7 °C. In addition, when measured according to ASTM m D3418-97, the glass transition temperature (T g ) of the polyamide or polyether block amide is about 17 °C to 23 °C. In some aspects, when measured according to ASTM m D3418-97, the melting temperature (T g ) of the polyamide or polyether block amide is about -20 °C, -19 °C, -18 °C, -17 °C, -16 °C, -15 °C, -14 °C, -13 °C, -12 °C, -10 °C, -9 °C, -8 °C, -7 °C, -6 °C, -5 °C, -4 °C, -3 °C, -2 °C, -1 °C, 0 °C, 1 °C, 2 °C, 3 °C, 4 °C, 5 °C, 6 °C, 7 °C, 8 °C, 9 °C, 10 °C, 11 °C, 12 °C, 13 °C, 14 °C, 15 °C, 16 °C, 17 °C, 18 °C, 19 °C, 20 °C, or any value within the range of glass transition temperature (T g ) composed of the above values, or a combination of the above glass transition temperature (T g ) values.

[0384] In every aspect, when tested according to ASTM D1238-13 at a temperature of 160 °C using a 2.16 kg weight, the fiber or yarn contains a polyamide or polyether block amide low-temperature treated polymer composition with a melt flow index of about 10 cm m / 10 min to 30 cm 3 / 10 min. On the other hand, when tested according to ASTM D1238-13 at a temperature of 160 °C using a 2.16 kg weight, the melt flow index of the polyamide or polyether block amide is about 22 cm 3 / 10 min to 28 cm m / 10 min. In some aspects, when tested according to ASTM D1238-13 at a temperature of 160 °C using a 2.16 kg weight, the melt flow index of the polyamide or polyether block amide is about 10 cm 3 / 10 min, 11 cm 3 / 10 min, 12 cm m / 10 min, 13 cm 3 / 10 min, 14 cm 3 / 10 min, 15 cm 3 / 10 min, 16 cm 3 / 10 min, 17 cm 3 / 10 min, 18 cm 3 / 10 min, 19 cm 3 / 10 min, 20 cm 3 / 10 min, 21 cm 3 / 10 min, 22 cm 3 / 10 min, 23 cm 3 / 10 min, 24 cm 3 / 10 min, 25 cm 3 / 10 min, 26 cm 3 / 10 min, 27 cm 3 / 10 min, 28 cm 3 / 10 min, 29 cm 3 / 10 min, 27 cm 3 / 10 min, 28 cm 3 / 10 min, 29 cm 3 / 10 min, 30 cm 3 / 10 min, or within the melt flow index value range composed of any of the above values, or a combination of the above melt flow index values.

[0385] In various aspects, when a polyamide or polyether block amide thermoformed substrate is tested according to the low temperature Ross flex test described below, the fiber or yarn contains a low temperature treated polymer composition with a low temperature Ross flex test result of about 120,000 to 180,000. On the other hand, when a polyamide or polyether block amide thermoformed substrate is tested according to the low temperature Ross flex test described below, the low temperature Ross flex test result of the polyamide or polyether block amide is about 140,000 to 160,000. In addition, when a polyamide or polyether block amide thermoformed substrate is tested according to the low temperature Ross flex test described below, the low temperature Ross flex test result of the polyamide or polyether block amide is about 130,000 to 170,000. In certain aspects, when a polyamide or polyether block amide thermoformed substrate is tested according to the low temperature Ross flex test described below, the low temperature Ross flex test result of the polyamide or polyether block amide is about 120,000, 125,000, 130,000, 135,000, 140,000, 145,000, 150,000, 155,000, 160,000, 165,000, 170,000, 175,000, 180,000, or within the range of low temperature Ross flex test values composed of any of the above values, or a combination of the above low temperature Ross flex test values.

[0386] In various aspects, when a polyamide or polyether block amide thermoformed substrate is determined according to the ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers, the fiber or yarn contains a low temperature treated polymer composition with a modulus of about 5 MPa to 100 MPa. On the other hand, when a polyamide or polyether block amide thermoformed substrate is determined according to the ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers, the modulus of the polyamide or polyether block amide is about 20 MPa to 80 MPa. In certain aspects, when a polyamide or polyether block amide thermoformed substrate is determined according to the ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers, the modulus of the polyamide or polyether block amide is about 5 MPa, 10 MPa, 15 MPa, 20 MPa, 25 MPa, 30 MPa, 35 MPa, 40 MPa, 45 MPa, 50 MPa, 55 MPa, 60 MPa, 65 MPa, 70 MPa, 75 MPa, 80 MPa, 85 MPa, 90 MPa, 95 MPa, 100 MPa, or within the range of modulus values composed of any of the above values, or a combination of the above modulus values.

[0387] In every aspect, when measured according to ASTM m D3418-97, the fiber or yarn contains a polyamide or polyether block amide low-temperature treated polymer composition with a melting temperature (T m ) of about 115 °C; when measured according to ASTM m D3418-97, the glass transition temperature state transition temperature (T g ) is about -10 °C; when tested according to ASTM m D1238-13 at a temperature of 160 °C using a 2.16 kg weight, the melt flow index is about 25 cm 3 / 10 min; when the polyamide or polyether block amide thermoformed substrate is tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result is about 150,000; when the polyamide or polyether block amide thermoformed substrate is measured according to ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers, the modulus is about 25 MPa to 70 MPa.

[0388] In every aspect, when measured according to ASTM m D3418-97, the fiber or yarn contains a polyamide or polyether block amide low-temperature treated polymer composition with a melting temperature (T m ) of about 96 °C; when measured according to ASTM m D3418-97, the glass transition temperature state transition temperature (T g ) is about 20 °C; when the thermoformed substrate is tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result is about 150,000; when the thermoformed substrate is measured according to ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers, the modulus is less than or equal to 10 MPa.

[0389] In every aspect, when measured according to ASTM m D3418-97, the fiber or yarn contains a low-temperature treated polymer composition with a melting temperature (T m ) of about 115 °C - a polyamide or polyether block amide mixture composed of polyamide or polyether block amide prepared first; when measured according to ASTM m D3418-97, the glass transition temperature state transition temperature (T g) is approximately -10 °C; when tested according to ASTM m D1238-13 at a temperature of 160 °C using a 2.16 kg weight, the melt flow index is approximately 25 cm 3 / 10 min; when the thermoformed substrate is tested according to the Low Temperature Ross Flex Test described below, the Low Temperature Ross Flex Test result is approximately 150,000; when according to ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber and Thermoplastic Elastomers is used to measure the thermoformed substrate, the modulus is approximately 25 MPa to 70 MPa; when according to ASTM m D3418-97 is used for measurement, the melting temperature (T m ) of the second-prepared polyamide or polyether block amide is about 96 °C; when according to ASTM m D3418-97 is used for measurement, the glass transition temperature state transition temperature (T g ) is approximately 20 °C; when the thermoformed substrate is tested according to the Low Temperature Ross Flex Test described below, the Low Temperature Ross Flex Test result is approximately 150,000; when according to ASTM m D412-98 Standard Tension Test for Vulcanized Rubber, Thermoplastic Rubber and Thermoplastic Elastomers is used to measure the thermoformed substrate, the modulus is less than or equal to 10 MPa.

[0390] In all aspects, the fineness of the yarn containing the cryogenically treated polymer composition is around 750 to 1100.

[0391] In various aspects, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength, as measured according to EN ISO 2062, of greater than or equal to 1.5 grams per denier. In another aspect, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength, as measured according to EN ISO 2062, between 1.5 grams per denier and 3.0 grams per denier. In yet another aspect, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength, as measured according to EN ISO 2062, between 1.7 grams per denier and 1.8 grams per denier. In yet another aspect, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength, as measured according to EN ISO 2062, between 3.3 grams per denier and 3.6 grams per denier. In some aspects, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength, as measured according to EN ISO 2062, of 1.5 grams per denier, 1.6 grams per denier, 1.7 grams per denier, 1.8 grams per denier, 1.9 grams per denier, 2.0 grams per denier, 2.1 grams per denier, 2.2 grams per denier, 2.3 grams per denier, 2.4 grams per denier, 2.5 grams per denier, 2.6 grams per denier, 2.7 grams per denier, 2.8 grams per denier, 2.9 grams per denier, 3.0 grams per denier, any range of strength values encompassed by any of the foregoing values, or any combination of the foregoing strength values.

[0392] In various aspects, when tested in accordance with EN ISO 2062, with the modifications as described hereinafter, the yarns comprising the low processing temperature polymer composition have a yarn elongation of less than or equal to about 150%. In another aspect, the yarns comprising the low temperature processing polymer composition, with the modifications as described hereinafter, have a yarn elongation measured in accordance with EN ISO 2062 of from 30% to 130%. In yet another aspect, the yarns comprising the low temperature processing polymer composition, with the modifications as described hereinafter, have a yarn elongation measured in accordance with EN ISO 2062 of from 115% to 120%. In yet another aspect, the yarns comprising the low temperature processing polymer composition, with the modifications as described hereinafter, have a yarn elongation measured in accordance with EN ISO 2062 of from 120% to 140%. In yet another aspect, the yarns comprising the low temperature processing polymer composition, with the modifications as described hereinafter, have a yarn elongation measured in accordance with EN ISO 2062 of from 35% to 45% on a thermoformed sheet of polyamide or polymer (ether-block-amide). In some aspects, the yarns comprising the low temperature processing polymer composition, with the modifications as described hereinafter, have a yarn elongation measured in accordance with EN ISO 2062 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 elongation value range included in any of the above values, or any combination of the above elongation values.

[0393] In various aspects, a yarn comprising a cryogenically treated polymer composition has a yarn shrinkage measured at 50 °C by the methods described herein of less than or equal to about 15%. In another aspect, a yarn comprising a cryogenically treated polymer composition has a yarn shrinkage measured at 50 °C by the methods described herein of from about 7% to about 13%. In yet another aspect, a yarn comprising a cryogenically treated polymer composition has a yarn shrinkage measured at 50 °C by the methods described herein of from about 9.5% to about 10.5%. In yet another aspect, a yarn comprising a cryogenically treated polymer composition has a yarn shrinkage measured at 50 °C by the methods described herein of from 0% to about 5%. In some aspects, a yarn comprising a cryogenically treated polymer composition has a yarn shrinkage measured at 50 °C by the methods described herein 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 these values, or any combination of these shrinkage values.

[0394] In various aspects, a yarn comprising a cryogenically treated polymer composition has an enthalpy of fusion (a measure of crystallinity) measured by the methods described herein of from about 15 J / g to 50 J / g. In another aspect, a yarn comprising a cryogenically treated polymer composition has an enthalpy of fusion measured by the methods described herein of from about 17 J / g to 23 J / g. In yet another aspect, a yarn comprising a cryogenically treated polymer composition has an enthalpy of fusion measured by the methods described herein of from about 35 J / g to 42 J / g. In some aspects, a yarn comprising a cryogenically treated polymer composition has an enthalpy of fusion measured by the methods described herein of about 15 J / g, about 20 J / g, about 25 J / g, about 30 J / g, about 35 J / g, about 40 J / g, about 45 J / g, about 50 J / g, any range of enthalpy of fusion values encompassed by any of these values, or any combination of these enthalpy of fusion values.

[0395] In various aspects, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength measured according to EN ISO 2062 of from about 2.0 to 2.2 grams per denier; a yarn elongation measured according to EN ISO 2062 of from 116% to 122%; a yarn shrinkage measured at 50 °C by the methods described herein of from about 8% to 12%; and an enthalpy of fusion measured by the methods described herein of from about 18 J / g to 22 J / g. Expected yarns include those having any value within a given range, including values equal to or about equal to the lower or upper limit values of the given range.

[0396] In all aspects, a yarn comprising a cryogenically treated polymer composition, as modified hereinafter, has a yarn strength of about 3.2 to 3.6 grams per denier as measured in accordance with the provisions of EN ISO 2062; a yarn elongation of 37% to 43% as measured in accordance with the provisions of EN ISO 2062; a yarn shrinkage of about 0% to 3% at 50 °C as measured by the method described herein; and a melt enthalpy of about 35 J / g to 42 J / g as measured by the method described herein. The expected yarns include yarns having any value within the given range, including values equal to or approximately equal to the lower or upper limit values of the given range.

[0397] In all aspects, a yarn comprising a cryogenically treated polymer composition, comprising a first yarn, as modified hereinafter, has a yarn strength of about 2.0 to 2.2 grams per denier as measured in accordance with the provisions of EN ISO 2062; a yarn elongation of 116% to 122% as measured in accordance with the provisions of EN ISO 2062 as modified hereinafter; a yarn shrinkage of about 8% to 12% at 50 °C as measured by the method described herein; and a melt enthalpy of about 18 J / g to 22 J / g as measured by the method described herein. The expected yarns include yarns having any value within the given range, including values equal to or approximately equal to the lower or upper limit values of the given range; and a second yarn, as modified hereinafter, has a yarn strength of about 3.2 to 3.6 grams per denier as measured in accordance with the provisions of EN ISO 2062; a yarn elongation of 37% to 43% as measured in accordance with the provisions of EN ISO 2062 as modified hereinafter; a yarn shrinkage of about 0% to 3% at 50 °C as measured by the method described herein; and a melt enthalpy of about 35 J / g to 42 J / g as measured by the method described herein. The expected yarns include yarns having any value within the given range, including values equal to or approximately equal to the lower or upper limit values of the given range.

[0398] Shaped articles and films

[0399] As discussed above, the disclosed membranes and shaped articles described herein may include the selective incorporation of low processing temperature polymer compositions and / or the selective incorporation of high processing temperature polymer compositions. In several aspects, these low processing temperature polymer compositions may be present in the form of membranes or shaped articles of low processing temperature polymer compositions. In some aspects, the membranes or shaped articles comprising low processing temperature polymer compositions are substantially free of high processing temperature polymer compositions. In other aspects, the membranes or shaped articles comprising low processing temperature polymer compositions consist essentially of low processing temperature polymer compositions. These shaped articles may be manufactured by any suitable means known in the art for manufacturing shaped articles, such as polymer extrusion, polymer blow molding, injection molding, and machining. These membranes may be manufactured by any suitable means known in the art for manufacturing membranes, such as polymer extrusion.

[0400] Similarly, the high processing temperature polymer compositions described above may be present in the form of membranes or shaped articles of high processing temperature polymer compositions. In some aspects, the membranes or shaped articles comprising high processing temperature polymer compositions are substantially free of low processing temperature polymer compositions. In other aspects, the membranes or shaped articles comprising high processing temperature polymer compositions consist essentially of high processing temperature polymer compositions. These shaped articles may be manufactured by any suitable means known in the art for manufacturing shaped articles, such as polymer extrusion, polymer blow molding, injection molding, and machining. These membranes may be manufactured by any suitable means known in the art for manufacturing membranes, such as polymer extrusion.

[0401] In some aspects, the membranes or shaped articles comprising low processing temperature polymer compositions may further include high processing temperature polymer compositions. For example, the membrane or shaped article may be a two-component material formed by co-extruding or co-injecting a low processing temperature polymer composition and a high processing temperature polymer composition.

[0402] In certain aspects, the membranes or shaped articles described herein may be used to provide specific functionality. For example, in certain aspects, membranes comprising low processing temperature polymer compositions may be thermoformed to form membranes having water-resistant or water-impermeable properties. In these aspects, the membrane on the outer surface of the article may be provided by using a membrane comprising a low processing temperature polymeric material.

[0403] As discussed above, in some aspects, the film or formed component can be colored, for example, for aesthetic purposes. In various aspects, the film or formed component can be colored using conventional coloring techniques. In some aspects, the film or formed component comprising a low processing temperature polymer composition is uncolored and can be formed from a polymer composition that is substantially free of pigments, colorants, or dyes, which can result in the region comprising the low processing temperature polymer composition being clear or substantially transparent (e.g., non-yarn or non-fiber material after thermoforming).

[0404] In one or more aspects, the film or formed component comprising a low processing temperature polymer composition can exhibit a modulus ranging from about 1 MPa to about 500 MPa. In some aspects, the yarn comprising a low processing temperature polymer composition can exhibit a modulus ranging from about 5 MPa to about 150 MPa. In one aspect, the yarn comprising a low processing temperature polymer composition can exhibit a modulus ranging from about 20 MPa to about 130 MPa. In another aspect, the yarn comprising a low processing temperature polymer composition can exhibit a modulus ranging from about 30 MPa to about 120 MPa. In yet another aspect, the yarn comprising a low processing temperature polymer composition can exhibit a modulus ranging from about 40 MPa to about 110 MPa. As used herein, the term "modulus" refers to the corresponding test method described below in the section on property analysis and characterization procedures.

[0405] In one or more aspects, when the film or formed component comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature T m of the low processing temperature polymer composition and then brought to a temperature below the melting temperature T m of the low processing temperature polymer composition, when tested at approximately 20 °C and 1 ATM of pressure, the resulting thermoformed material (e.g., melted yarn component) can exhibit a modulus ranging from about 1 MPa to about 500 MPa. In several aspects, when the yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature T m of the low processing temperature polymer composition and then brought to a temperature below the melting temperature T m of the low processing temperature polymer composition, when tested at approximately 20 °C and 1 ATM of pressure, the resulting thermoformed material (e.g., melted yarn component) can exhibit a modulus ranging from about 5 MPa to about 150 MPa. In one or more aspects, when the yarn comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature T m of the low processing temperature polymer composition and then brought to a temperature below the melting temperature T mWhen at a temperature of, when tested at a pressure of approximately 20 °C and 1 ATM, the resulting thermoformed material (e.g., molten yarn component) can exhibit a modulus ranging from about 20 MPa to about 130 MPa. In one or more aspects, when a yarn containing 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 brought to a temperature below the melting temperature T of the low processing temperature polymer composition m When at a temperature of, when tested at a pressure of approximately 20 °C and 1 ATM, the resulting thermoformed material (e.g., molten yarn component) can exhibit a modulus ranging from about 30 MPa to about 120 MPa. In one or more aspects, when a yarn containing 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 brought to a temperature below the melting temperature T of the low processing temperature polymer composition m When at a temperature of, when tested at a pressure of approximately 20 °C and 1 ATM, the resulting thermoformed material (e.g., molten yarn component) can exhibit a modulus ranging from about 40 MPa to about 110 MPa.

[0406] 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, these different properties allow the low processing temperature polymer composition to melt and flow during the thermoforming process and then cool and solidify into a structure different from the structure before the thermoforming process (e.g., thermoforming from a film or formed component into a molten or partially molten film or formed component), while when the thermoforming process is carried out at a temperature below the creep relaxation temperature, heat distortion temperature or Vicat softening temperature of the high processing temperature polymer composition, the high processing temperature polymer composition cannot deform or melt during this process and can maintain its structure (e.g., as a film or formed component). In these aspects, the molten yarn component formed from 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 formed component), which can provide three-dimensional structures and / or other properties targeted at specific points on the wearable article.

[0407] In various aspects, the film or formed component can be a coated film or formed component. In yet another aspect, the coated film or formed component can be any suitable film or formed component on which a coating is formed, the coating comprising a thermoplastic coating composition or other suitable coating.

[0408] In some aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition and optionally comprises one or more additives. In yet another aspect, the thermoplastic coating composition comprises a low processing temperature polymer composition comprising a thermoplastic polyurethane and optionally comprises one or more additives. In yet another aspect, the thermoplastic coating composition comprises a low processing temperature polymer composition comprising a thermoplastic poly(ether block amide) and optionally comprises one or more additives.

[0409] In some aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition and optionally comprises one or more additives. In yet another aspect, the thermoplastic coating composition comprises a high processing temperature polymer composition comprising a thermoplastic polyurethane and optionally comprises one or more additives. In yet another aspect, the thermoplastic coating composition comprises a high processing temperature polymer composition comprising a thermoplastic poly(ether block amide) and optionally comprises one or more additives.

[0410] In some aspects, the thermoplastic coating composition comprises a TPU. In some aspects, the TPU can be any such material described in the present disclosure, for example, a TPU prepared by polymerizing an aromatic isocyanate or an aliphatic isocyanate with a polyether polyol or a polycaprolactone using a short-chain diol (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of the disclosed TPU. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0411] In various aspects, the thermoplastic coating composition may further comprise additives, such as but not limited to, one or more of a thickener, a processing aid, a dye, or a colorant. In yet another aspect, the additive is not optional and comprises at least one thickener. In yet another aspect, the additive is not optional and comprises at least one processing aid. In yet another aspect, the additive is not optional and comprises at least one thickener and at least one processing aid. In some aspects, the thickener may comprise an inorganic material, such as silica, talc, or calcium carbonate (CaCO3).

[0412] In some aspects, as described herein, a thickener may be used during the preparation of the thermoplastic coating composition to improve productivity and matting properties. In yet another aspect, the thickener is silica powder, talc, or CaCO3. The thickener is at least partially used to increase the viscosity of the thermoplastic coating composition. In yet another aspect, the thickener used in the disclosed thermoplastic coating composition may be an alloy with a resin, such as a styrene-butadiene-styrene (SBS) block copolymer, a styrene-ethylene / butylene-styrene (SEBS) resin, a poly...

Claims

1. A method for manufacturing a combined upper and sole of a footwear article, the combined upper and sole of the footwear article comprising a medial midfoot region, a lateral midfoot region, and a sole region facing the ground, the method comprising: Provide a first reflow material, wherein the first reflow material is a melted and re-solidified product of a first yarn and comprises a low processing temperature polymer composition, and wherein the low processing temperature polymer composition exhibits a melting temperature T of 135 °C or lower m ; Provide a second yarn, the second yarn comprising a high processing temperature polymer composition, wherein the high processing temperature polymer composition exhibits at least one of the following that is higher than the melting temperature T of the low processing temperature polymer composition m : 1) creep relaxation temperature T cr ; 2) heat distortion temperature T hd ; or 3) Vicat softening temperature T vs ; causing at least a portion of the second yarn to be present in at least a first course and a second course, and connecting at least a portion of the first course of the second yarn and at least a portion of the second course of the second yarn through at least a portion of the first return material; and causing at least a portion of the first return material to be present on the sole region facing the ground, wherein the combined upper and sole further comprises an outer surface having at least a first zone, a second zone, and a third zone, the second zone being located between the first zone and the third zone, wherein the first zone comprises an increased concentration of the second yarn compared to the second zone, and wherein the third zone comprises an increased concentration of the first return material compared to the second zone.

2. The method according to claim 1, wherein the at least a portion of the first return material is on at least 40% of the sole region facing the ground.

3. The method according to claim 2, wherein the at least a portion of the first return material is on at least 90% of the sole region facing the ground.

4. The method according to claim 1, wherein the third zone is in the sole region facing the ground.

5. The method according to claim 1, wherein at least a portion of the sole region facing the ground comprises at least one anchoring yarn.

6. The method according to claim 1, wherein at least one anchoring yarn extends from the third zone to the second zone.

7. The method according to claim 1, wherein the first zone is in the medial midfoot region or the lateral midfoot region or both.

8. The method according to claim 1, wherein the combined upper and sole further comprises a pull-on region, and at least a portion of the pull-on region comprises the first return material.

9. The method according to claim 1, wherein the combined upper and sole further comprises a heel region, and the heel region comprises the first return material.

10. The method according to claim 1, wherein the combined upper and sole further comprises an ankle collar region, and the ankle collar region is substantially free of the first return material.

11. The method according to claim 1, further comprising providing one or more traction elements in the sole region facing the ground.

12. The method according to claim 11, wherein the one or more traction elements are applied to the sole region facing the ground as part of a melting and re-solidifying process of the first yarn.

13. The method according to claim 2, wherein the second yarn is a package-dyed yarn.

14. The method according to claim 1, wherein the low processing temperature polymer composition exhibits a melting temperature of 80°C to 135°C.

15. The method according to claim 1, wherein the low processing temperature polymer composition exhibits a glass transition temperature T of 50 °C or lower g , exhibits a melt flow index of from 0.1 g / 10 min to 60 g / 10 min at 160 °C using a test weight of 2.16 kg, exhibits a melting enthalpy of at least 5 J / g, exhibits a modulus of from 1 MPa to 500 MPa, or any combination of the foregoing.

16. The method according to claim 15, wherein the low processing temperature polymer composition exhibits a melting temperature of less than 125 °C, exhibits a glass transition temperature T of 0 °C or lower g , exhibits a melt flow index of 5 g / 10 min to 40 g / 10 min at 160 °C using a test weight of 2.16 kg, exhibits a melting enthalpy of 10 J / g to 30 J / g, and exhibits a modulus of 30 MPa to 120 MPa.

17. The method according to claim 1, wherein the high processing temperature polymer composition exhibits a melting temperature T higher than 140 °C m .

18. The method according to claim 1, wherein the high processing temperature polymer composition exhibits a melting temperature T that is at least 10 °C higher than the melting temperature T of the low processing temperature polymer composition m of the low processing temperature polymer composition m .

19. The method according to claim 1, wherein the first yarn forms a third course of loops interconnecting the first course of loops and the second course of loops, and the first yarn exhibits a tenacity of from 1 gram per denier to 5 grams per denier, an elongation of less than 130%, and a shrinkage of less than 60%.

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