Knitted textiles and shoe uppers and methods of making the same

Abstract

This application relates to a knitted textile and shoe upper, and methods for making the same. Disclosed are wearable articles comprising one or more textiles comprising a low-processing temperature polymer composition and a high-processing temperature polymer composition, and methods for making the wearable articles. 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 searching within a specific technical field and is not intended to limit the present disclosure.

Description

[0001] This application is a divisional application of the application with the application date of November 9, 2017, application number 202110802431X, and invention name “Knitted textiles and shoe uppers and their manufacturing methods”.

[0002] The application with the application date of November 9, 2017, application number 202110802431X, and invention name “Knitted textiles and shoe uppers and methods for making the same” is a divisional application of the application with the application date of November 9, 2017, application number 201711100304.5, and invention name “Knitted textiles and shoe uppers and methods for making the same”.

[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, each of which is incorporated herein by reference in its entirety. Technical Field

[0005] The present disclosure relates to articles of manufacture, such as articles of clothing, footwear, and sports equipment. More specifically, the present disclosure relates to articles of manufacture comprising 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 of manufacture using materials comprising a low processing temperature polymer composition and a high processing temperature polymer composition. Background of the Invention

[0006] Traditionally, certain articles of clothing, such as footwear, are manufactured by cutting individual pieces of material and combining them. The individual pieces may be combined by sewing and / or using adhesives. However, cutting and combining multiple pieces of material is a wasteful, labor-intensive, and error-prone process, wherein such errors result in increased waste material and increased manufacturing time and energy. Summary of the Invention

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

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

[0009] A second yarn comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a melting temperature T higher than the low processing temperature polymer composition.m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs ;

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

[0011] In some embodiments, the knitted textile is a component of an article of footwear, a component of an article of apparel, or a component of an article of sporting equipment.

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

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

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

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

[0016] In some embodiments, the first yarn exhibits a tenacity of about 1 g / denier to about 5 g / 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 polyesters, polyethers, polyamides, polyurethanes, and polyolefins.

[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 about 80° C. to about 135° C., a glass transition temperature T of about 50° C. or less, and a low processing temperature polymer composition having a low processing temperature of about 135° C. to about 135° C. g , exhibits a melt flow index of about 0.1 g / 10 minutes to about 60 g / 10 minutes at 160°C using a 2.16 kg test weight, exhibits an enthalpy of fusion of at least 5 J / g, and exhibits a modulus of 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] A complete knitted textile is provided, the complete knitted textile comprising a first yarn comprising a low processing temperature polymer composition comprising one or more first thermoplastic polymers and a second yarn comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a higher melting temperature T than the low processing temperature polymer composition. m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs wherein the first yarn and the second yarn at least partially form a plurality of interconnected courses on an outer surface of the complete knitted textile, the outer surface comprising at least a first region, a second region, and a third region, the second region being positioned between the first region and the third region, the first region comprising an increased concentration of the second yarn as compared to the second region, and the third region comprising an increased concentration of the first yarn as compared to the second region;

[0023] placing at least a portion of the completed knitted textile on a molded outer surface;

[0024] While the at least a portion of the complete knitted textile is on the molded outer surface, the temperature of the complete knitted textile is increased to a temperature that is greater than the melting temperature T of the low processing temperature polymer composition. mand lower than at least one of the following of the high processing temperature polymer composition: 1) the creep relaxation temperature T cr ; 2) the thermal deformation temperature T hd ; or 3) the Vicat softening temperature T vs ;as well as

[0025] After increasing the temperature of the intact knitted textile, while the at least a portion of the intact knitted textile is still on the molded outer surface, reducing the temperature of the intact knitted textile to below the melting temperature T of the low processing temperature polymer composition. m temperature, thereby forming a knitted product.

[0026] In some embodiments, the molded exterior surface is a last for an article of footwear.

[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 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 last further includes placing a protective cover in contact with at least a portion of the complete knitted textile on the 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 intact knitted textile is increasing the temperature of the intact knitted textile to a temperature below a melting temperature or a degradation temperature of the silicone elastomer.

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

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

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

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

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

[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 connected 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 positioned 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 an article of footwear, a component of an article of apparel, or a component of an article of sporting equipment.

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

[0037]

[0011] Other aspects of the present disclosure will become readily apparent upon review of the detailed description described below in conjunction with the accompanying drawings.

[0038] Figure 1A are top and side perspective views of an article of footwear according to aspects of the present invention, primarily illustrating the locations of the three distinct textile zones.

[0039] Figure 1B According to various aspects of the present invention Figure 1A Bottom and side perspective views of an article of footwear.

[0040] Figure 1C According to various aspects of the present invention Figure 1A Top and side perspective views of alternative aspects of an article of footwear, primarily illustrating the positions of three different textile zones.

[0041] Figure 2A is a side view of an article of clothing according to aspects of the present invention, primarily illustrating 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] Figures 4A to 4E Describes aspects of the present invention Figure 3 Exemplary cross-sections of textile areas of various types.

[0045] Figures 5A to 5J Describing various aspects of the present invention may be present in Figures 4A to 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 interleaved interface in accordance with aspects of the present invention.

[0047] Figure 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 after exposure to a thermoforming process according to aspects of the present invention Figure 7A Schematic representation of interconnected courses of yarn and showing that the middle course is converted to a molten yarn component after thermoforming, but the two outer courses 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 outer courses is encapsulated within the melted yarn component.

[0050] Figure 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 and one coil in the upper row, in accordance with aspects of the present invention.

[0051] Figure 9B is after the interconnected rows of FIG. 7 have been exposed to a thermoforming process according to aspects of the present invention. Figure 9A Schematic representation of a cross section showing how the yarn loops in the middle course are deformed but still maintain the general yarn structure.

[0052] Figure 10A is a schematic representation of three interconnected courses of yarn of one type according to aspects of the present invention, with anchor yarns in float and tuck stitches.

[0053] Figure 10B According to various aspects of the present invention Figure 10A and showing that after thermoforming one type of yarn forming the interconnected courses has been transformed into a molten yarn component, wherein the anchor yarns are still present as yarns.

[0054] Figure 10C According to various aspects of the present invention Figure 10B Schematic representation of a cross-section of a melted yarn component showing that the anchor yarn is encapsulated within the melted yarn component.

[0055] Figure 11A According to various aspects of the present invention Figure 3 Schematic representation of a portion of one of the weaving areas of a textile and showing areas of different types of fibers.

[0056] Figure 11B is after exposure to a thermoforming process according to aspects of the present invention Figure 11A Schematic representation of a portion of and showing that one type of fibers among multiple types of fibers has been converted into a non-fibrous material with fibers of another material embedded within the non-fibrous material.

[0057] Figure 11C According to various aspects of the present invention Figure 11B A cross-section of a non-fibrous material showing two other fibers encapsulated within the non-fibrous material.

[0058] Figure 12 is a side view of a schematic representation of an article of footwear comprising a textile material according to aspects of the present invention and showing a chassis, heel counter, and sockliner for incorporation into the article of footwear.

[0059] Figure 13 According to various aspects of the present invention Figure 12 A cross-section of an article of footwear having a chassis, a heel counter, and a sockliner positioned within an interior of the article of footwear.

[0060] Figure 14 is a side view of a schematic representation of an article of footwear comprising textile material showing the addition of ground engaging cleats to a ground-facing outsole area of ​​the article of footwear according to aspects of the present invention.

[0061] Figure 15are top and side perspective views showing placement of an upper for an article of footwear on a last according to aspects of the present invention.

[0062] Figure 16 The shoe last according to various aspects of the present invention is Figure 15 Top and side perspective views of a shoe upper showing the upper wrapping around at least a bottom portion of a last.

[0063] Figure 17 According to various aspects of the present invention, Figure 16 Cross-section of a shoe upper on a last, showing the last in contact with the inner surface of the upper.

[0064] Figure 18 According to various aspects of the present invention, Figure 16 Top and side perspective views of the upper on the last, showing the protective cover surrounding the upper.

[0065] Figure 19 According to various aspects of the present invention, Figure 18 A cross-section of a shoe upper covered with a protective cover showing the protective cover contacting the outer surface of the shoe upper.

[0066] Figure 20A According to various aspects of the present invention, Figure 16 Side view of the shoe upper on the last showing the vacuum bag with the shoe upper placed inside.

[0067] Figure 20B According to various aspects of the present invention Figure 20A A side view of the shoe upper inside the vacuum bag, showing the vacuum bag compressing the outer surface of the shoe upper.

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

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

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

[0071] Figure 24 is a flow chart of an exemplary process for making a knitted upper for an article of footwear according to aspects of the present invention.

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

[0073] Figure 26 is a flow chart of an exemplary process for making an upper for an article of footwear according to aspects of the present invention.

[0074] Figure 27 is a flow chart of an exemplary process for making an outsole for an article of footwear according to aspects of the present invention. Specific implementation plan

[0075] The present disclosure relates to a combination of a textile or a textile and other materials (e.g., a formed component, a film, a second textile, a yarn or a fiber), wherein one or more of the textile or other materials comprises a low processing temperature composition, and one or more of the textile or other materials comprises a high processing temperature composition. In some aspects, a single textile comprises both a low processing temperature composition and a high processing temperature composition. The present disclosure also relates to a method for thermoforming a textile on a molded surface, alone or in combination with one or more other materials, to reshape the textile, attach the one or more other materials to the textile using a reflow polymeric material, or perform both operations. The thermoforming process involves placing at least a portion of the textile on a molded surface, and while the textile remains in contact with the molded surface, increasing the temperature of the complete textile to a first temperature, and then reducing the temperature of the complete textile to a second temperature. The first temperature is a temperature that is higher than the melting point of the low processing temperature composition but lower than at least one of the following of the high processing temperature polymeric composition: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs. Therefore, using the disclosed process, the portion of the textile and / or one or more materials comprising the low processing temperature composition will melt, reflow and then resolidify into a new shape or configuration, while the portion forming the high processing temperature composition will maintain its original shape or configuration. Forming a first fiber and / or yarn from a 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 is an especially effective and efficient way to incorporate low processing temperature compositions in these thermoforming processes. For example, the use of the disclosed textiles and processes makes it possible to use only a single textile to produce thermoformed articles comprising an integrally formed area using only a single thermoforming process, the articles having properties ranging from conventional textiles to solid molded polymeric materials. It has been found that producing yarns and or fibers that work well in the disclosed process while also producing final products with desired properties also requires the use of low processing temperature compositions, which have a balance of several properties disclosed herein. The example of a polymer that can provide this property balance in a low processing temperature composition is also disclosed. In certain examples, low processing temperature compositions for making yarn suitable for use on commercial weaving or knitting equipment are also disclosed.

[0076] Thus, in various aspects, the present disclosure is directed to overcoming various shortcomings of the prior art. In particular, one aspect of the present disclosure provides a knitted fabric that can be used as a component of a footwear article, a component of an article of apparel, or a component of sports equipment comprising a low-temperature-processable polymer composition and a high-temperature-processable polymer composition. In some aspects, the knitted fabric is a component of a footwear article, such as a shoe upper. The knitted fabric can be made using a disclosed process, which comprises knitting a first course of stitches comprised of a first yarn comprising a low-temperature-processable polymer composition comprising one or more first thermoplastic polymers and a second yarn comprising a high-temperature-processable 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, which is a product of melting and resolidifying a first yarn and comprises a low-temperature-processed polymer composition comprising one or more first thermoplastic polymers; and a second yarn and a high-temperature-processed polymer composition comprising one or more second thermoplastic polymers. Also disclosed herein is a process for making the knitted article. The knitted article can be footwear, apparel, or sports equipment.

[0078] In various aspects, the present disclosure relates to a composition of a knitted article: a first yarn comprising a low temperature processed polymer composition comprising one or more first thermoplastic polymers, and a second yarn comprising a high temperature processed polymer composition comprising one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits a creep relaxation temperature T cr Above the melting temperature T of the low temperature processing polymer composition m The first portion of the knitted article is formed into a plurality of interconnected loops using at least a first yarn and a second yarn.

[0079] In one aspect, the present disclosure relates to a composition of a knitted article: a first yarn comprising a low temperature processed polymer composition comprising one or more first thermoplastic polymers, and a second yarn comprising a high temperature processed polymer composition comprising one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits a heat distortion temperature T hd Above the melting temperature T of the low temperature processing polymer composition m The first portion of the knitted article is formed into a plurality of interconnected loops using at least a first yarn and a second yarn.

[0080] In one aspect, the present disclosure relates to a composition of a knitted article: a first yarn comprising a low temperature processed polymer composition comprising one or more first thermoplastic polymers, and a second yarn comprising a high temperature processed polymer composition comprising one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits a Vicat softening temperature T vs Above the melting temperature T of the low temperature processing polymer composition m The first portion of the knitted article is formed into a plurality of interconnected loops using at least a first yarn and a second yarn.

[0081] In one aspect, the present disclosure relates to a composition for a knitted article: a first yarn comprising a low temperature processing polymer composition comprising one or more first thermoplastic polymers, the low temperature processing polymer composition exhibiting a melting temperature T m 135 ℃ or less; the second yarn comprises a high temperature processed polymer composition, and the high temperature processed polymer composition comprises one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; 3) Vicat softening temperature T vs wherein at least one temperature is higher than the melting temperature T of the low temperature processing polymer composition m The first portion of the knitted article is formed into a plurality of interconnected loops using at least a first yarn and a second yarn.

[0082] In one aspect, the present disclosure relates to a process for making an article component: providing a knitted article according to any of aspects 1-117; and combining the knitted article with one or more other components to form an article of footwear, an article of apparel, or an article of sporting equipment.

[0083] In one aspect, the present disclosure relates to a process for making a knitted article, the process comprising: knitting a first course of stitches comprised of a first yarn and a second yarn, the first yarn comprising a low temperature processed polymer composition comprising one or more first thermoplastic polymers, the second yarn comprising a high temperature processed polymer composition comprising one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; 3) Vicat softening temperature T vs wherein at least one temperature is higher than the melting temperature T of the low temperature processing polymer composition m ; Weaving a second row of stitches consisting of the first yarn and the second yarn, at least a portion of the first row and a portion of the second row forming a plurality of interconnected stitches.

[0084] In one aspect, the present disclosure relates to a process for making a knitted article, the process comprising: knitting a first course, the first course comprising a first yarn and a second yarn, wherein the first yarn comprises a low temperature processed polymer composition comprising one or more first thermoplastic polymers, and the second yarn comprises a high temperature processed polymer composition comprising one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs wherein at least one temperature is higher than the melting temperature T of the low temperature processing polymer composition m knitting an anchor yarn into one or more loops of the first yarn in a first row of stitches, wherein the anchor yarn comprises an anchor yarn composition comprising one or more polymers, the anchor yarn composition exhibiting an elongation lower than an elongation of the low temperature processed polymer composition, the first row of stitches being on an outer surface of the knitted article, the outer surface comprising at least a first region, a second region, and a third region, wherein the second region is intermediate the first region and the third region, and the first yarns in the third region are denser than those in the second region.

[0085] In one aspect, the present disclosure relates to a composition of a knitted article: a first reflow material, wherein the first reflow material is a product of melting and resolidifying on a first yarn, the first reflow material comprising a low temperature processing polymer composition, wherein the low temperature processing polymer composition comprises one or more first thermoplastic polymers; and a second yarn, wherein the second yarn comprises a high temperature processing polymer composition, wherein the high temperature processing polymer composition comprises one or more second thermoplastic polymers; wherein the high temperature processing polymer composition exhibits a creep relaxation temperature T cr Above the melting temperature T of the low temperature processing polymer composition m At least a portion of the second yarn is located in at least the first row of loops and the second row of loops, and at least a portion of the first row of the second yarn loops and at least a portion of the second row of the second yarn loops are connected to at least a portion of the first reflow material.

[0086] In one aspect, the present disclosure relates to a composition of a knitted article: a first reflow material, wherein the first reflow material is a product of melting and resolidifying on a first yarn, the first reflow material comprising a low temperature processing polymer composition, wherein the low temperature processing polymer composition comprises one or more first thermoplastic polymers; and a second yarn, wherein the second yarn comprises a high temperature processing polymer composition, wherein the high temperature processing polymer composition comprises one or more second thermoplastic polymers; wherein the high temperature processing polymer composition exhibits a heat distortion temperature T hd Above the melting temperature T of the low temperature processing polymer composition m At least a portion of the second yarn is located in at least the first row of loops and the second row of loops, and at least a portion of the first row of the second yarn loops and at least a portion of the second row of the second yarn loops are connected to at least a portion of the first reflow material.

[0087] In one aspect, the present disclosure relates to a composition of a knitted article: a first reflow material, wherein the first reflow material is a product of melting and resolidifying on a first yarn, the first reflow material comprising a low temperature processing polymer composition, wherein the low temperature processing polymer composition comprises one or more first thermoplastic polymers; and a second yarn, wherein the second yarn comprises a high temperature processing polymer composition, wherein the high temperature processing polymer composition comprises one or more second thermoplastic polymers; wherein the high temperature processing polymer composition exhibits a Vicat softening temperature T vs Above the melting temperature T of the low temperature processing polymer composition m At least a portion of the second yarn is located in at least the first row of loops and the second row of loops, and at least a portion of the first row of the second yarn loops and at least a portion of the second row of the second yarn loops are connected to at least a portion of the first reflow material.

[0088] In one aspect, the present disclosure relates to a composition for a knitted article: a first reflow material, wherein the first reflow material is a product of melting and resolidifying on a first yarn, the first reflow material comprising a low temperature processing polymer composition, wherein the low temperature processing polymer composition comprises one or more first thermoplastic polymers; the low temperature processing polymer composition exhibits a melting temperature T m 135 ° C or less; and a second yarn, the second yarn comprising a high temperature processed polymer composition, and the high temperature processed polymer composition comprises one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs wherein at least one temperature is higher than the melting temperature T of the low temperature processing polymer composition m At least a portion of the second yarn is located in at least the first row of loops and the second row of loops, and at least a portion of the first row of the second yarn loops and at least a portion of the second row of the second yarn loops are connected to at least a portion of the first reflow material.

[0089] In various aspects, the present disclosure relates to a process for making an article component by providing the disclosed knitted article; and then combining the knitted article with one or more other materials to form an article of footwear, apparel, or sporting equipment.

[0090] In various aspects, the present disclosure relates to a process for making a knitted article, the process comprising: forming a complete knitted fabric, the knitted fabric comprising a first yarn and a second yarn, wherein the first yarn comprises a low temperature processed polymer composition, which comprises one or more first thermoplastic polymers, and wherein the second yarn comprises a high temperature processed polymer composition, which comprises one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; 3) Vicat softening temperature T vs wherein at least one temperature is higher than the melting temperature T of the low temperature processing polymer composition m wherein at least one of the first yarn and the second yarn in the first portion of the knitted fabric is capable of forming a plurality of interconnected loops; placing at least a portion of the knitted fabric on a forming surface; and raising the temperature of the entire knitted fabric while at least a portion of the knitted fabric is on the forming surface to a temperature above the melting temperature T of the low temperature processed polymer composition. m , which is lower than the following: 1) creep relaxation temperature T of the high temperature treated polymer composition cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature Tvs After the entire knitted fabric is heated, while at least a portion of the knitted fabric is still placed on the forming surface, the temperature of the entire knitted fabric is reduced to a temperature below the melting temperature T of the low-temperature treated polymer composition. m , thus forming a knitted product.

[0091] In one aspect, the present disclosure relates to a process for making a knitted article, the process comprising: forming a complete knitted fabric, the knitted fabric comprising a first yarn and a second yarn, wherein the first yarn comprises a low temperature processed polymer composition, and the low temperature processed polymer composition comprises one or more first thermoplastic polymers, wherein the second yarn comprises a high temperature processed polymer composition, and the high temperature processed polymer composition comprises one or more second thermoplastic polymers, wherein the high temperature processed polymer composition exhibits: 1) a creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs wherein at least one temperature is higher than the melting temperature T of the low temperature processing polymer composition m a first portion of the knitted fabric comprising a first row of loops, the loops comprising a first yarn and a second yarn; an anchor yarn being knitted into one or more loops of the first yarn in the first row of loops, wherein the anchor yarn comprises an anchor yarn composition comprising one or more polymers, the anchor yarn composition exhibiting an elongation lower than an elongation of the low-temperature processed polymer composition, the first row of loops being on an outer surface of the knitted article, the outer surface comprising at least a first region, a second region, and a third region, wherein the second region is intermediate between the first region and the third region, and the first threads of the third region are denser than those of the second region; placing at least a portion of the knitted fabric on a forming surface; while at least a portion of the knitted fabric is on the forming surface, raising the temperature of the entire knitted fabric to a temperature above the melting temperature, T, of the low-temperature processed polymer composition. m , which is lower than the following: 1) creep relaxation temperature T of the high temperature treated polymer composition cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs After the entire knitted fabric is heated, while at least a portion of the knitted fabric is still placed on the forming surface, the temperature of the entire knitted fabric is reduced to a temperature below the melting temperature T of the low-temperature treated polymer composition. m , thus forming a knitted product.

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

[0093] Exemplary footwear is an athletic or sports shoe, including, but not limited to, running shoes, basketball shoes, soccer shoes, baseball shoes, football shoes, tennis shoes, rugby shoes, cross-training shoes, walking shoes, hiking boots, golf shoes, sneakers, and the like. Alternatively, the footwear may be a non-athletic shoe, including, but not limited to, dress shoes, slippers, casual shoes, sandals, and boots, including work boots. The shoe may or may not cover the entire foot of the wearer. For example, the shoe may be a sandal or other article that exposes a large portion of the foot being worn. Therefore, those skilled in the art will appreciate that the materials and processes disclosed herein are applicable to a wide variety of shoe types or styles beyond the specific types or styles discussed in the following materials and depicted in the accompanying drawings.

[0094] The disclosed textiles and articles can include yarns, fibers, or combinations of yarns and fibers including low processing temperature polymer compositions (described below) and yarns, fibers, or combinations of yarns and fibers including high processing temperature polymer compositions (also described below). The disclosed textiles and articles include at least two yarns that balance several material properties as described herein. In addition, 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 a sports footwear product or a non-sports footwear product) and the typical uses of the footwear product. For example, when considering the type of yarn and fiber used in sports footwear products, the type of sports used by the sports footwear products and / or the conditions in which the sports footwear products will be worn (e.g., indoors or outdoors) can be considered.

[0095] The disclosed articles may include formed parts, films, fibers, yarns, or combinations thereof that include low processing temperature polymer compositions (described below) and formed parts, films, fibers, yarns, or combinations thereof that include high processing temperature polymer compositions (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 uses of the article.

[0096] In various aspects, the disclosed shaped parts, films, textiles and articles include two different polymer compositions, one of which can melt or deform during a thermoforming process performed within a first temperature range (referred to herein as a low processing temperature polymer composition), while the other polymer composition maintains its shape within the first temperature range (referred to herein as a high processing temperature polymer composition). It will be understood that reference to a "polymer composition" is intended to refer to a composition comprising at least one polymer. Optionally, additional ingredients such as pigments, dyes, fillers, processing aids, etc. may 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 examples, 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 shaped parts, films and / or fibers. The shaped 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, disclosed textiles and articles include a first film, fiber, or yarn comprising a low processing temperature polymer composition and a second film, fiber, or yarn comprising a high processing temperature polymer composition.

[0097] As mentioned above, the articles described herein can include materials such as formed parts, films, fibers, yarns, and / or textiles, wherein the articles are formed at least in part from a low processing temperature polymer composition and a high processing temperature polymer composition. In some instances, the materials are formed at least in part 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" refer to the relative creep relaxation temperature (T) of each of these compositions. cr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) and / or melting temperature (T m ) is a relative term. The creep relaxation temperature (Tcr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) and melting temperature (T m ) is understood to be lower than the decomposition temperature of the high treatment temperature polymeric composition.These parameters are described in further detail hereinafter.Should be understood that other properties and parameters can be different between the low treatment temperature polymeric composition and the high treatment temperature polymeric composition, as discussed in detail hereinafter.In various fields, the low treatment temperature polymeric composition and / or the high treatment temperature polymeric composition or the above two can be present in a formed 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 ) is lower than at least one of the following properties of the high processing temperature polymer composition: (1) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m That is, for example, the low processing temperature polymer composition exhibits a creep relaxation temperature (T) that is lower than that of the high processing temperature polymer composition. cr ), Vicat softening temperature (T vs ), heat deformation temperature (T hd ) or melting temperature (T m ) of one or more of the temperatures (T m ), the melting temperature (T m ) is lower than the melting temperature (T m ).

[0099] On the other hand, the melting temperature (T m ) is lower than the creep relaxation temperature (T cr On the other hand, the melting temperature (T m ) is lower than the Vicat softening temperature (T vs On the other hand, the melting temperature (T m ) is lower than the heat distortion temperature (T hd On the other hand, the melting temperature (T m ) is lower than the melting temperature (T m ).

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

[0101] On the other hand, the melting temperature (T m ) is greater than the creep relaxation temperature (T cr On the other hand, the melting temperature (T m ) is greater than the Vicat softening temperature (T vs On the other hand, the melting temperature (T m ) is greater than the heat distortion temperature (T hd On the other hand, the melting temperature (T m ) is greater than the melting temperature (T m ).

[0102] In various aspects, the low processing temperature polymer composition and the high processing temperature polymer composition can be selectively incorporated into a textile or article to provide one or more structural properties and / or other advantageous properties to the textile or article. In various aspects, the textile 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) creep relaxation temperature (T cr ); (2) Vicat softening temperature (T vs ); (3) thermal deformation temperature (T hd ); or (4) melting temperature (T m). The creep relaxation temperature (T cr The thermoforming can be performed in a temperature range below the Vicat softening temperature (T vs The thermoforming can be performed in a temperature range below the heat deformation temperature (T hd The thermoforming can be performed in a temperature range below the melting temperature (T m ) is performed within a temperature range of .

[0103] In various aspects, low treatment temperature polymer composition can be used to form fiber.As used herein, " fiber " should be understood to comprise filament.Similarly, in various aspects, high treatment temperature polymer composition can be used to form fiber.In various aspects, fiber can be a bicomponent fiber comprising a first part formed by a low treatment temperature polymer composition and a second part formed by a high treatment temperature polymer composition.For example, a low treatment temperature polymer composition and a high treatment temperature polymer composition can be co-extruded to form a bicomponent fiber. Fiber can be extruded from a low treatment temperature polymer composition, and subsequently coated with a high treatment temperature polymer composition. Alternatively, fiber can be extruded from a high treatment temperature polymer composition, and subsequently coated with a low treatment temperature polymer composition. On the other hand, fiber can be a multicomponent fiber comprising three or more polymer compositions comprising one or more low treatment temperature polymer compositions and one or more high treatment temperature polymer compositions.

[0104] In various aspects, the disclosed fiber can be used to prepare yarn. Short fibers can be used or long fibers can be used to form yarn. The yarn of the present disclosure includes at least one of a low treatment temperature polymer composition and a high treatment temperature polymer composition. Examples of the present disclosure include both a low treatment temperature polymer composition and a high treatment temperature polymer composition. For example, the yarn can include one or more disclosed fibers, the fiber including a low treatment temperature polymer composition, a mixture of two or more low treatment temperature polymer compositions, a high treatment temperature polymer composition, a high treatment temperature polymer composition or a mixture of more low treatment temperature polymer compositions, or a mixture of one or more low treatment temperature polymer compositions and one or more high treatment temperature polymer compositions. Substantially all or most of the fibers of the yarn can be formed by the low treatment temperature polymer composition. Alternatively, substantially all or most of the fibers of the yarn can be formed by the high treatment temperature polymer composition. The yarn can include the fiber formed by the low treatment temperature polymer composition or the fiber formed by the high treatment temperature polymer composition, or the above two types of fibers. The yarn can include the fiber formed by the low treatment temperature polymer composition, wherein the yarn is coated with the high treatment temperature polymer composition. Alternatively, the yarn may 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 aforementioned fibers or yarns can be used to prepare textiles. The textiles can include one or more of the disclosed fibers or yarns. In various aspects, the textiles can be woven textiles including one or more of the disclosed yarns. In 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 all respects, low treatment temperature polymer composition or high treatment temperature polymer composition or above both can be used to prepare shaped parts.Shaped parts can be the molded parts that can be manufactured by injection molding, compression molding, blow molding, rotational molding or other molding techniques well known to those skilled in the art. In some respects, shaped parts can comprise the mixture of two or more low treatment temperature polymer compositions. In alternative, shaped parts can comprise the mixture of two or more high treatment temperature polymer compositions. On the other hand, shaped parts can comprise one or more low treatment temperature polymer compositions and one or more high treatment temperature polymer compositions. For example, shaped parts can comprise two or more parts, wherein the first portion is formed by the low treatment temperature polymer composition and the second portion is formed by the high treatment temperature polymer composition. Dual molding process can be used to form described two or more parts.

[0107] In various aspects, low treatment temperature polymer composition or high treatment temperature polymer composition can be used to make film.In some aspects, film can comprise one or more low treatment temperature polymer compositions.Alternatively, in some aspects, film can comprise one or more high treatment temperature polymer compositions.On the other hand, film can comprise one or more low treatment temperature polymer compositions and one or more high treatment temperature polymer compositions.In various aspects, film can be a multilayer film comprising one or more disclosed films, for example, comprising the first layer comprising the low treatment temperature polymer composition and the double-layer film comprising the second layer of the high treatment temperature polymer composition.Described multilayer film can be formed by coextrusion or lamination.

[0108] In conventional manufacturing processes for articles, including wearable articles, the transition from a first functional zone to a second functional zone can be achieved by changing the material imparting the functionality. This transition from a first material with a first functional description to a second material with a different functional description can introduce limitations to the final product. For example, in the case of a shoe, the transition from the sole to the upper occurs near the shoe's bite line. This transition zone may be referred to as a hard-soft transition zone because the sole generally has a relatively rigid response to foot movement, while the upper has a relatively non-rigid response to foot movement. Other such hard-soft transition zones may exist elsewhere on the shoe, depending on the design and construction methods used. At this transition zone, the wearer of the shoe may experience discomfort because the portion of the foot on one side of the transition zone is allowed to move differently (e.g., more freely) than the portion of the foot on the other side of the transition zone. This abrupt change in the allowed freedom of movement of the wearer's foot (e.g., a hard-soft transition zone) can affect the perceived performance and feel of the shoe. To limit the impact of the hard-soft transition zone, manufacturers may insert multiple material layers or otherwise mechanically manipulate the transition zone to mask the change. Each of these changes may insert complexity, additional processing steps, and / or materials, which may further impact the efficiency, cost, and weight of the shoe.

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

[0110] In one aspect, a textile is provided, comprising a first plurality of fibers comprising a low-processing temperature polymer composition. The textile further comprises a second plurality of fibers comprising a high-processing temperature polymer composition. The first plurality of fibers and the second plurality of fibers 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 a central portion of the first surface of the textile, and the second plurality of fibers can form lateral portions of the first surface of the textile. The first plurality of fibers and the second plurality of fibers can be arranged in a first zone, a second zone, and a third zone, the second zone being positioned between the first and third zones, wherein the first zone comprises an increased concentration of the second plurality of fibers compared to the second zone, and wherein the third zone comprises an increased concentration of the first plurality of fibers compared to the second zone. In specific examples, the textile is a nonwoven textile. In some examples, the textile is a component of an article of the present disclosure, such as an article of clothing, an article of footwear, or an article of sports equipment. In specific examples, the textile is a component of a shoe upper for an article of footwear. The textile component may comprise at least 75 weight percent of an upper for an article of footwear.

[0111] On the one hand, a textile is provided, comprising a first yarn comprising a low processing temperature polymer composition. The textile further comprises a second yarn comprising a high processing temperature polymer composition. The first and second yarns can be used to form separate areas of the textile. The first yarn and the second yarn can be contained in a first zone, a second zone, and a third zone, the second zone being positioned between the first zone and the third zone, wherein the first zone comprises 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 textile is a component of an article of the present disclosure, such as an article of clothing, an article of footwear, or an article of sports equipment. In a specific example, the textile is a component of a shoe upper for a footwear article. The textile component can comprise at least 75% by weight of the shoe upper for the footwear article.

[0112] In one aspect, a woven textile is provided, comprising a first yarn comprising a low-processing temperature polymer composition. The woven textile further comprises a second yarn comprising a high-processing temperature polymer composition. The first yarn and the second yarn can be used to form separate regions of the woven textile. For example, the first yarn can form substantially all or a portion of the warp yarns of the weave of the woven textile, and the second yarn can form substantially all or a portion of the weft yarns of the weave of the woven textile, or vice versa. The first yarn and the second yarn can form 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 woven textile is a component of an article of the present disclosure, such as an article of clothing, an article of footwear, or an article of sports equipment. In a specific example, the woven textile is a component of a shoe upper for a footwear article. The woven textile component can comprise at least 75% by weight of the shoe upper for the footwear article.

[0113] In one aspect, a knitted textile is provided, comprising a first yarn comprising a 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 comprising one or more second thermoplastic polymers. The first and second yarns at least partially form a plurality of interconnected rows in at least one knit layer of the knitted textile, the at least one knit 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 clothing, an article of footwear, or an article of sporting equipment. In a specific example, the knitted textile is a component of an upper for an article of footwear. The knitted textile component may comprise at least 75% by weight of the upper for the article of footwear.

[0114] The knitted textile can be formed by a knitting process, such as horizontal knitting or circular knitting. In some aspects, the knitted textile can have a substantially seamless configuration knitted product. On the other hand, the knitted textile can be a knitted product formed by a single knitting structure. As used herein, a knitted product is defined as being formed by a "single knitting structure" when it is formed as a single element by a knitting process. That is, the knitting process basically forms the various features and structures of the knitted product without requiring a large number of additional manufacturing steps or processes. Although parts of the knitted product can be joined to each other after the knitting process (for example, the edges of the knitted product are joined together, such as at a seam), the knitted product remains formed by a single knitting structure because it is formed as a single knitted element. In various aspects, the knitted product can further include other elements (for example, a tongue, a label, a shoelace, a heel support frame, a logo, a trademark, a sign) that can be added after the knitting process.

[0115] Knitted textiles can be incorporated with various types of stitches and yarns and combinations of stitches and yarns. About stitches, knitted textiles can have one type of stitch in one area of ​​knitted textiles and another type of stitch in another area of ​​knitted textiles. Depending on the type and combination of stitches utilized, the area of ​​knitted textiles can have (for example) a plain weft knit structure, a mesh knit structure or a rib knit structure. Different types of stitches can affect the physical properties of knitted textiles, including aesthetics, stretchability, thickness, air permeability and abrasion resistance. In other words, different types of stitches can give different properties to different areas of knitted textiles. About yarn, knitted textiles can have one type of yarn in one area of ​​knitted textiles and another type of yarn in another area of ​​knitted textiles, for example, a yarn comprising a low treatment temperature polymer composition in one area of ​​knitted textiles and a yarn comprising a high treatment temperature polymer composition in another area of ​​knitted textiles. According to various design standards, knitted textiles can be incorporated with yarns with different deniers, materials (for example, cotton, spandex, polyester, rayon, wool and nylon) and twist. Different types of yarn can influence the physical properties of knitted textiles, including aesthetics, stretchability, thickness, breathability, and abrasion resistance. In other words, different types of yarn can impart different properties to different areas of the knitted textile. By combining various types of stitches and yarns, and combinations of stitches and yarns, each area of ​​the knitted textile can have specific properties, which, when used in footwear, apparel, or sports equipment, can improve the comfort, durability, and performance of the knitted textile as needed.

[0116] The knitted textile can be produced by a variety of suitable processes. For example, a flat knitting process can be used to manufacture the knitted textile. Although flat knitting can provide a suitable process for forming a knitted textile, other knitting processes can also be used, such as wide tube circular knitting, narrow tube circular knitting jacquard, single-sided circular knitting jacquard, double-sided circular knitting jacquard, warp knitted fabric, warp knitted raschel, and double needle comb raschel. In various aspects, the knitted textile can be subjected to post-processing steps, for example, to remove a portion of the knitted textile, to add components to the knitted textile, to form a wool texture, etc. In other aspects, the knitted textile can include various knit structures and / or include different knitted sublayers.

[0117] In certain aspects, the entire knitted article can be seamless. Seamless knitted articles can be provided, for example, through circular knitting. Circular knitted articles can allow for the provision of three-dimensional preformed articles without the need for seams at designated locations. Thus, unwanted seams in the knitted article can be avoided, and the three-dimensional preformed knitted article can have the particularly good fit of a seamless structure and the additional benefits previously mentioned.

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

[0119] In one aspect, a textile is provided that includes a first plurality of fibers, the first plurality of fibers comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile may be a nonwoven textile. The textile may be a textile article. The textile article may be a component of a sports equipment article. The textile article may be a component of an article of clothing. The textile article may be a component of an article of footwear. The textile article may be an upper portion of a article of footwear.

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

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

[0122] In another aspect, the textile comprises a second plurality of fibers comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the low processing temperature polymer composition in the plurality of fibers. m ) Large thermal deformation temperature (T hd ).

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

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

[0125] In another aspect, a textile comprises a first yarn comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile may be a knitted textile. The textile may be a woven textile. The textile may be a textile article. The textile article may be an upper portion of a footwear article.

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

[0127] In another aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the low processing temperature polymer composition in the first yarn. m )The maximum creep relaxation temperature (T cr ).

[0128] In another aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is greater than the low processing temperature polymer composition in the yarn. m ) Large thermal deformation temperature (T hd ).

[0129] In another aspect, the textile comprises a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the low processing temperature polymer composition in the first yarn. m ) Large Vicat softening temperature (T vs ).

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

[0131] In certain aspects, a textile article is provided, comprising a melted fiber component that is thermoformed from a first state as a first plurality of fibers into a second state as a melted fiber component (i.e., a component formed from a plurality of fibers wherein at least a portion of the plurality of fibers have been at least partially melted and resolidified into a new form different from their fiber form). The first plurality of fibers comprises a low processing temperature polymer composition. It will be understood that the melted fiber component may comprise structures such as a partially melted first plurality of fibers, a substantially completely melted first plurality of fibers, and mixtures thereof. The textile article may also comprise a second plurality of fibers comprising a high processing temperature polymer composition. Optionally, the melted fiber component and the second plurality of fibers at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is positioned between the first and third regions. The first region comprises a higher concentration of the second plurality of fibers than the second region, and the third region comprises a higher concentration of the melted plurality of fiber components than the second region. In some examples, this structure may form an outer surface of the article, wherein the first, second, and third regions each form a portion of the outer surface.

[0132] In one aspect, a textile article comprises a first plurality of fibers comprising a low processing temperature polymer composition comprising one or more thermoplastic polymers. The textile article can be a component of an article of clothing. The textile article can be a nonwoven textile article. The textile article can be a component of an article of sports equipment. The textile article can be a component of an article of footwear. The textile article can be an upper portion of an article of footwear.

[0133] In various aspects, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than the low processing temperature polymer composition of the first plurality of fibers. m ) is greater than at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m), wherein the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0134] In another aspect, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first plurality of fibers. m )The maximum creep relaxation temperature (T cr ), wherein the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0135] In another aspect, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first plurality of fibers. m ) Large thermal deformation temperature (T hd ), wherein the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0136] In another aspect, the textile article comprises a second plurality of fibers comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first plurality of fibers. m ) Large Vicat softening temperature (T vs ), wherein the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0137] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is greater than the low processing temperature polymer composition of the first plurality of fibers. m ) Large melting temperature (T m ), wherein the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0138] In certain aspects, a textile article is provided, comprising a melted yarn component that is thermoformed from a first state as a first yarn to a second state as a melted yarn component (i.e., a component formed from a yarn that has been at least partially melted and resolidified into a new form that is different from its yarn form). The first yarn comprises a low processing temperature polymer composition. It will be understood that the melted yarn component may include structures such as a partially melted first yarn, a substantially completely melted first yarn, and mixtures thereof. The knitted article may also include a second yarn comprising a high processing temperature polymer composition. Optionally, the melted yarn component and the second yarn at least partially form a structure having at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. The first zone contains a higher concentration of the second yarn than the second zone, and the third zone contains a higher concentration of the melted yarn component than 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 portion of the outer surface.

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

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

[0141] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the low processing temperature polymer composition in the first yarn. m )The maximum creep relaxation temperature (T cr), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0142] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the low processing temperature polymer composition in the first yarn. m ) Large thermal deformation temperature (T hd ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

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

[0144] In another aspect, the textile article includes a second yarn comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the low processing temperature polymer composition in the first yarn. m ) Large melting temperature (T m ), the first yarn is transformed from a first state as a first yarn to a second state as a melted yarn component.

[0145] In some aspects, the textile article is a knitted article comprising a plurality of interconnected rows. Each row of the plurality of interconnected rows comprises a first yarn and a second yarn. The first yarn comprises a low-processing temperature polymer composition. The second yarn comprises a high-processing temperature polymer composition. The knitted article further comprises at least one knit layer comprising at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. Each row of the plurality of interconnected rows 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 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. In addition, the knitted article comprises an anchor yarn extending through at least a portion of the third zone. The anchor yarn comprises a high-processing temperature polymer composition, for example, a fiber formed from a high-processing temperature polymer composition. The anchor yarn exhibits an elongation that is less than the elongation of the first yarn.

[0146] In addition to textiles and articles comprising textiles, the present disclosure also relates to articles comprising a melted film component that is thermoformed from a first state as a film to a second state as a melted film (i.e., a film comprising a low processing temperature polymeric material, wherein at least a portion of the low processing temperature polymeric material of the film has melted and resolidified on a substrate into a new form that is different from its film form). The article may also include a high processing temperature composition. Optionally, the melted 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 contains a higher concentration of the high processing temperature composition than the second zone, and the third zone contains a higher concentration of the melted film component than 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 portion of the outer surface.

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

[0148] In various aspects, the article comprises a second element (e.g., a formed part, film, textile, fiber, yarn) comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the melting film part's low processing temperature polymer composition. m ) is greater than at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0149] In another aspect, the article includes a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the melting temperature polymer composition of the film component. m )The maximum creep relaxation temperature (T cr ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0150] In another aspect, the article includes a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the melting temperature polymer composition of the film component. m ) Large thermal deformation temperature (T hd ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0151] In another aspect, the article includes a second element comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is lower than the melting temperature polymer composition of the film component. m ) Large Vicat softening temperature (T vs ), the melted film member is transformed from a first state as a film to a second state as a melted film member.

[0152] In another aspect, the textile article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first plurality of fibers. m ) Large melting temperature (T m ), wherein the first plurality of fibers transitions from a first state as a first plurality of fibers to a second state as a melted fibrous member.

[0153] The present disclosure also relates to an article comprising a first polymeric component comprising a melt zone, the melt zone being thermoformed from a first state as a formed component to a second state as a molten formed component (i.e., the formed component comprises a low processing temperature polymeric material, wherein at least a portion of the low processing temperature polymeric material has melted and resolidified into a new form that is different from its original formed part form). The first component may also comprise a region formed by a high processing temperature. Alternatively or additionally, the article may also comprise a second component comprising a high processing temperature polymer composition.

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

[0155] In various aspects, the article comprises a second element (e.g., a shaped part, film, textile, fiber, yarn) comprising a high processing temperature polymer composition that exhibits a melting temperature (T) that is greater than the low processing temperature polymer composition of the first shaped part.m ) is greater than at least one of the following: (1) creep relaxation temperature (T cr ); (2) thermal deformation temperature (T hd ); (3) Vicat softening temperature (T vs ); or (4) melting temperature (T m ), the first formed part is transformed from a first state as a formed part to a second state as a molten formed part.

[0156] In another aspect, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first formed part. m )The maximum creep relaxation temperature (T cr ), the first formed part is transformed from a first state as a first formed part to a second state as a molten formed part.

[0157] In another aspect, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first shaped element. m ) Large thermal deformation temperature (T hd ), the first forming element is transformed from a first state as a forming element to a second state as a molten forming part.

[0158] In another aspect, the article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first shaped element. m ) Large Vicat softening temperature (T vs ), the first forming element is transformed from a first state as a first forming element to a second state as a molten forming part.

[0159] In another aspect, the textile article comprises a second element comprising a high processing temperature polymer composition exhibiting a melting temperature (T) greater than that of the low processing temperature polymer composition of the first plurality of fibers. m ) Large melting temperature (T m ), wherein the first plurality of fibers are transformed from a first state as a first formed part to a second state as a molten formed part.

[0160] In one aspect, a knitted upper for a footwear article is provided, the knitted upper comprising a first yarn comprising a low-processing temperature polymer composition. The knitted upper for a footwear article further comprises 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 knit layer of the knitted upper for a footwear article, the at least one knit layer having at least a first zone, a second zone, and a third zone, the second zone being positioned between the first and third zones, 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, this structure can form an exterior surface of an article, wherein the first zone, the second zone, and the third zone each form a portion of the exterior surface.

[0161] In certain aspects, a knitted upper for a footwear article is provided, the knitted upper comprising a melted yarn component comprising a low-processing temperature polymer composition. The melted yarn component is thermoformed from a first state as a first yarn to a second state as a melted yarn component. The knitted upper for a footwear article further comprises a second yarn comprising a high-processing temperature polymer composition. The melted yarn component and the second yarn at least partially form a surface having at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. The first zone comprises a higher concentration of the second yarn than the second zone, and the third zone comprises a higher concentration of the melted yarn component than the second zone. In some examples, this structure can form an outer surface of an article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface.

[0162] In some aspects, the article of wear is a footwear article, including, but not limited to, articles such as shoes. A footwear article generally comprises an upper and a sole structure. The upper provides a covering for the foot that comfortably receives the foot and securely positions the foot relative to the sole structure. In addition, the upper generally provides protection for the foot. The sole structure can provide various support, cushioning, and shock absorption. The sole structure is secured to the 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 ambulatory activities, the sole structure can, for example, influence foot motion (e.g., by resisting inward rotation), impart stability, and provide grip. Thus, the upper and sole structure operate in tandem to provide a comfortable structure suitable for a wide variety of athletic activities.

[0163] The upper forms a structure that provides a covering for some or all of the wearer's foot and positions the foot relative to the sole structure of that shoe. The upper forms holes on the interior of the shoe for receiving the foot. The holes have the general shape of the foot and provide access to the holes at the ankle opening. In some aspects, the upper extends over the instep and toe areas of the foot, along the middle and sides of the foot, and around the heel area of ​​the foot. The upper can have any design, shape, size, and / or color. For example, in some aspects, such as if the product is a basketball shoe, the upper can be a high-top upper shaped to provide high support to the ankle. Alternatively, in some aspects, such as if the product is a running shoe, the upper can be a low-top upper.

[0164] The upper may also incorporate a lacing system to adjust the fit of the shoe and to allow the foot to enter and remove the foot from the holes in the upper. Lacing systems are often incorporated into the upper to selectively change the size of the ankle opening and allow the wearer to modify certain dimensions of the upper (particularly girth) to accommodate feet of different sizes. In addition, the upper may include a tongue that extends under the lacing system to improve the comfort of the shoe (for example, to adjust the pressure applied to the foot through the laces), and the upper may also include a heel counter to limit or control the movement of the heel. In addition, the upper may include a tongue that extends under the lacing system to improve the adaptability and comfort of the shoe, and the upper may incorporate a heel counter.

[0165] In some respects, sole structure can comprise one or more parts or layers, and described one or more parts or layers can provide some attributes to footwear products individually or jointly, for example support, rigidity, flexibility, stability, cushioning, comfort, reduced weight or other attributes. In some respects, sole structure can comprise the layer that is called as insole, midsole and outsole. However, in some respects, one or more of these parts can be omitted. In some respects, sole can optionally comprise sole plate. In some respects, sole structure comprises outsole components, and described outsole components comprises the outside major surface that can expose and contact ground, and inner major surface. On the other hand, sole structure can further comprise the midsole components that can be attached to the entire length of the upper along the upper. When existing, midsole forms the intermediate layer of sole structure and is used for multiple purposes, comprises control foot motion and weakens impact force.

[0166] The midsole, which may be attached to the upper along its entire length, forms the middle layer of the sole structure and serves a variety of purposes, including controlling foot motion and attenuating impact forces. Many midsole configurations are primarily formed from a resilient polymer foam material, such as polyurethane (PU) or ethylene vinyl acetate (EVA), that extends across the entire length and width of the shoe. The midsole may also incorporate plates, modulators, fluid-filled chambers, and / or other elements that, for example, further attenuate forces, influence foot motion, and / or impart stability.

[0167] The outsole forms the ground-contacting element of the shoe and is typically formed of a durable, wear-resistant material that includes texture or other features for improving grip. The outsole may be formed of a durable and wear-resistant material (e.g., rubber) that includes texture for improving grip. The outsole may optionally further include cleats.

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

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

[0170] Exemplary Aspects of Articles of Sporting Equipment, Articles of Wear, and Textiles

[0171] As discussed above, some aspects relate to one or more textiles comprising fibers and / or yarns comprising a low processing temperature polymer composition and a high processing temperature polymer composition. In some aspects, such textiles can form at least a portion of a sports equipment article or a clothing article. In some aspects, the disclosed textiles can form at least a portion of a component of a footwear article. In some 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 sneaker.

[0172] Now turn to the diagram, specifically, to Figure 1A and Figure 1B , an article of footwear 100 is depicted as an exemplary article of wear. Figure 1A and Figure 1B An article of footwear 100 is depicted. Although Figure 1A and Figure 1B Article of footwear 100 is depicted, but it should be understood that other articles of wear are also contemplated by the present disclosure. Figure 1A and Figure 1B The article of footwear 100 may generally include a ground-facing outsole region 110, an ankle collar region 112, lateral and medial midfoot regions 114a and 114b, a pull-on region 116, and a heel region 118. In addition, the article of footwear 100 may include a plurality of eyelets 120, an upper region 122, a tongue region 124, and a throat region 126. Figure 1A and Figure 1B As shown, article of footwear 100 is intended for use with a right foot; however, it should be understood that the following discussion may apply equally to a mirror image of article of footwear 100 intended for a left foot.

[0173] exist Figure 1A and Figure 1B 100 can include at least one textile 102 that at least partially forms a portion of article of footwear 100. Textile 102 of article of footwear 100 can include at least three separate textile zones, such as zones 104, 106, and 108, that identify specific functional areas of article of footwear 100. In some aspects, these specific functional areas are at least partially related to the targeted incorporation of specific textile media into these textile zones in varying amounts, techniques, and combinations (e.g., zones 104, 106, and 108). Figure 1A and Figure 1B It should be understood that while textile 102 includes three specific functional regions, more than three functional regions are also contemplated.

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

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

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

[0177] Furthermore, in these aspects, textile region 106 can exhibit less rigidity or semi-rigidity than textile region 104 but more rigidity than textile region 108. Also, in the same or alternative aspects, textile region 106 can exhibit less flexibility than textile region 108 but more flexibility than textile region 104.

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

[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 the article of footwear 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 the article of footwear 100.

[0180] In some respects, such as Figure 1A 1. As seen in FIG. 1, textile region 106 extends away from textile region 104 toward eyelet 120. In these aspects, the combination of a textile medium comprising a low-processing-temperature polymer composition and a textile medium comprising a high-processing-temperature polymer composition can allow forces transmitted from eyelet 120 or other lacing mechanisms to be transferred to this combination of textile media present in lateral midfoot region 114a and / or medial midfoot region 114b. In certain aspects, to successfully transfer forces transmitted from eyelet 120, textile region 104 and / or the low-processing-temperature polymer composition present in textile region 104 can terminate at region 128, which, when textile 102 is a knitted textile formed on a commercial knitting machine, 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, at least about 4, or at least about 5 stitches below eyelet 120. In these aspects, the flexible and pliable properties of the high processing temperature polymer composition present in area 108 adjacent to the eyelet 120 can facilitate the transfer of forces transmitted from the eyelet 120 to the textile area 106 and / or the low processing temperature polymer composition present in the lateral midfoot area 114a and / or the medial midfoot area 114b.

[0181] is Figure 1A and Figure 1B In the aspects depicted in FIG, textile zone 106 is positioned in pullover region 116 and 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 wear resistance in pullover region 116 and / or heel region 118. In alternative aspects, textile zone 104 can form at least a portion of pullover region 116 and / or heel region 118 to achieve increased rigidity or increased wear resistance because textile zone 104 includes a greater amount of the low processing temperature polymer composition than textile zone 106 or an alternative positioning of the low processing temperature polymer composition (e.g., an outer knit surface).

[0182] Figure 1CDepicting alternative aspects of article of footwear 100a. In these aspects, article of footwear 100a can generally include at least three types of textile areas: textile area 104a, textile area 106a, and textile area 108a. In certain aspects, textile areas 104a, 106a, and 108a can each have the same characteristics as those described above with reference to FIG. Figure 1A The same properties and parameters of textile areas 104, 106, and 108 of article of footwear 100 are discussed.

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

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

[0185] Figure 2A and Figure 2B Shirt 200 is depicted as an exemplary article of apparel. Figure 2A and Figure 2B The shirt 200 depicted in FIG includes at least one textile 202 that at least partially forms a part of the shirt 200. Figure 2B As best seen in FIG, textile 202 can include three separate textile regions 204, 206a-d, and 208 that can identify specific functional areas of textile 200. In some aspects, these specific functional areas are associated, at least in part, with the targeted incorporation of specific textile media into these textile regions 204, 206a-d, and 208 in varying amounts and combinations.

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

[0187] In various aspects, textile zone 208 can exhibit flexibility and / or pliability similar to conventional shirting materials. In these aspects, textile zone 208 can include or consist solely of a high processing temperature polymer composition. Furthermore, in certain aspects, textile zone 206 can at least partially provide a transition zone within textile 202 from a rigid or semi-rigid patch 210 present in textile zone 204 to a flexible, pliable portion present in textile zone 208. In these aspects, textile zones 206a-d can include a combination of a low processing temperature polymer composition present in textile zone 204 and a high processing temperature polymer composition present in textile zone 208. While in Figure 2A and Figure 2B Not shown, textile regions 206b - d also provide a transition region to a flexible, yielding material such as that present in textile region 208 .

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

[0189] Although Figure 2A and Figure 2B This exemplary description of textile regions 204, 206a-d, and 208 relates to the elbow region of the article of apparel 200, but it should be understood that textile regions 204, 206a-d, and 208 and associated properties may be applicable to other regions of a shirt or other article of apparel (e.g., knees, thighs, buttocks, chest), and / or the lower back region of an article of apparel, or areas requiring reinforcement, such as areas adjacent to fasteners (e.g., zippers, buttons, snap fasteners, drawstrings, etc.).

[0190] Now turn Figure 3, provides a plan view of an illustrative textile 300. It should be understood that textile 300 can be any type of textile known to those skilled in the art. A non-limiting list of textiles suitable for use in the wearing articles and methods disclosed herein includes knitted textiles, woven textiles, non-woven textiles, and braided textiles.

[0191] Similar to Figure 1A and Figure 1B Textiles 102 and Figure 2A and Figure 2B Textiles 202, Figure 3 The textile 300 includes three types of textile regions. For example, the textile 300 includes: a textile region 302, which may include fibers and / or yarns including 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 including a low processing temperature polymer composition and fibers and / or yarns including a high processing temperature polymer composition. Figure 3 In textile 300 , textile regions 304 a and 304 b may be positioned on either side of textile region 302 , while textile regions 306 a and 306 b may be positioned on opposite sides of textile regions 304 and 304 b , respectively.

[0192] In certain aspects, the fibers and / or yarns comprising the low processing temperature polymer composition present in textile region 302, when exposed to a thermoforming process, can impart structural or functional properties to textile 300 that can be used to form an article of wear. For example, textile region 302 can represent a region that forms at least a portion of ground-facing outsole 112. Figure 1A and Figure 1B In various aspects, the fibers and / or yarns comprising the high processing temperature polymer composition present in 306a and 306b can be added to the textile 300 (e.g., at Figure 1A and Figure 1B). Furthermore, in various aspects, textile zones 304a and 304b may include a combination of fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile zone 302 and fibers and / or yarns comprising a high-processing-temperature polymer composition present in textile zones 306a and 306b to provide structural support and three-dimensional structure for a particular article of wear. Furthermore, as discussed above, in certain aspects, this 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 textile zones 304a and 304b may provide an integrated transition between the rigid thermoformable material in textile zone 302 and the flexible, pliable high-processing-temperature polymer composition in textile zones 306a and 306b.

[0193] In one or more aspects, textile zones 304a and 304b can include multiple sub-zones, such as sub-zones 305a, 305b, 305c, and 305d of textile zone 304a, which can include different combinations and / or different positioning of fibers and / or yarns comprising low-processing temperature polymer compositions and fibers and / or yarns comprising high-processing temperature polymer compositions. In certain aspects, sub-zone 305a can include fibers and / or yarns comprising low-processing temperature polymer compositions, but does not include fibers and / or yarns comprising high-processing temperature polymer compositions present in textile zones 306a and / or 306b. In the same or alternative aspects, sub-zone 305d can include fibers and / or yarns comprising high-processing temperature polymer compositions, but does not include fibers and / or yarns comprising low-processing temperature polymer compositions present in textile zone 302.

[0194] It should be understood that although only a sub-area of ​​textile zone 304a may be further described herein, such descriptions apply to sub-areas present in textile zone 304b. Furthermore, it should be understood that if only textile zones 304a and / or 306a are further discussed in certain descriptions, such descriptions also apply to textile zones 304b and 306b, respectively.

[0195] In some aspects, based on the relative positioning 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 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, and 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) in a knitted textile (e.g., by weight in grams). For example, in a knitted textile, a first portion of a single knit layer of the textile can have an increased concentration of a first yarn compared to a second portion of the textile by having more stitches (e.g., knit stitches, tuck stitches, and / or float stitches) of the first yarn than the second portion of equal size. In another example, in a nonwoven textile, a first portion of the textile can have an increased concentration of the first fiber if the first portion is formed to have more first fibers (e.g., by weight in grams) than a second portion of equal size.

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

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

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

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

[0201] Figures 4A to 4D Schematically depict exemplary cross-sections of textile regions 302, 304a, and 306a of textile 300. In general, Figure 4A An exemplary cross-section from 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 An exemplary cross-section from 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 exemplary cross-sections from textile region 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 region 304a.

[0202] The textile 300 will now be described from the perspective of being a knitted textile. Figures 4A to 4D The cross-section depicted in FIG. The various processes used to form knitted textiles and the types of yarns that can be used are discussed in detail below. It is expected that a variety of knitting techniques can be implemented to achieve the described results. For example, in some aspects, a purl stitch can be used instead of a "knit stitch" to achieve comparable results with different aesthetics and / or textures. For simplicity, the "knit stitch" will be discussed herein, but it is expected that functional equivalents can be substituted. Similarly, a "tuck stitch" can be discussed in certain aspects, but it is also expected that alternative stitch techniques can be implemented to achieve comparable results. Although relatively simple knit structures are depicted and discussed, a large number of warp knit and weft knit structures can be formed by (for example) flat knitting, wide tube circular knitting, narrow tube circular knitting jacquard, single knit circular knitting jacquard, double knit circular knitting jacquard, double needle comb raschel, warp knitting jacquard and warp knitting.

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

[0204] Figures 5A to 5J Describing the possible existence of Figures 4A to 4D Exemplary potential knit structures in various segments of the cross-section depicted in FIG. Figure 5A Depicts a lower needle (or sometimes referred to as a flat stitch) structure 502 formed by a back needle bed 504. It should be understood that the row of small circles associated with the back needle bed 504 represents the needles (e.g., needle 505) of the back needle bed 504, according to conventional stitch diagrams. Additionally, for the front needle bed, e.g., Figure 5B The same is true for the front needle bed 508 depicted in FIG; that is, the row of small circles associated with the front needle bed 508 represents the needles in the front needle bed 508 (eg, needle 507 ).

[0205] Figure 5B A lower needle structure 506 formed by a front needle bed 508 is depicted. Figure 5C A float stitch and tuck stitch structure 510 is depicted having a tuck stitch formed by a front needle bed 512 and a back needle bed 514 . Figure 5D Another float stitch and tuck stitch structure 516 is depicted having a tuck stitch formed by a front needle bed 518 and a back needle bed 520 . Figure 5E A floating line tissue structure 522 is depicted. Figure 5F A drop stitch and tuck stitch structure 524 is depicted having drop stitches 524a formed by a back needle bed 528 and tuck stitches 524b formed by a front needle bed 526 . Figure 5G A drop stitch and float stitch structure 530 is depicted, wherein the drop stitch is formed on a front needle bed 532 . Figure 5HA drop stitch and float stitch structure 534 is depicted, wherein the drop stitch is formed on a back needle bed 536 . Figure 5I A tuck and floating knit structure 538 is depicted, wherein the tuck stitch is formed by a front needle bed 540 . Figure 5J A tuck and floating knit structure 542 is depicted, wherein the tuck stitch is formed by a back needle bed 544 .

[0206] Returning now to cross-sections 4A-4D of textile 300, in general, the cross-sections depicted in 4A-4D are similarly structured due to the primary structure of a knitted textile. For example, in various aspects, there is a tubular knit structure comprising a knit structure primarily formed by the back needle bed (e.g., at Figure 5A ) and the knitted structure formed mainly on the front needle bed (e.g., Figure 5B ). In addition, in these aspects, the tubular knit structure is connected via one or more tuck stitch and float stitch structures, wherein the tuck stitch is formed by the rear needle bed and the front needle bed (e.g., at Figure 5C and Figure 5D tuck and float structures 510 and 516 depicted in FIG.

[0207] This connected tubular knit structure is schematically depicted by the three horizontal rows highlighted in the cross-sections depicted in 4A-4D. For example, Figure 4A Describing a high processing temperature polymer composition Figure 3 A cross-section 402 of the textile region 306a.

[0208] Figure 4A The cross section 402 schematically depicts a top segment 404, a middle segment 406, and a bottom segment 408. The top segment 404 and the bottom segment 408 represent the knitting structure used to form the tubular knitting structure, while the middle segment 406 represents the tuck stitch and float stitch structures used to connect the tubular knitting structure together. Figure 5A and Figure 5F One or more of the knitted structures 502 and 524 depicted in FIG. The bottom segment 408 may be included in Figure 5B The knitted structure 506 is depicted in FIG. The middle section 406 may include Figure 5C and Figure 5D One or more of the knitted structures 510 and 516 depicted in .

[0209] Figure 4B Depicts a cross section 410 of a textile region 302 comprising yarn comprising a low processing temperature polymer composition. The cross section 410 comprises a top section 412, a middle section 414, and a bottom section 416, which may comprise the components described above with respect to Figure 4AThe same knit structure is identified in the top segment 404, the middle segment 406 and the bottom segment 408 of the cross-section 402.

[0210] In some aspects, it may be desirable to expand the low processing temperature polymer composition in the textile zone 302 in order to provide the desired thickness and rigidity to the thermoformed textile zone 302, for example, to form a ground-facing outsole for an article of footwear. In these aspects, the textile zone 302 may include repeated stitches to increase the concentration of yarns comprising the low processing temperature polymer composition relative to other textile zones (e.g., textile zones 304a and / or 306a). In some aspects, repeated stitches may be provided, for example, by including multiple stitch structures in any or all of the top segment 412, the middle segment 414, and the bottom segment 416 of the cross-section 410. In one example, a plurality of overlapping tuck stitch and float stitch structures may be provided in the middle segment 414 of the cross-section 410 (e.g., in the Figure 5C 、 Figure 5D 、 Figure 5I and Figure 5J structure depicted in ).

[0211] In certain aspects, in regions of textile 300 that include a plurality of yarns comprising a low processing temperature polymer composition (e.g., textile region 302), anchor yarns 413 can be provided in textile 300 to help constrain the flow of the molten low processing temperature polymer composition and / or provide some flexibility to the thermoformed material. Figure 4B , anchor yarns 413 are depicted as being present in intermediate segment 414 between top segment 412 and bottom segment 416, respectively. In these aspects, this positioning of anchor yarns 413 can result in embedding or encapsulating anchor yarns 413 with a low processing temperature polymer composition after thermoforming of textile 300.

[0212] Although it will Figure 4B The anchor yarn 413 in FIG is depicted as a straight line, but it should be understood that this is a schematic representation of the anchor yarn 413 and is not intended to specify any particular type of knit structure. For example, the anchor yarn 413 can be present in the textile 300 as many different types of knit structures, such as in FIG. Figure 5E and Figure 5G-J. In certain aspects, the stitch selection for anchor yarn 413 can depend on the desired resistance to elongation of the material through which anchor yarn 413 extends. For example, an anchor yarn stitch that floats five stitches between tuck stitches or bottom stitches will provide greater resistance to stretching of the material through which anchor yarn 413 extends than an anchor yarn stitch that floats only two or three stitches between tuck stitches or bottom stitches. In this example, the different resistance to elongation between the floating lengths is due to the nonlinear portions (e.g., stitch loops) that are more easily elongated than linear segments, resulting in different amounts of resistance to elongation.

[0213] In some aspects, when the anchor yarn 413 is used as Figure 5G -J, the anchor yarn 413 extends as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low processing temperature polymer composition, because the yarn comprising the low processing temperature polymer composition also serves as a Figure 5A and Figure 5B In some aspects, anchor yarn 413 may be present in one or more of the knitted structures of textile 300. Furthermore, in some aspects, anchor yarn 413 may extend as a float stitch along at least two, at least three, at least four, or at least five adjacent stitches of a yarn comprising a low-processing-temperature polymer composition, and the yarn comprising a low-processing-temperature polymer composition may also be used to form at least a portion of a tuck stitch and / or a knit stitch. In these aspects, anchor yarn 413 may extend along at least two, at least three, at least four, or at least five adjacent stitches of the yarn comprising a low-processing-temperature polymer composition, at least partially forming the length between the tuck stitch or the knit stitch. In the same or alternative aspects, anchor yarn 413 may be tied at stitches spaced apart by an amount within 50% or within 25% of the gauge of the knitting machine used to form at least a portion of textile 300, as represented by the number of needles in a typical needle bed. For example, the tuck stitch or the knit stitch may be formed at least partially using the yarn comprising a low-processing-temperature polymer composition and the anchor yarn.

[0214] Figure 4C and Figure 4D Depicts a cross section of textile region 304a and portions of textile regions 302 and 306a. For example, Figure 4C Cross section 418 of textile 300 includes portion 422 corresponding to textile region 302 and portion 420 corresponding to textile region 306a. Portions 424a, 424b, 424c, and 424d correspond to sub-regions 305a, 305b, 305c, and 305d, respectively, of textile region 304a of textile 300. Figures 4C to 4Ecross-section; however, it is contemplated that one or more regions and / or portions of the cross-section may contain a variety of fibers and / or yarns in different configurations and concentrations. For example, weave zone 424c in middle segment 428 may include both fibers and / or yarns comprising a low processing temperature polymer composition and fibers and / or yarns comprising a high processing temperature polymer composition, but in a different configuration / concentration than that in weave zones 424b and / or 424d of middle segment 428. In other words, various construction techniques allow for different combinations of fibers and / or yarns in a given segment and weave zone by varying the methods of combining, including, attaching, depositing, or applying fibers and / or yarns (e.g., stitch selection), which allows for varying fiber and / or yarn concentrations at the segment level and / or weave zone level.

[0215] Figure 4C The cross section 418 includes the above Figure 4A and Figure 4B The cross-section 418 may include the same type of generally tubular knitted structure discussed above with reference to cross-sections 402 and 410. Thus, the cross-section 418 includes a top section 426, a middle section 428, and a bottom section 430. The top section 426, the middle section 428, and the bottom section 430 may each include the same type of generally tubular knitted structure discussed above with reference to cross-sections 402 and 410. Figure 4A The same knit structure discussed above is shown with reference to the top segment 404, the middle segment 406, and the bottom segment 408 of the cross-section 402.

[0216] exist Figure 4C In cross-section 418, sections 422 and 424a comprise knitted structures made using yarns comprising a low processing temperature polymer composition, while sections 420, 424d, and 424c comprise knitted structures made using yarns comprising a high processing temperature polymer composition. However, as provided above, it is contemplated that combinations of fibers and / or yarns based on different stitch technologies may be implemented in various sections to achieve a transition from one primary material to another.

[0217] Section 424b comprises a tubular knit structure made from yarn comprising a high-processing temperature polymer composition; however, the knit structure formed by the front and rear needle beds (using yarn comprising a high-processing temperature polymer composition) is connected via a float stitch and a tuck stitch (or equivalent effective stitch) from yarn comprising a low-processing temperature polymer composition. This section 424b illustrates how, once textile 300 is thermoformed, the low-processing temperature polymer composition, upon melting and solidifying, can physically connect the two outer knit layers together via a panel or film of thermoformed material. In these aspects, a wearing article having this type of tubular knit structure that has been thermoformed and connected via an integral thermoformed material would primarily comprise typical knit yarn layers connected together via a thermoformed film on opposing outer surfaces of the textile. This structure can be utilized to provide waterproof / water-resistant or other weather-resistant properties to a wearing article while still maintaining the typical knitted article aesthetics and feel.

[0218] and Figure 4C The cross section 418 is the same as that of Figure 4D Cross-section 432 of textile 300 includes portion 436 corresponding to textile area 302 and portion 434 corresponding to textile area 306a. Portions 438a, 438b, 438c, and 438d correspond to sub-regions 305a, 305b, 305c, and 305d, respectively, of textile area 304a of textile 300.

[0219] Figure 4D The top region 440, the middle region 442 and the bottom region 444 of the cross section 432 may respectively include the above reference Figure 4A The top segment 404, the middle segment 406, and the bottom segment 408 of the cross-section 402 of FIG. 4 are the same knitted structures discussed above so as to provide the same type of generally tubular structure.

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

[0221] Section 438c comprises a tubular structure using yarn comprising a low-processing temperature polymer composition, connected via a float stitch and a tuck stitch from yarn comprising a high-processing temperature polymer composition. In these aspects, after thermoforming, this section 438c can encapsulate the yarn comprising the high-processing temperature polymer composition within a panel of melted and cooled thermoformed material. In certain aspects, such a structure can provide some flexibility to an otherwise rigid thermoformed material.

[0222] For example, Figure 4E Describing and Figure 4D The cross-section 432 is the same as the cross-section 446 except that an anchor yarn 448 has been added to at least a portion of the zone containing yarns comprising the low processing temperature polymer composition. In certain aspects, the anchor yarn 448 can have the same cross-section 446 as described above with respect to Figure 4B For example, anchor yarns may be incorporated into a fabric used in a Figure 5E and Figure 5G -In a textile having one or more of the knitted structures described in J.

[0223] Can be Figure 4E , anchor yarn 448 extends from portion 450 corresponding to cross-section 446 of textile region 302 and into portions 452a and 452b corresponding to sub-regions 305a and 305b of textile region 304a. Figure 4E Description of the yarn comprising the low processing temperature polymer composition is also present (e.g., as a yarn having a Figure 5A and Figure 5BIn some aspects, the anchor yarn 448 may extend along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low processing temperature polymer composition as a float. Furthermore, in some aspects, the anchor yarn 448 may extend along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low processing temperature polymer composition as a float, and the yarn comprising the low processing temperature polymer composition may also be used to form at least a portion of a tuck stitch and / or a lower stitch. In these aspects, between at least partially forming the tuck stitch or lower stitch using the yarn comprising the low processing temperature polymer composition and the anchor yarn 448, the anchor yarn 448 may 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, anchor yarn 448 can be tucked at stitches spaced apart by a number of stitches within 50% or within 25% of the gauge of a knitting machine used to form at least a portion of textile 300, e.g., tuck stitch or down stitch.

[0224] As discussed above, in one or more aspects, the anchor yarn 448 can extend from the textile region 302 toward the textile region 306a into the textile region 304a. In these aspects, the anchor yarn 448 can extend less from the textile region 302 toward the textile region 306a into the textile region 304a than the yarn comprising the low processing temperature polymer composition extends toward the textile region 306a into the textile region 304a because there is less need to restrict flow and / or provide flexibility to the thermoformed material during thermoforming because the yarn comprising the high processing temperature polymer composition from the region 306a is also present in the textile region 304a.

[0225] For example, in Figure 4E In cross-section 446 of FIG. 4 , anchor yarns extend from portion 450 (corresponding to a portion of textile region 302) and into portion 452b (corresponding to sub-region 305b of textile 300). Furthermore, cross-section 446 illustrates that top segment 456 and bottom segment 460 of cross-section 446 show that yarns comprising a low processing temperature polymer composition extend from portion 450 toward portion 454 (corresponding to textile region 406a) into portion 452c, exceeding the extension of anchor yarn 448 in the same direction. However, in middle segment 458, in portions 452c and 452d, yarns comprising a high processing temperature polymer composition are present, which can provide flexibility to the thermoformed textile and / or restrict flow during thermoforming.

[0226] As discussed above, in certain aspects, when textile 300 is a knitted textile, Figures 4A to 4E The cross-section of the textile depicted in is depicted as having a top segment, a bottom segment, and a middle segment, wherein the top segment and the bottom segment can form a tubular knit structure having a top knit layer and a bottom knit layer (and wherein the tuck stitch or other connecting stitches present in the middle segment can also form part of the tubular or general knit structure). In these aspects, each of the top and bottom outer knit layers can include a plurality of interconnected courses.

[0227] In addition, Figure 3 In textile 300, it can be seen that in region 304a, subregions 305a-d have at least one staggered interface, e.g., staggered interface 306. Staggered interfaces, e.g., staggered interface 306, provide staggered or nonlinear transitions between subregions of textile 300 along the width w of textile 300. In these aspects, when textile 300 is thermoformed, these staggered interfaces provide a more refined, integrated transition between the rigid region formed by the low-processing-temperature polymer composition in textile region 302 and the flexible, pliable region formed by yarns comprising the high-processing-temperature polymer composition in textile region 306a. In various aspects, this refined, integrated transition, provided at least in part by the staggered interfaces, can increase the durability or tear strength of thermoformed textile 300, as compared to similar textiles that have a linear, abrupt transition between a unitary rigid material and a flexible material.

[0228] In the case where the textile 300 is a knitted textile, the interlaced interface 306 can depict how different rows of yarn on the top or bottom outer knit layer can have different amounts of loops (or general stitch selections) of yarn comprising a low processing temperature polymer composition and / or yarn comprising a high processing temperature polymer composition. Because a textile can have multiple layers (e.g., top, middle, and bottom), the interlaced interface can be found in any combination of layers and is not limited to the exposed or depicted surfaces. Alternatively, as provided herein and as contemplated, a transition region from a first primary material (e.g., fibers and / or yarn comprising a high processing temperature polymer composition) to a second primary material (e.g., fibers and / or yarn comprising a low processing temperature polymer composition) forms the textile, and the transition region can occur only at the middle layer or at a combination of the middle layer and one or more outer layers. It should be understood that for the purposes of the following discussion of the knit layer, it is assumed that when Figure 3 When textile 300 is a knitted textile, the view of textile 300 depicts the top layer. In addition, the same description also applies to the bottom knitted layer.

[0229] Figure 6 An exemplary portion 600 of the top layer of textile 300 is schematically depicted, showing a portion of interlaced interface 306. Figure 6As can be seen in section 600, a first row 602 of coils is interconnected to a second row 604 of coils. It should be understood that although Figure 6 Only two interconnected courses are depicted in , but more than two courses may be interconnected in the top knit layer of textile 300. As used herein, "interconnected" when referring to interconnected courses refers to how at least a portion of the stitches in a first course are tied to at least a portion of the stitches in a second course. Figure 6 , wherein individual stitches from the second course 604 are intertwined with individual stitches from the first course 602. As used herein, "intertwined" refers to how stitches from one course can wrap around stitches from another course, for example, in the knitting process, and also refers to how one stitch can have another length of yarn passed through the stitch (or through the stitch and around the yarn forming the stitch) to form a second stitch, for example, during the serging process.

[0230] In portion 600 of textile 300, it can be seen that first course 602 and second course 604 include two types of yarn: first yarn 606, which may include a high processing temperature polymer composition, and second yarn 608, which may include a low processing temperature polymer composition. Although only two courses are depicted in portion 600, it should be understood that the top knit layer of textile 300 may include any number of courses. In various aspects, each of the courses present in the top knit layer of textile 300 may include two or more types of yarn, such as Figure 6 Depicted in.

[0231] exist Figure 6 As can be seen in FIG, each course, for example, first course 602 and second course 604, can extend from textile region 302 to textile region 306a (in various aspects, each of the courses can extend from textile region 306a to textile region 306b). Figure 6 6, second yarn 608 in first course 602 and second course 604 can extend from weaving region 302 into weaving region 304a. In the same or alternative aspects, first yarn 606 can extend from weaving region 304a into weaving region 306a. It should be understood that although schematic portion 600 of textile 300 depicts each loop as having only a single yarn, more than one yarn can be present at one or more loops (e.g., another yarn can be present at the same loop). Figure 6 The loops of part 600 form a tuck structure), such as Figures 4A to 4E depicted in cross section.

[0232] As discussed above, portion 600 of the outer knit layer of textile 300 illustrates at least a portion of interlaced interface 306. In some aspects, interlaced interface 306 (and any other interlaced interfaces) can be formed by the same type of yarn in multiple courses extending different distances from one region (or sub-region) into the next region or sub-region. Figure 6 As can be seen in the figure, in first course 602, second yarn 608 extends further from weaving area 302 toward weaving area 306a into weaving area 304a than second yarn 608 extends from weaving area 302 toward weaving area 306a into weaving area 304a. In these aspects, the different distances that second yarn 608 extends into weaving area 304a result in different amounts of loops of second yarn 608 in each of first course 602 and second course 604, which can vary the concentration of yarn in a given area / sub-area. Thus, in these aspects, within weaving area 304a, the loops of second yarn 608 in first course 602 can interlace with the loops of second yarn 608 in first course 602 at first ridge 608, while at second ridge 610, second yarn 608 in first course 602 can interlace with the loops of first yarn 604 in first course 602. In the same or alternative aspects, within weave zone 304a, first yarn 604 in first course 602 can be interlocked with first yarn 604 in second course 604 at third rib 612.

[0233] In one or more aspects, a staggered interface, such as staggered interface 306, can result in adjacent courses of the plurality of courses in textile 300 having different numbers of stitches of yarn comprising a low processing temperature polymer composition and yarn comprising a high processing temperature polymer composition. Figure 6 As can be seen in portion 600 of the upper knit layer of textile 300 depicted in FIG, in at least a portion of textile area 304a, first course 602 has a different number of stitches of first yarn 606 and / or second yarn 608 than second course 604. Additionally, in the same or alternative aspects, within at least a portion of textile area 304a, adjacent ribs can have one or more stitches of different yarns. For example, Figure 6 As illustrated in portion 600 of the upper knit layer of textile 300 in FIG, rib 610 includes loops of both first yarn 606 and second yarn 608 , while rib 612 includes loops of first yarn 606 .

[0234] As discussed above, the textiles described herein, which may include fibers and / or yarns comprising a low processing temperature polymer composition, may be thermoformed to impart certain structural properties to the article of wear. Furthermore, as discussed above, the thermoforming process may cause at least a portion of the low processing temperature polymer composition present in the textile to melt or deform and subsequently solidify.

[0235] Figure 7A Schematic depiction of the process before thermoforming Figure 3 3. Portion 700 of textile region 304a of an upper knit layer of textile 300. Portion 700 includes a first course 702 and a second course 704 having a first yarn 708 including a high processing temperature polymer composition. The portion also includes a third course 706 of second yarn 710 including a low processing temperature polymer composition. In this regard, third course 706 of loops of second yarn 710 can be interconnected (e.g., intertwined) to first course 702 and second course 707 having first yarn 708.

[0236] Figure 7B Depicted is portion 700 after exposure to a thermoforming process. By comparison Figure 7A and Figure 7B It can be seen that the second yarn 710 comprising the low processing temperature polymer composition is thermoformed from the yarn material into a molten yarn component 712. In certain aspects, the heating step of the thermoforming process causes, at least in part, the low processing temperature polymer composition in the second yarn 710 to melt and flow, and then subsequently solidify into the molten yarn component 712 by completing the thermoforming process.

[0237] In all aspects, Figure 7A and Figure 7B As can be seen, the hot forming process has also changed Figure 3 At least a portion of the knitted structure of the portion 700 of the upper knitted layer of the textile 300 has been transformed. Figure 7A , such that portion 700 no longer comprises interconnected courses of yarn comprising a low processing temperature polymer composition and yarn comprising a high processing temperature polymer composition, at least in part due to the conversion of yarn 710 in second course 706 to melted yarn component 712. Figure 7B As can be seen in the figure, although the hot forming process can eliminate Figure 3 The interconnected loops in the portion 700 of the upper knit layer of the textile 300 may be connected by the remaining courses 702 and 704 via the melted yarn components 712. Figure 3This portion 700 of the upper knit layer of textile 300 can fix the positions of courses 702 and 704 relative to each other, as opposed to when courses 702 and 704 are interconnected via course 706 prior to thermoforming. Furthermore, in these aspects, top portions 714 of the stitches 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 described in Figure 3 A cross section of a portion 700 of the upper knitted layer of the textile 300. Figure 8 , at least a portion of the first yarn 708 can be encapsulated within the 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] is 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 FIG. Figure 7B and Figure 8 As can be seen in FIG. 5 , there is no visible leaching of the dye 716 from the first yarn 708 into adjacent regions (e.g., adjacent regions 718) of the melted yarn component 712. In certain aspects, at least about 80%, at least about 90%, at least about 95%, or at least 99% by weight of the dye 716 remains within or within the first yarn 708. Figure 3 In the thermoformed portion 700 of the upper knit layer of the textile 300. 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] Figure 9A and Figure 9B Describe one aspect, Figure 3 The portion 700 of the upper knit layer of the textile 300 is exposed to a thermoforming process that only causes deformation of the low processing temperature polymer composition in the second yarn 710 without eliminating Figure 7AAs used herein, "texturing" in the context of a thermoforming process for a knitted textile refers to modifying the structure of the yarn so that the yarn does not melt and flow in a manner that substantially eliminates the knit structure of the textile (e.g., eliminating one or more interconnected loops or nested rows).

[0241] Figure 9A Depicts the thermoforming process along section line 9A-B prior to the thermoforming process. Figure 3 a cross-section of a portion 700 of the upper knit layer of the textile 300, and Figure 9B Depicted is the same cross section after the thermoforming process. Figure 9B , after exposure to the thermoforming process, the second yarn 710 in the third course 706 has a modified yarn structure 710a, while the structure of the first yarn 708 has not been modified. In this regard, the second yarn 710 in the third course 706 remains interlaced with the first course 702 and the second course 704, and maintains Figure 3 The overall knit structure of portion 700 of the upper knit layer of textile 300 .

[0242] In some aspects, this modified yarn structure 710a can result in a 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 above the glass transition temperature T of the low processing temperature polymer composition. g In some embodiments, the second yarn 710 is subjected to an elevated temperature, but not greater 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 pliable but not melt, thereby allowing the yarn to slightly mold around at least a portion of an adjacent yarn (e.g., the first yarn 706), and upon cooling, this altered yarn structure can be mechanically locked in place to physically bond to the adjacent yarn.

[0243] Figures 10A to 10C Depicted before and after thermoforming Figure 3 The textile area 302 of the textile 300 is a portion 1000 of the upper knitted layer. Figure 10A Three courses 1010, 1012, 1014 of yarn comprising a low processing temperature polymer composition are depicted. Figure 10A The anchor yarn 1016 is further depicted extending as a float stitch 1016a and a tuck stitch 1016b.

[0244] Figure 10B Depicted after exposure to the thermoforming process Figure 3 The same portion 1000 of the upper knitted layer of the textile area 302 of the textile 300. Figure 10B It can be seen that the interlocking rows of yarns 1010, 1012 and 1014 have been transformed into melted yarn components 1018. Figure 10B and Figure 10C (It is along Figure 10B 10C cross section), it can be seen that the anchor yarn 1016 has maintained its yarn structure and is now encapsulated within the melted yarn component 1018. It should be understood that although Figure 10B The anchoring yarn 1016 will be depicted as being encapsulated within the melted yarn component 1018, but it is also contemplated that the anchoring yarn 1016 can be at least partially embedded within the melted yarn component 1018 such that at least a portion of the anchoring yarn 1016 is not completely covered in the melted yarn component 1018.

[0245] As discussed above, in certain aspects, the textiles described herein may comprise knitted textiles, e.g., Figures 4A to 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 from a knitted textile. The knitted textile can additionally or alternatively form another element of the footwear article, such as a midsole or a ground-facing outsole. The knitted textile can have a first side forming the inner surface of the upper (e.g., facing the holes of the footwear article) and a second side forming the outer surface of the upper. The upper comprising the knitted textile can substantially surround the holes so as to substantially enclose a person's foot when the footwear article is in use. The first side and the second side of the knitted textile can exhibit different properties (e.g., the first side can provide wear 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 a unitary, 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 knit structure of the knitted textile without requiring significant post-knitting processes or steps. Alternatively, two or more parts of the knitted textile can be formed separately and subsequently attached. In some embodiments, the knitted textile can be formed after the knitting process to form and maintain the desired shape of the shoe upper (e.g., by using a foot-shaped shoe last). The forming process can include attaching the knitted textile to another object (e.g., a label) at a seam by sewing, by using an adhesive, or by another suitable attachment process and / or attaching one part of a knitted component to another part of a knitted component.

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

[0248] Knitted textiles can also provide desirable aesthetic properties by incorporating yarns with different colors or other visual properties arranged in a specific pattern. The yarn and / or knit structure of a knitted textile can be changed at different locations so that the knitted component has two or more parts with different properties (for example, the part forming the throat area of ​​the upper can be relatively elastic, while another part can be relatively inelastic). In some aspects, knitted textiles can be incorporated with one or more materials having properties that change in response to a stimulus (for example, temperature, moisture, electric current, magnetic field, or light).

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

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

[0251] Figures 11A to 11C Describe it Figure 3 The textile 300 is a non-woven textile and is subjected to aspects of a thermoforming process. Figure 11A yes Figure 3 Schematic depiction of portion 1100 of textile region 304a of textile 300 . Figure 11A , portion 1100 includes first fibers 1116 of a high processing temperature polymer composition, second fibers 1112 of first fibers 1116, and third fibers 1114 of a low processing temperature polymer composition. It should be understood that portion 1100 of textile 300 is schematic and that the placement and spacing of first fibers 1116 and second fibers 1118 may vary within the textile.

[0252] Although Figures 11A to 11C Not depicted in FIG, but in aspects where textile 300 is a nonwoven textile, the one or more interfaces between different portions of different fibers can also include one or more staggered interfaces, such as, for example, staggered interface 306. In these aspects, staggered interface 306 can depict how transitions between regions or sub-regions having different concentrations of fibers comprising a low processing temperature polymer composition and / or different concentrations of fibers comprising a high processing temperature polymer composition are not along Figure 3 The width w of textile 300 occurs in a linear manner.

[0253] Now return to Figures 11A to 11C as well as Figure 11C In particular, in aspects where the thermoforming process causes melting and flowing of the low processing temperature polymer composition in the second fibers 1118, the second fibers 1118 have been transformed into the non-fibrous material 1120, while the first fibers 1116 have not been transformed and therefore remain in fibrous form. In these aspects, the non-fibrous material 1120 can join the first grouping 1110 of the first fibers 1116 with the second grouping 1112 of the first fibers 1116. Figure 11C A cross-section along section line 11C is shown, which in certain aspects illustrates how at least a portion of the first fibers 1116 can be encapsulated within the non-fibrous material 1120. In various aspects, it is contemplated that at least a portion of the first fibers 1116 can be at least partially embedded within the non-fibrous material 1120 such that the first fibers 1116 are not completely encapsulated by the non-fibrous material 1120.

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

[0255] Method for manufacturing

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

[0257] The manufacturing methods disclosed herein solve one or more of the aforementioned problems. The manufacturing methods disclosed herein utilize one or more of the formed parts, films, textiles, yarns, and fibers disclosed herein, wherein the one or more formed parts, films, textiles, yarns, and fibers 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 parts, films, textiles, yarns, and fibers disclosed herein, wherein the one or more formed parts, films, textiles, yarns, and fibers include at least one high processing temperature polymer composition as disclosed herein. The disclosed manufacturing methods include a thermoforming step, wherein the low processing temperature polymer composition is softened or melted without melting or softening the high processing temperature polymer composition. The thermoforming is performed within 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 deformation temperature (Thd); or (4) melting temperature (Tm). Thermoforming can be performed within a temperature range below the creep relaxation temperature (Tcr) of the high processing temperature polymer composition. Thermoforming can be performed within a temperature range below the Vicat softening temperature (Tvs) of the high processing temperature polymer composition. Thermoforming can be performed within a temperature range below the heat deformation temperature (Thd) of the high processing temperature polymer composition. Thermoforming can be performed within a temperature range below the melting temperature (Tm) of the high processing temperature polymer composition.

[0258] For example, in certain aspects, as discussed further below, the specific and selective incorporation of a low processing temperature polymer composition and a high processing temperature polymer composition into an article provides a means to program structural features into an article that can be formed after thermoforming. In some aspects, the article can include a textile comprising a low processing temperature polymer composition and a high processing temperature polymer composition, such as a textile comprising at least a plurality of fibers or yarns, at least a portion of which comprises the low processing temperature polymer composition. In another aspect, the article can include a first forming component, film, textile, yarn, or plurality of fibers comprising the low processing temperature polymer composition; and a second forming component, film, textile, yarn, or plurality of fibers comprising the high processing temperature polymer composition, such as a knitted upper of a footwear article comprising the high processing temperature polymer composition; and a film comprising the low processing temperature polymer composition. In a further aspect, the article can include a polymer of a component, at least a portion of which comprises the low processing temperature polymer composition and the high processing temperature polymer composition, to which the disclosed thermoforming process has been applied.

[0259] Because 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, these structural features immediately become integrated with each other after thermoforming, thereby 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 the textiles disclosed herein. For example, the process for forming structural features in the disclosed article can utilize a film comprising a low processing temperature polymer composition, and a textile comprising a high processing temperature polymer composition, which process is also expected to be 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 part comprising a low processing temperature polymer composition, and a textile comprising a high processing temperature polymer composition.

[0260] In addition, this selective incorporation of low processing temperature polymer compositions and high processing temperature polymer compositions into articles provides a streamlined manufacturing process. For example, in some aspects, an entire article can be formed by arranging components and exposing the arranged components to a thermoforming process, wherein the components comprising the low processing temperature polymer composition melt, flow, and resolidify into more rigid structural features, while the components comprising the high processing temperature polymer composition do not deform during the thermoforming process. In such aspects, this allows the entire article to be exposed to the thermoforming process without the need to shield or protect areas that the manufacturer does not want to melt, flow, and resolidify, thereby resulting in a more efficient manufacturing method in terms of time and energy. In addition, in some cases, using the articles described herein in the manufacturing methods described herein also allows for providing several different structures or other advantageous features in the article without having to combine individual components into the final article, because such features can be built into the article at the textile level using the low processing temperature polymer composition and the high processing temperature polymer composition.

[0261] In various aspects, the thermoforming process occurs at a temperature at which the yarn or fiber has been dyed (e.g., a temperature at which the yarn or fiber comprising the high processing temperature polymer composition was previously dyed), such that during the thermoforming process, such dye does not leach out of the yarn or fiber and into the surrounding low processing temperature polymer composition. Thus, to form the various textiles and articles described herein, the melting temperature of the low processing temperature polymer composition in the first yarn or fiber is lower than the temperature used to dye the second yarn or fiber (e.g., a second yarn or fiber comprising the high processing temperature polymer composition).

[0262] Additionally, compositions having a melting temperature in this range (i.e., a melting temperature below the temperature at which the second yarn or fiber comprising the high processing temperature polymer composition was dyed) create another problem because so many of the low processing temperature polymer compositions evaluated and tested did not produce yarns suitable for use in commercial knitting equipment, as the yarns shrank significantly when exposed to the temperatures at which commercial knitting equipment typically operates.

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

[0264] In certain aspects, thermoforming the articles and textiles described herein can be performed within a temperature range that causes the low processing temperature polymer composition to melt or deform (and subsequently solidify), while the high processing temperature polymer composition does not melt and / or deform, thereby maintaining the structure of the element (e.g., yarn or fiber) comprising the high processing temperature polymer composition. In such aspects, this thermoforming process can produce a relatively rigid structural component (e.g., the outsole portion of a shoe) that is integrally connected to a less rigid portion of the article or textile, such as the upper portion of a shoe, that has yarn or fiber comprising the high processing temperature polymer composition.

[0265] Thus, in one aspect, a method for manufacturing an article is provided. The article may be a component of a footwear article, a component of an apparel article, or a component of a sporting equipment article. For example, the sporting equipment article component may be a hat, a bag, a ball, or a protective equipment component. The method comprises receiving an article comprising 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 comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers, wherein the second forming component. The second film, the second textile, the second yarn, or the second fiber comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits at least one of the following: 1) a creep relaxation temperature, Tcr; 2) a heat deformation temperature, Thd; or 3) a Vicat softening temperature, Tvs, that 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 increasing the temperature of the entire article while the at least a portion of the article is on the molding surface to a temperature greater than the melting temperature (Tm) of the low-processing-temperature polymer composition and less than at least one of: 1) a creep relaxation temperature (Tcr); 2) a heat deformation temperature (Thd); or 3) a Vicat softening temperature (Tvs) of the high-processing-temperature polymer composition. After increasing the temperature of the entire article, while the at least a portion of the article is still on the molding surface, decreasing the temperature of the entire article to a temperature less than 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 an article of clothing is provided. The method comprises knitting a first course comprising interlacing a first yarn with a second yarn. The first yarn comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat deformation 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 a shoe upper is provided. The method includes receiving a shoe upper comprising a first yarn and a second yarn. The first yarn comprises a low-processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high-processing temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat deformation 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 shoe upper, at least one of the first yarn and the second yarn forms a plurality of interconnected loops. The method also includes placing the shoe upper on a shoe last. In addition, the method includes heating the entire shoe upper while the entire shoe upper is on the shoe last to a temperature that is greater than the melting temperature (Tm) of the low processing temperature polymer composition and less than at least one of the following: (1) creep relaxation temperature (Tcr); (2) Vicat softening temperature (Tvs); (3) heat distortion temperature (Thd); or (4) the melting temperature (Tm) of the high processing temperature polymer composition. After heating the entire shoe upper, cooling the entire shoe upper while the entire shoe upper is on the shoe last to a temperature less than the melting temperature (Tm) of the first yarn composition, thereby forming a thermoformed shoe upper.

[0268] In yet another aspect, a method for manufacturing a shoe upper is provided. The method includes receiving a shoe upper comprising: one or more first fibers, yarns, films, or formed parts comprising a low processing temperature polymer composition; and one or more second fibers, yarns, films, or formed parts comprising a high processing temperature polymer composition. Each of the one or more first fibers, yarns, films, or formed parts comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. Each of the one or more second fibers, yarns, films, or formed parts comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition of the one or more second fibers exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat deformation 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 ground-facing outsole area, and wherein at least a portion of the one or more first fibers is present on the ground-facing outsole area. The method further includes placing the shoe upper on a shoe last such that at least a portion of the ground-facing outsole area covers at least a portion of a bottom of the shoe last. The method also includes heating the entire shoe upper while the entire shoe upper is on the shoe last to a temperature that is greater than the melting temperature (Tm) of the low-processing-temperature polymer composition of the one or more first fibers and less than at least one of the following: (1) creep relaxation temperature (Tcr); (2) Vicat softening temperature (Tvs); (3) heat deformation temperature (Thd); or (4) the melting temperature (Tm) of the high-processing-temperature polymer composition of the one or more second fibers. After heating the entire shoe upper, cooling the entire shoe upper while the entire shoe upper is on the shoe last to a temperature that is less than 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 an article of footwear is provided. The method comprises knitting a first course comprising loops of a first yarn and a second yarn. The first yarn comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers. The high processing temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat deformation 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 comprises knitting a second course comprising loops of the first yarn and the second yarn. At least a portion of the first course and at least a portion of the second course form a plurality of interconnected loops.

[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 specifically identified as an order of performance. Additional or alternative steps may be used.

[0271] Exemplary pre-heat forming and thermoforming processes

[0272] As discussed above, in certain aspects, the articles and textiles described above, e.g. Figure 3 The textile 300 can form at least a portion of an article of wear (e.g., a footwear article). In such aspects, the textile can form an upper of the footwear article, wherein the upper includes a ground-facing outsole portion.

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

[0274] In certain aspects, to provide additional comfort and / or support to a wearer of an article of footwear formed at least in part from the textiles described herein, an internal support device or base plate may be provided. Figure 12 and 13 Depicted is an article of footwear 1200 comprising a base plate 1210. The article of footwear 1200 comprises a textile 1212 forming an upper 1214 having a ground-facing outsole portion 1216. In certain aspects, as may be Figure 13 It is best seen in Figure 13Depicting a cross-section of footwear article 1200, base plate 1210 is positioned within interior portion 1218 of footwear article 1200 and contacts interior surface 1220 of textile 1212. In certain aspects, base plate 1210 can comprise a polymeric material, such as a high processing temperature polymeric material, such as a polyether block amide, having a melting or deformation temperature above the temperature range within which the thermoforming process is performed, such that the polymeric material does not melt or deform during the thermoforming processes described herein.

[0275] In various aspects, heel counter 1222 can be located on interior portion 1218 of upper 1214, or on exterior portion of upper 1214, or can form a portion of upper 1214, for heel support of the wearer. In several aspects, similar to base plate 1210, heel counter 1222 can comprise a polymeric material, such as a high processing temperature polymeric material, such as a polyether block amide that is capable of not melting or deforming when exposed to a thermoforming process. In several aspects, similar to base plate 1210, heel counter 1222 can include a portion formed from a low processing temperature polymeric composition and a portion formed from a high processing temperature polymeric composition.

[0276] In some aspects, sockliner 1224 can be located above bottom plate 1210 in interior 1218 of footwear article 1200. In such aspects, sockliner 1224 can include conventional insole materials, such as one or more layers of foam or memory foam and a textile layer. It should be understood that while bottom plate 1210, heel counter 1222, and sockliner 1224 are depicted as additional materials used to form the upper of the footwear article, other materials, such as plates, pullovers, and / or structures along the sides, can also be added.

[0277] In various aspects, prior to thermoforming, heel counter 1222 and bottom plate 1210 can be positioned within interior 1218 of footwear article 1200. In certain aspects, a sockliner can be applied after the thermoforming process is complete.

[0278] In some aspects, such as Figure 14 In some aspects, the ground engaging cleats 1410 may be applied to the footwear 1400. In some aspects, the footwear 1400 may include the same as described above with reference to Figure 12 and 13 The same features as described above for footwear 1200. Figure 1414, ground engaging cleats 1410 can be applied to a ground-facing outsole area 1412 of article of footwear 1400 to provide increased stability and traction. In several aspects, ground engaging cleats 1410 can be applied to ground-facing outsole area 1412 after the thermoforming process is complete. In other aspects, ground engaging cleats 1410 can be applied to ground-facing outsole area 1412 as part of the thermoforming process.

[0279] In various aspects, prior to thermoforming the footwear article, any of the textiles discussed above, as well as additional materials, may be braided, woven, knitted, or preformed into a general boot-like shape having an upper with a ground-facing outsole portion, e.g. Figure 15 In such aspects, the upper 1500 may also include a bottom plate or heel support frame located on the interior 1510 of the upper 1500, such as the one described above with respect to the Figure 12 The base plate 1210 and the heel counter 1222 are discussed.

[0280] To prepare upper 1500 for the thermoforming process, upper 1500 is placed on last 1520 such that last 1520 enters interior 1510 of upper 1500. In certain aspects, last 1520 can be formed from a polymeric material (e.g., a high-processing temperature polymer composition). In particular aspects, last 1520 can be formed from a polymeric material having a melting temperature, Tm, or degradation temperature, greater than 250°C or greater than 300°C (e.g., a silicone polymer). Last 1520 can be made from other types of materials, as long as such materials do not deform or melt during the thermoforming process or otherwise interfere with the thermoforming of the upper. Figure 16 Depict upper 1500 positioned on last 1520. Figure 16 As can be seen in FIG, the upper 1500 is wrapped around the last 1520 to cover a bottom portion 1522 of the last 1520, a forefoot portion 1524 of the last 1520, and a heel portion 1526 of the last 1520. In such aspects, the outsole portion 1512 of the upper, which faces the ground, covers the bottom portion 1524 of the last 1520. Although Figure 15 and 161500 is illustrated as having a sock-like structure that wraps around and covers a bottom portion 1522, a forefoot portion 1524, and a heel portion 1526 of a last 1520, but in other aspects, the upper 1500 may only partially wrap around the last 1520. Similarly, in other aspects, the upper 1500 may cover only the bottom portion 1522 of the last 1520, only the forefoot portion 1524 of the last 1520, only the heel portion 1526 of the last 1520, or a combination thereof. In still other aspects, the upper 1500 may cover only a portion of the bottom portion 1522 of the last 1520, a portion of the forefoot portion 1524 of the last 1520, a portion of the heel portion 1526 of the last 1520, or a combination thereof.

[0281] Figure 17 A cross section of upper 1500 positioned on last 1520 is shown along cutting line 17. Cross section 1700 reveals that last 1500 contacts inner surface 1540 of upper 1500. Cross section 1700 also reveals the presence of two types of materials in upper 1500. For example, cross section 1700 reveals three types of textile areas forming the textile of upper 1500. Figure 17 1524 of the shoe last 1520. In such aspects, 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 is covering at least a portion of the bottom portion 1524 of the shoe last 1520.

[0282] Additionally, textile region 1714 covers forefoot portion 1524 of last 1520, while textile region 1712 covers midfoot region 1528 of last. In some aspects, textile regions 1710, 1712, and 1714 can each have the same dimensions as those described above with reference to FIG. Figure 3 Any or all of the properties discussed for textile regions 302, 304a, 306a.

[0283] In certain aspects, a first layer can be placed on a molding surface (e.g., a last) before the article (e.g., an article of footwear or a component of an article of footwear) is molded. For example, a first layer (e.g., a lining) can be optionally placed over a molding surface (e.g., a last). For example, referring to Figure 17To further demonstrate an aspect of the first layer, before the article, lining, can be placed over last 1520, the first layer can optionally be placed on a molding surface (e.g., last) such that the forefoot region of the lining covers forefoot region 1524. Thus, the upper comprising 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 comprising the low processing temperature polymer composition is covering at least a portion of the lining. It should be understood that in certain aspects, textile regions 1710, 1712, and 1714 can each have the same shape as described above with reference to FIG. Figure 3 Any or all of the properties discussed for textile regions 302, 304a, 306a.

[0284] In a further aspect, an external layer may optionally be positioned over at least a portion of the article that is positioned on the molding surface and is covering at least a portion of the article. An external layer (which may be a film) may optionally be positioned over at least a portion of the article (e.g., an upper) that is positioned on the molding surface (e.g., a last). For example, see Figure 17 To further illustrate an aspect of an exterior layer that can optionally be placed over at least a portion of an upper already on a last, textile region 1710 associated with outsole portion 1512 of the upper that faces the ground covers bottom portion 1524 of last 1520. Thus, at least a portion of the upper, including textile regions 1710, 1712, and 1714, can be covered by at least a portion of the exterior layer. Thus, at least a portion of the yarn comprising the low processing temperature polymer composition is in contact with at least a portion of the exterior layer. It should be understood that in certain aspects, textile regions 1710, 1712, and 1714 can each have the same or similar configurations as described above with reference to FIG. Figure 3 Any or all of the properties discussed for textile regions 302, 304a, 306a. An outer layer may be utilized in conjunction with the first layer, as described in the previous paragraph.

[0285] In certain aspects, a forming component, such as a heel counter or a sleeve, may optionally be placed on the exterior surface 1530 of the upper 1500. Alternatively, a forming component, such as a heel counter or a sleeve, may optionally be placed on the interior surface 1540 of the upper 1500. It should be understood that placement of the forming component (whether on the exterior surface 1530 or the interior surface 1540 of the upper 1500) is accomplished prior to application of the protective cover, vacuum, or protective cover and vacuum bag, as described below.

[0286] In certain aspects, during the thermoforming process, the low processing temperature polymer composition may melt and flow. In various aspects, it may be desirable to restrict the flow of the molten low processing temperature polymer composition. In such aspects, a protective cover may be applied over the upper positioned on the last. For example, Figure 18 and 19As can be seen in FIG, protective cover 1800 is positioned above upper 1500 positioned on last 1520. In certain aspects, protective cover 1800 may be formed from a polymeric material, such as a high-processing temperature polymer composition. In particular aspects, protective cover 1800 may be formed from an elastomeric polymeric material (e.g., a silicone polymer) having a melting temperature, Tm, or degradation temperature, greater than 250°C or greater than 300°C. Protective cover 1800 may be made from other types of materials, as long as such materials do not deform or melt during the thermoforming process or otherwise interfere with the thermoforming of the upper. In some aspects, protective cover 1800 can apply a compressive force to outer surface 1530 of upper 1500, which can help restrict the flow of the molten low-processing temperature polymer composition. Additionally, in such aspects, a vacuum may be drawn on the combination of last 1520, upper 1500 positioned on the last, and protective cover positioned on upper 1500. For example, a vacuum bag may be compressed on the outside of protective sleeve 1800 to apply a compressive force to protective sleeve 1800 to ensure that sleeve 1800 is in flush contact with exterior surface 1530 of upper 1500. Vacuum bags are discussed in detail below.

[0287] In certain aspects, protective cover 1800 can be utilized to provide a pattern or indicia on the exterior surface of upper 1500. For example, interior surface 1810 of protective cover 1800 can include indicia or a pattern that, during the thermoforming process, due to the melting and cooling of the low processing temperature polymer composition in upper 1500, combined with the compressive force applied by protective cover 1800 (and optionally, the vacuum bag) to upper 1500, can be embossed or imprinted onto exterior surface 1530 of upper 1500. In such aspects, because protective cover 1800 can cover the entirety of upper 1500, it is possible for protective cover 1800 to emboss or imprint a pattern onto any portion of exterior surface 1530 of upper 1500 that includes the low processing temperature polymer composition.

[0288] In certain aspects, it may be desirable to optionally use both a protective cover and a vacuum bag together. In such aspects, the protective cover may be applied over the shoe upper positioned on the last. For example, Figure 18 and 19 As can be seen in FIG, protective cover 1800 is positioned above upper 1500, which is positioned on last 1520. As disclosed above, protective cover 1800 can be formed from an elastomeric polymeric material (e.g., a silicone polymer) having a melting temperature Tm or degradation temperature greater than 250° C. or greater than 300° C. Accordingly, protective cover 1800 is positioned on last and inside 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 the various methods of applying compressive force to the protective cover or vacuum bag, as discussed in this disclosure, can be used to apply compressive force to both the protective cover and vacuum bag, as used together.

[0289] In certain aspects, protective cover 1800 alone and when used under a vacuum can effectively reduce the number of bubbles trapped in the low processing temperature polymer material during the thermoforming process, as compared to the same upper thermoformed under similar conditions except without protective cover 1800.

[0290] exist Figures 15 to 19 In the aspects depicted in FIG, last 1520 is formed of a rigid material. Furthermore, in these aspects, when last 1520 is made of a rigid material, the compressive force applied via protective cover 1800 (and / or vacuum bag) creates a force or pressure differential between inner surface 1540 and outer surface 1530 of upper 1500 (because rigid last 1520 at least partially resists this compressive force, which causes upper 1500 to experience the compressive force). In such aspects, this pressure differential can at least partially provide the environment necessary to restrict the flow of the molten low-processing-temperature polymer composition and / or provide relief or patterning of outer surface 1530 of upper 1500.

[0291] In some aspects, the upper 1500 can be positioned on a shoe last 1520 (when formed of a rigid material), and the outer surface 1530 of the upper 1500 (with or without the protective cover 1800) can be exposed to a pressure above atmospheric pressure to create this pressure differential. In another aspect, the upper 1500 can be positioned on the shoe last 1520, and 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 interior surface 1540 and exterior surface 1530 of upper 1500 can also help form the three-dimensional structure of the footwear article during the thermoforming process. That is, in such aspects, as the low processing temperature polymer composition melts, the molten material and upper 1500 are forced against rigid last 1520, which, upon cooling, results in upper 1500 taking the shape of last 1520.

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

[0294] As discussed above, a vacuum bag may be applied to upper 1500 positioned on last 1520 , with or without protective cover 1800 . Figure 20AShoe upper 1500 is depicted positioned inside vacuum bag 2010 on last 1520. As used herein, the term "vacuum bag" refers to any material that can be compressed onto the outer surface of an object.

[0295] exist Figure 20A , vacuum bag 2010 may include a valve 2012 for reducing the pressure inside vacuum bag 2010. For example, the pressure between exterior surface 1530 of upper 1500 (or the exterior surface of protective cover 1800 on upper 1500) and interior 2014 of vacuum bag 2010 may be reduced, which will compress the vacuum bag against exterior surface 1530 of upper 1500 (or the exterior surface of protective cover 1800 on upper 1500). Figure 20B Depicts vacuum bag 2010 compressed onto exterior surface 1530 of upper 1500 (or exterior surface of protective cover 1800 on upper 1500). As discussed above, compressing vacuum bag 2010 onto upper 1500 may at least partially provide the above-referenced Figures 15 to 19 The pressure difference discussed.

[0296] Figure 21 Depicted is a thermoforming system 2100 . Figure 21 The thermoforming system 2100 may include an upper 1500 positioned on a last 1520, wherein a vacuum bag 2010 is compressed onto the upper 1500, as described above with respect to Figure 20A and 20B Discussed.

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

[0298] Thermoforming system 2100 includes a heating zone 2110 that can be configured to heat the entire upper 1500. In several aspects, 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 upper 1500.

[0299] In various aspects, it will be understood that, while the heating used in thermoforming has been specifically discussed with respect to applications having upper 1500, this is merely an exemplary aspect of the heating and thermoforming of the disclosed articles and methods. That is, the present invention contemplates utilizing any of the disclosed heating methods for providing a heating zone in a thermoforming system and process to heat to thermoform any disclosed article comprising 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 positioned on a molding surface, all of which are at least partially covered with a vacuum bag, a protective cover, or a combination of a protective cover and vacuum, and then heated to a temperature above the Tm of the low-processing-temperature composition. The first forming component, the first film, the first textile, the first yarn, or the first fiber comprises 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 comprising a low-processing temperature polymer composition and forming components, films, textiles, fibers, and / or yarns comprising 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 to only a portion of the upper) because the high-processing temperature polymer composition can resist undergoing any deformation or melting under conditions that would allow the low-processing temperature polymer composition to be thermoformed. However, additional heat treatment steps can optionally be performed on the thermoformed articles of the present invention. For example, one or more surfaces of the thermoformed article can be subjected to additional thermoforming processes, such as to heat-attach a cleat to a 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 does not deform or alter formed parts, films, textiles, fibers, and / or yarns comprising the high processing temperature polymer composition. In such aspects, the heating zone 2110 can heat the entire upper 1500 to a temperature below at least one of the creep relaxation temperature Tcr, heat deformation temperature Thd, or Vicat softening temperature Tvs of the high processing temperature polymer composition or the fibers and / or yarns comprising the high processing temperature polymer composition.

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

[0303] In some aspects, the temperature of the entire upper 1500 can be increased in about 10 seconds to about 5 minutes. In several aspects, the temperature of the entire upper 1500 can be increased 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, heating zone 2110 can expose entire upper 1500 to a temperature from about 90° C. to about 240° C. In several aspects, heating zone 2110 can expose entire upper 1500 to a temperature from about 90° C. to about 200° C. In one aspect, heating zone 2110 can expose entire upper 1500 to a temperature from about 110° C. to about 180° C.

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

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

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

[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 lower than the melting temperature Tm of the low processing temperature polymer composition, for a duration sufficient to solidify the low processing temperature polymer composition. For example, a heat source (including but not limited to a conventional heater, such as convection heating, a conventional oven, an air circulation oven or a forced hot air oven, steam, directional microwave heating, ultraviolet radiation, infrared heating, and a combination of any of the foregoing) can be used for heating. The heat source may further include a plurality of heat sources, such as a plurality of similar sources, for example, a plurality of heating coils or infrared emitters. Alternatively, a plurality of heat sources may include a plurality of one or more different heat sources, such as a plurality of heating coils and a plurality of infrared emitters that can be used simultaneously or sequentially, or a plurality of heating coils and a plurality of infrared emitters used in a mode in which only one of the plurality of heat sources is used at any given time.

[0309] In some aspects, heating can be performed so that heat is transferred from another material or object to the entire upper 1500. For example, the molding surface (e.g., the last) can itself be directly heated, for example, via a configuration as a resistive heating element. In alternative aspects, the molding surface (e.g., the last) can be preheated to a desired temperature immediately before the upper, textile, or article is positioned thereon. In the aforementioned aspects, the molding surface itself can serve as a heating zone that transfers heat to the entire upper.

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

[0311] Additionally, in some aspects, entire upper 1500 can be exposed to heating zone 2110 by moving entire upper 1500 into heating zone 2110, or by moving heating zone 2110 until upper 1500 is located therein and then removed after the heating step. Conventional transport systems can be used to automate or semi-automate the movement of upper 1500 and / or heating zone 2110.

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

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

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

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

[0316] Figure 22 An exemplary method 2200 of manufacturing an upper for a shoe is depicted. The method 2200 may include a step 2210 of receiving an upper including 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 Figure 22 And exemplary method 2200 of the present invention, typically, the low processing temperature polymer composition can exist in the form of a fiber (e.g., a fiber essentially consisting of the low processing temperature polymer composition). The low processing temperature polymer composition can exist in the received shoe upper in the form of a yarn (e.g., a yarn comprising the low processing temperature polymer composition, a yarn formed entirely of fibers comprising the low processing temperature polymer composition, a yarn formed partially of fibers comprising the low processing temperature polymer composition). Additionally or alternatively, the low processing temperature polymer composition can exist in the form of a part that is not a yarn structure. For example, the fiber may include the low processing temperature polymer composition, or may essentially consist of the low processing temperature polymer composition. The low processing temperature polymer composition can also exist in the form of a textile (including knitted, braided, woven and non-woven textiles), a film, a bed sheet or a molded article (e.g., an injection molded article). The low processing temperature polymer composition can also exist in the form of a foam material.

[0318] Although certain aspects of the present invention have been demonstrated with details about footwear or uppers, within the scope of the present invention, the demonstrated aspects are generally understood to be applicable to other disclosed aspects. For example, any disclosed low processing temperature composition can be used to form, make or manufacture shaped parts, films, textiles or other products and used in the methods disclosed herein. Similarly, any disclosed high processing temperature composition can be used to form, make or manufacture shaped parts, films, textiles or other products and used in the methods disclosed herein. Therefore, any such shaped parts, films, textiles or other products comprising a low processing temperature composition can be optionally brought into contact with a shaped part, film, textile or other product 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 certain aspects, the second material formed by the high processing temperature polymer composition may exhibit at least one of a creep relaxation temperature Tcr, a heat deformation temperature Thd, or a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymer composition. The material formed by the low processing temperature polymer composition may include any one or all of the properties of the low processing temperature polymer composition described above. The second material formed by the high processing temperature polymer composition may include any one or all of the properties of the high processing temperature polymer composition described above. The second material formed by the high processing temperature polymer composition may exist in the form of a fiber (e.g., a fiber essentially consisting of a high processing temperature polymer composition). The high processing temperature polymer composition may exist in the received shoe 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, or a yarn formed partially of fibers comprising a high processing temperature polymer composition). Additionally or alternatively, the high processing temperature polymer composition may exist in a form that is not part of the yarn structure. For example, the fiber may include a high processing temperature polymer composition, or may essentially consist of a high processing temperature polymer composition. The high processing temperature polymer composition can also be in the form of a textile (including knitted, braided, woven and non-woven textiles), a film, a sheet or a molded article (such as an injection molded article). The high processing temperature polymer composition can also be in the form of a foam material. In certain aspects, the upper can include the same as described above. Figures 15 to 21 Any or all of the properties of the upper 1500 described above. In addition, any of the textiles described above may be used, such as Figure 3 The textile 300 forms the upper.

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

[0321] In one or more aspects, in a first portion of the upper, when the upper includes a knitted textile having a first yarn including a low processing temperature polymer composition and a second yarn including a high processing temperature polymer composition, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, e.g. Figure 6 、 7A or a plurality of interconnected coils as depicted in 9 .

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

[0323] In step 2230 of method 2200, the temperature of the entire shoe upper is increased (e.g., heated) to a temperature greater than the melting temperature Tm of the first yarn composition and less than at least one of the creep relaxation temperature Tcr, heat deformation temperature Thd, or Vicat softening temperature Tvs of the second yarn composition while on the shoe last. Figure 21 The thermoforming system 2100 is used to heat the entire upper. Figure 21 The upper is heated according to any or all of the parameters described in the thermoforming system.

[0324] In step 2240 of method 2200, while the upper is still on the shoe last, after heating, the temperature of the entire upper is reduced to a temperature below the melting temperature Tm of the low processing temperature polymer composition. For example, while the entire upper is on the shoe last, the entire upper can be cooled to form a thermoformed upper. In various aspects, the above-described methods with respect to Figure 21 The thermoforming system 2100 described above is used to cool the entire shoe upper. Figure 21The upper is cooled by any or all of the parameters described in 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 performed at a temperature that is at or greater than the melting temperature Tm of the low processing temperature polymer composition, but less than the creep relaxation temperature Tcr or heat deformation temperature Thd or Vicat softening temperature Tvs of the high processing temperature polymer composition, the second material or component (fiber, yarn, textile, sheet, molded article, etc.) comprising the high processing temperature polymer composition maintains its original physical structure (e.g., fiber, yarn, textile, etc.).

[0326] Figure 23 An exemplary method 2300 for manufacturing an upper for a shoe is depicted. Method 2300 may include step 2310 of receiving an upper comprising a first yarn and a second yarn, wherein the first yarn comprises a low processing temperature polymer composition and the second yarn comprises a high processing temperature polymer composition. The low processing temperature polymer composition may comprise one or more first thermoplastic polymers and the high processing temperature polymer composition may comprise one or more second thermoplastic polymers. In several aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above with respect to the thermoplastic polymers. In certain aspects, the upper may comprise the same parameters as described above with respect to the thermoplastic polymers. Figures 15 to 21 Any or all of the properties of the upper 1500 described above. In addition, any of the textiles described above may be used, such as Figure 3 The textile 300 forms the upper.

[0327] In certain aspects, the high processing temperature polymer composition can exhibit at least one of a creep relaxation temperature, Tcr, a heat deformation 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 can include any or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition can include any or all of the properties of the high processing temperature polymer composition described above. Additionally, the first and second yarns can exhibit any or all of the properties and parameters discussed above.

[0328] In one or more aspects, in the first portion of the upper, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, e.g. Figure 6 、 7A or a plurality of interconnected coils as depicted in 9 .

[0329] In step 2320 of method 2300, the upper is placed on a shoe last, e.g. Figures 15 to 17In various aspects, the last can be formed of a rigid material, or can be an expandable last. Additionally, as described above, the upper can have a base plate, heel counter, or other components inserted into the upper before being placed on the last.

[0330] In step 2330 of method 2300, the entire shoe upper is heated 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, heat deformation temperature Thd, or Vicat softening temperature Tvs of the high processing temperature polymer composition while on the shoe last. Figure 21 Thermoforming system 2100 can be used to heat the entire upper. Figure 21 The upper is heated according to any or all of the parameters described in the thermoforming system.

[0331] In step 2340 of method 2300, after heating the entire upper, the entire upper is cooled while on the last to form a thermoformed upper. Figure 21 The thermoforming system 2100 described above is used to cool the entire shoe upper. Figure 21 The upper is cooled by any or all of the parameters described in the thermoforming system.

[0332] Figure 24 Depicted is a method 2400 for manufacturing a shoe upper. Method 2400 may include step 2410 of receiving an upper comprising one or more first fibers and one or more second fibers. The one or more first fibers may comprise a low-processing temperature polymer composition comprising one or more first thermoplastic polymers. The low-processing temperature polymer composition may have any or all of the properties discussed above with respect to the low-processing temperature polymer composition. The one or more second fibers may comprise a high-processing temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing temperature polymer composition may have any or all of the properties discussed above with respect to the high-processing temperature polymer composition. In some aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above with respect to the thermoplastic polymers. Additionally, in some aspects, the first and second fibers may comprise any 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 a creep relaxation temperature Tcr, a heat deformation 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 certain aspects, the upper may include a ground-facing outsole area, wherein at least a portion of the first fibers are present in the ground-facing outsole area.

[0335] The method 2400 may include a step 2420 of placing the shoe upper on the last such that at least a portion of the outsole area facing the ground covers at least a bottom portion of the last, e.g. Figures 15 to 17 In various aspects, the last can be formed of a rigid material, or can be an expandable last. Additionally, as described above, the upper can have a base plate and / or heel counter inserted into the upper before being placed on the last.

[0336] Method 2400 may also include step 2430 of heating the entire shoe upper while on the shoe last to a temperature that is greater than the melting temperature Tm of the low processing temperature polymer composition and less than at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs of the high processing temperature polymer composition. Figure 21 Thermoforming system 2100 can be used to heat the entire upper. Figure 21 The upper is heated according to any or all of the parameters described in the thermoforming system.

[0337] In step 2440 of method 2400, after heating the entire upper, the entire upper is cooled while on the last to form a thermoformed upper. Figure 21 The thermoforming system 2100 described above is used to cool the entire shoe upper. Figure 21 The upper is cooled by any or all of the parameters described in the thermoforming system.

[0338] Figure 25 A method 2500 for making a knitted upper for an article of footwear is depicted. The method 2500 includes a step 2510 of knitting a first course comprising loops of a first yarn and a second yarn. In several 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 several aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above with respect to the thermoplastic polymers. In certain aspects, the upper may comprise the same as described above with reference to Figures 15 to 21 Any or all of the properties of upper 1500 described above.

[0339] In certain aspects, the high processing temperature polymer composition can exhibit at least one of a creep relaxation temperature, Tcr, a heat deformation 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 can include any or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition can include any or all of the properties of the high processing temperature polymer composition described above. Additionally, the first and second yarns can exhibit any or all of the properties and parameters discussed above.

[0340] Method 2500 may also include knitting a second course of stitches comprising the first yarn and the second yarn at step 2520. In some aspects, the first and second courses may be knitted using any commercial knitting technique as described above. 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 stitches, e.g. Figure 6 The interconnected coils depicted in .

[0341] Figure 26 A method 2600 of forming a knitted article is depicted. Method 2600 may include step 2610 of knitting a first course 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 or all of the parameters discussed above with respect to thermoplastic polymers.

[0342] In certain aspects, the high processing temperature polymer composition can exhibit at least one of a creep relaxation temperature, Tcr, a heat deformation 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 can include any or all of the properties of the low processing temperature polymer composition described above. The high processing temperature polymer composition can include any or all of the properties of the high processing temperature polymer composition described above. Additionally, the first and second yarns can exhibit any 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. The anchor yarn comprises an anchor yarn composition, wherein the anchor yarn composition comprises one or more polymers. The anchor yarn composition exhibits an elongation that is less than the elongation of the low processing temperature polymer composition. In several aspects, the anchor yarn may have the Figure 4B 、 4E, 10A and 10B discuss any or all of the properties of the anchor yarn.

[0344] In some aspects, the first course of stitches may be present on the outer surface of the knitted upper. In such aspects, the outer surface of the knitted upper may include a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. Additionally, in such aspects, the third region has an increased concentration of the first yarn compared to the second region. The first region, the second region, and the third region may each comprise the first region, the second region, and the third region described above. Figure 3 Any or all of the properties of textile regions 306a, 304a, and 302 discussed for textile 300.

[0345] Figure 27 A method 2700 for making an upper for an article of footwear is depicted. Step 2710 of method 2700 includes forming a ground-facing outsole region comprising a first set of one or more first fibers. In such aspects, the one or more first fibers may comprise a low processing temperature polymer composition comprising one or more first thermoplastic polymers.

[0346] Method 2700 may include step 2720 of forming a second region comprising one or more second fibers and a second set of one or more first fibers. In such aspects, the one or more second fibers comprise a high processing temperature polymer composition comprising one or more second thermoplastic fibers. The high processing temperature polymer composition exhibits at least one of the following: a creep relaxation temperature, Tcr; a heat deformation 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. The first and second fibers, the low and high processing temperature polymer compositions, and the first and second thermoplastic polymers may comprise any or all of the corresponding properties discussed above.

[0347] Textiles, yarns and fibers

[0348] As discussed above, fiber described herein, yarn, textile, film and formed part can comprise the selectivity of low treatment temperature polymer composition and / or the selectivity of high treatment temperature polymer composition and incorporate into.In some aspects, such low treatment temperature polymer composition can comprise the form of the fiber of low treatment temperature polymer composition to exist.In some aspects, comprise that the fiber of low treatment temperature polymer composition does not have high treatment temperature polymer composition in essence.In other aspects, comprise that the fiber of low treatment temperature polymer composition is made up of low treatment temperature polymer composition in essence.According to the present invention, these fibers can be used to form yarn, which can be used to form textiles in turn, comprises the textiles of knitting, weaving or braiding.According to the present invention, these fibers can also be used to form non-woven textiles.

[0349] Similarly, the high treatment temperature polymer composition described above can include the presence of a fiber of the high treatment temperature polymer composition. In some respects, the fiber comprising the high treatment temperature polymer composition is essentially free of low treatment temperature polymer compositions. In other respects, the fiber comprising the high treatment temperature polymer composition is essentially composed of the high treatment temperature polymer composition. According to the present invention, these fibers can be used to form yarns, which can in turn be used to form textiles, comprising knitting, weaving or braiding textiles. According to the present invention, these fibers can also be used to form non-woven textiles.

[0350] In some respects, the fiber and / or the yarn comprising low treatment temperature polymer composition may further comprise high treatment temperature polymer composition. For example, the fiber may be a bicomponent fiber having the low treatment temperature polymer composition present on at least a portion of the outer surface of the fiber. For example, low and high treatment temperature polymer composition may have a side-by-side structure, or may have a core and sheath structure, wherein there is a low treatment temperature polymer composition in the sheath. In some respects, low treatment temperature polymer composition, high treatment temperature polymer composition or both may also be included in one or more conventional additives found in the yarn or fiber comprising polymeric material. Although the foregoing can only describe the property and parameter of yarn or yarn composition, it should be understood that such property and parameter are also applicable to fiber or fiber composition, unless otherwise mentioned.

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

[0352] In certain aspects, the fibers described herein can be fibers of different sizes, including fibers that are not suitable for spinning into commercial yarns. The yarns described herein include yarns that are suitable for use in commercial knitting machines, as well as 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, a yarn comprising a low processing temperature polymer composition can be thermoformed to form a membrane having waterproof or water-resistant properties. In such aspects, a membrane on the outer surface of an article is provided by utilizing yarns and / or fibers comprising a low processing temperature polymeric material on the outer portion of a textile (including a knitted structure forming the textile).

[0354] As discussed above, in some aspects, can be for example for aesthetic purposes, come for one or more dyeing in yarn and / or fiber.In various aspects, conventional dyeing technology (such as beam dyeing or solution dyeing) can be used to dye the yarn and / or fiber.Usually, beam dyeing is the process performed on the yarn and / or fiber that has been formed, and before fiber is formed into yarn, solution dyeing is the fiber dyeing.In some aspects, can be the yarn or fiber dyeing that comprises high processing temperature polymer composition.In some aspects, do not comprise the yarn or fiber dyeing of low processing temperature polymer composition, and can be formed by the polymer composition of no pigment or dye in essence, it can comprise the district that produces transparent or almost transparent low processing temperature polymer composition (such as, non-yarn or non-fiber material after thermoforming).

[0355] In some aspects, the yarn comprising a low treatment temperature polymer composition can exhibit a toughness from about 1 gram / fineness to about 5 grams / fineness. In one or more aspects, the yarn comprising a low treatment temperature polymer composition can exhibit a toughness from about 1.5 grams / fineness to about 4.5 grams / fineness. In one aspect, the yarn comprising a low treatment temperature polymer composition can exhibit a toughness from about 2 grams / fineness to about 4.5 grams / fineness. " Toughness " as used herein refers to the property of fiber or yarn, and is determined using the corresponding test method and sampling procedure described below in property analysis and characterization program part.

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

[0357] As discussed above, in certain aspects, it may be desirable to utilize yarns that are suitable for use on commercial knitting equipment. The independent shrinkage of a yarn at 50°C is one property that can predictably make a yarn suitable for use on a commercial knitting machine. In certain aspects, a yarn comprising a low processing temperature polymer composition may exhibit an independent shrinkage of from about 0% to about 60% when heated from 20°C to 50°C. In one or more aspects, a yarn comprising a low processing temperature polymer composition may exhibit an independent shrinkage of from about 0% to about 30% when heated from 20°C to 50°C. In one aspect, a yarn comprising a low processing temperature polymer composition may exhibit an independent shrinkage of from about 0% to about 20% when heated from 20°C to 50°C. The term "independent shrinkage" as used herein refers to the properties of a yarn, and the corresponding test methods described below in the Property Analysis and Characterization section.

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

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

[0360] In one or more aspects, when in the form of a plaque, the low processing temperature polymer composition can exhibit a modulus of from about 1 MPa to about 500 MPa. In certain aspects, in the form of a plaque, the low processing temperature polymer composition can exhibit a modulus of from about 5 MPa to about 150 MPa. In one aspect, in the form of a plaque, the low processing temperature polymer composition can exhibit a modulus of from about 20 MPa to about 130 MPa. In another aspect, in the form of a plaque, the low processing temperature polymer composition can exhibit a modulus of from about 30 MPa to about 120 MPa. In yet another aspect, in the form of a plaque, the low processing temperature polymer composition can exhibit a modulus of 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 brought to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus from about 1 MPa to about 500 MPa when tested at approximately 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 brought to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus from about 5 MPa to about 150 MPa when tested at approximately 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 brought to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 20 MPa to about 130 MPa when tested at approximately 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 brought to a temperature below the melting temperature Tm of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 30 MPa to about 120 MPa when tested at approximately 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 brought to a temperature below the melting temperature, Tm, of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus from about 40 MPa to about 110 MPa when tested at approximately 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, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross flex of from about 5000 cycles to about 500,000 cycles 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 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, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross flex of from about 10,000 cycles to about 300,000 cycles when tested at about 20°C and a pressure of 1 ATM. 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, the resulting thermoformed material (or melted yarn component) exhibits a cold Ross flex of at least about 150,000 cycles when tested at approximately 20° C. and a pressure of 1 ATM. The term “cold Ross flex” as used herein refers to the corresponding test method described below in the Property Analysis and Characterization Procedures section.

[0363] In certain aspects, as discussed in detail below, anchor yarns 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 to impart a certain flexibility to the thermoformed material. In such aspects, the anchor yarn can exhibit an elongation that is less than the elongation of the low processing temperature polymer composition (e.g., a yarn comprising a low processing temperature polymer composition, or a molten yarn component produced by thermoforming such a yarn). For example, in several aspects, the anchor yarn can exhibit an elongation that is at least 10% less than the elongation of the yarn comprising a low processing temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising a low processing temperature polymer composition. In one aspect, the anchor yarn can exhibit an elongation that is at least about 25% less than the elongation of the yarn comprising a low processing temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising a low processing temperature polymer composition. In another aspect, the anchor yarn can exhibit an elongation that is at least about 50% less than the elongation of a yarn comprising a low processing temperature polymer composition or a melted yarn component produced by thermoforming a yarn comprising a low processing temperature polymer composition. In yet another aspect, the anchor yarn can exhibit an elongation that is at least about 75% less than the elongation of a yarn comprising a low processing temperature polymer composition or a melted yarn component produced by thermoforming a yarn comprising a low processing temperature polymer composition. Exemplary anchor yarns include polyamide yarns, polyolefin yarns, and polyester yarns, including yarns having a tenacity of from about 5 grams per denier to about 10 grams per denier.

[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 anchor yarn high processing temperature polymer composition 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 forming a second yarn used in the textile comprising the anchor yarn. In other aspects, the one or more polymers of the high processing temperature polymer composition of the anchor yarn can be different from the one or more polymers of the high processing temperature polymer composition forming a second yarn used in the textile comprising the anchor yarn.

[0365] As discussed above, in certain aspects, the low processing temperature polymer composition and the high processing temperature polymer composition have different properties. In various aspects, when the thermoforming process is performed at a temperature below the creep relaxation temperature, heat deformation temperature, or Vicat softening temperature of the high processing temperature polymer composition, these different properties allow the low processing temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from that before the thermoforming process (e.g., thermoformed from a yarn into a melted 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 melted yarn component formed from the low processing temperature polymer composition during the thermoforming process can be integrally connected to an unaltered structure (e.g., a yarn or fiber), which can provide a three-dimensional structure and / or other properties targeted to a specific point on the wearable article.

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

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

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

[0369] In certain aspects, the coated yarn can be a monofilament or multifilament yarn. The yarn can be based on natural or man-made fibers including polyester, high tenacity polyester, polyamide yarn, metallic 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 comprising one or more of the foregoing yarns.

[0370] In certain aspects, the thermoplastic coating composition includes a TPU. In some aspects, the TPU can be any of the materials described herein, such as TPUs prepared by polymerizing aromatic 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 TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0371] In various aspects, the thermoplastic coating composition may further include additives, such as but not limited to thickeners, processing aids, dyes or colorants. On the other hand, the additives are not optional and include at least one thickener. On the other hand, the additives are not optional and include at least one processing aid. On the other hand, the additives are not optional and include at least one thickener and at least one processing aid. In some aspects, the thickener may include an inorganic material, such as silica, talc or calcium carbonate (CaCO ).

[0372] In certain aspects, as described herein, a thickener can be used during the preparation of the thermoplastic coating composition to improve productivity and matte properties. In another aspect, the thickener is silica powder, talc, or CaCO3. The thickener is used, at least in part, 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 / butylene-styrene (SEBS) resin, a polyacetal resin (POM), or a styrene-acrylonitrile resin (SAN), which can impart compatibility with the thermoplastic polyurethane.

[0373] In certain aspects, the thermoplastic coating composition may include a processing aid to improve productivity. In another aspect, the processing aid may be montan wax or a fatty acid ester (C5-C9) with pentaerythritol. Other processing aids are known to those skilled in the art and may also be used in the disclosed thermoplastic compositions. 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 for coating the yarn. In another aspect, a TPU compound for coating the yarn can be prepared to have a desired hardness by controlling the content of the raw materials. In yet another aspect, the thickness of the coated yarn can be reduced depending on the thickness of the yarn made of polyester, nylon, spandex, etc.

[0375] In certain aspects, the coated yarn is prepared by compounding a thermoplastic coating composition comprising a thermoplastic polymer (e.g., thermoplastic polyurethane), and optionally one or more additives, in a conventional extruder, and then applying the compounded thermoplastic polyurethane coating composition to the surface of the yarn. In another aspect, a method for preparing the coated yarn comprises the steps of: 1) preparing shaped thermoplastic pellets; and 2) producing the coated yarn. The shaped thermoplastic pellets can be prepared by the methods disclosed herein, by similar methods known to those skilled in the art, or obtained from commercial sources.

[0376] The steps of preparing shaped thermoplastic pellets may include the following steps: 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 compounding the mixture in the barrel of the compounding extruder at a suitable temperature and pressure; 3) cutting the compounded thermoplastic coating composition, discharging it through the small cubes of the compounding extruder, and forming pellets in cooling water; and 4) drying the shaped thermoplastic polyurethane pellets at a suitable temperature for an approximately time period, and aging the dried pellets at a suitable temperature for a suitable time period.

[0377] In a specific example, the step of preparing shaped thermoplastic pellets includes at least the following steps: 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) compounding 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 compounded thermoplastic polyurethane and discharging it through the small cubes 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 steps of producing the coated yarn may include the following steps: 1) mixing the shaped thermoplastic polymer pellets prepared as described above with a masterbatch corresponding to the desired color and feeding the mixture into the funnel of a yarn coating extruder; 2) melting the mixture of the shaped thermoplastic polymer pellets and the masterbatch in the cylinder of the yarn coating extruder at a suitable temperature and a suitable pressure; 3) coating the surface of the yarn passing through the joint and the small square with the combined thermoplastic polymer and masterbatch to produce the coated yarn; and 4) winding the coated yarn around a bobbin using a winding machine.

[0379] Specifically, the steps of producing coated yarn may include the following steps: 1) mixing shaped thermoplastic polyurethane pellets with a masterbatch corresponding to a desired color and feeding the mixture into a funnel 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 joints and small squares to produce coated yarn; and 4) winding the coated yarn around a bobbin using a winding machine.

[0380] An illustrative, non-limiting example of a suitable commercially available coated yarn is Dream-Sil, a TPU coated yarn available from Sambu Fine Chemicals (Korea).

[0381] As discussed above, anchor yarns can be used to assist in limiting the flow of 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 yarns may not melt or deform during the thermoforming process. Thus, in certain aspects, the anchor yarns may include 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 deformation temperature T hd Or melting temperature T m At least one of the melting temperature T m Greater than the melting temperature T of the low processing temperature polymer composition m In certain aspects, the anchor yarn composition can have specific ranges associated with the properties discussed above with respect to the high processing temperature polymer composition. In certain aspects, the anchor yarn can be formed from the high processing temperature polymer composition, and thus can include any of the thermoplastic polymers discussed above with reference to the high processing temperature polymer composition.

[0382] In all respects, when in accordance with the AS T m When tested according to D3418-97, the fiber or yarn contains a melting temperature (T m ) about 90 ℃ to 120 ℃ of polyamide or polyether block amide low temperature processing polymer composition. On the other hand, when according to the AS T described below m When measured by D3418-97, the melting temperature (T m ) is about 93°C to 99°C. In addition, when the AS T mWhen measured by D3418-97, the melting temperature (T m ) is about 112° C. to 118° C. In certain aspects, when the AS T described below m When measured by D3418-97, the melting temperature (T m ) is approximately 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 a combination of any of the foregoing values. m ) value range, or the above melting temperature (T m ) value combination.

[0383] In all respects, when in accordance with the AS T m When tested using D3418-97, the fiber or yarn contains a glass transition temperature (T g ) about -20 ℃ to 30 ℃ of polyamide or polyether block amide low temperature processing polymer composition. On the other hand, when according to the AS T described below m When measured by D3418-97, the glass transition temperature (T g ) is about -13°C to -7°C. In addition, when the AS T m When measured by D3418-97, the glass transition temperature (T g ) is about 17°C to 23°C. In certain aspects, when the AS T described below m When measured by D3418-97, the melting temperature (T g ) is approximately -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 combination thereof. g ) value range, or the above-mentioned glass transition temperature state transition temperature (T g ) value combination.

[0384] In all respects, when in accordance with the AS T m D1238-13 When tested at 160°C using a 2.16 kg weight, the fiber or yarn has a melt flow index of approximately 10 cm 3 / 10min to 30cm 3 / 10min polyamide or polyether block amide low temperature treatment polymer composition. On the other hand, when according to the AS T described below m The melt flow index of polyamide or polyether block amide is about 22 cm when tested at 160°C using a 2.16 kg weight. 3 / 10min to 28cm 3 / 10min. In certain aspects, when the AS T described below m The melt flow index of polyamide or polyether block amide is about 10 cm when tested at 160°C using a 2.16 kg weight. 3 / 10min、11cm 3 / 10min、12cm 3 / 10min、13cm 3 / 10min、14cm 3 / 10min、15cm 3 / 10min、16cm 3 / 10min、17cm 3 / 10min、18cm 3 / 10min、19cm 3 / 10min、20cm 3 / 10min、21cm 3 / 10min、22cm 3 / 10min、23cm 3 / 10min、24cm 3 / 10min、25cm 3 / 10min、26cm 3 / 10min、27cm 3 / 10min、28cm 3 / 10min、29cm 3 / 10min、30cm 3 / 10min, 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, the fiber or yarn comprises a low temperature processed polymer composition having a low temperature Ross Flex Test result of about 120,000 to about 180,000 when the polyamide or polyether block amide thermoplastic substrate is tested according to the Low Temperature Ross Flex Test described below. In another aspect, when the polyamide or polyether block amide thermoplastic substrate is tested according to the Low Temperature Ross Flex Test described below, the polyamide or polyether block amide has a low temperature Ross Flex Test result of about 140,000 to about 160,000. Furthermore, when the polyamide or polyether block amide thermoplastic substrate is tested according to the Low Temperature Ross Flex Test described below, the polyamide or polyether block amide has a low temperature Ross Flex Test result of about 130,000 to about 170,000. In certain aspects, when the polyamide or polyether block amide thermoplastic formed substrate is tested according to the Low Temperature Ross Flex Test described below, the polyamide or polyether block amide has a Low Temperature Ross Flex Test result of approximately 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 a Low Temperature Ross Flex Test value range consisting of any of the foregoing values, or a combination of the foregoing Low Temperature Ross Flex Test values.

[0386] In various aspects, when according to the AS T as described below m The fiber or yarn comprises a low temperature processed polymer composition having a modulus of about 5 MPa to 100 MPa when measured on a polyamide or polyether block amide thermoplastic formed substrate according to D412-98 Standard Tensile Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomer. On the other hand, when subjected to the AS T test as described below, m The modulus of the polyamide or polyether block amide is about 20 MPa to 80 MPa when measured on a polyamide or polyether block amide thermoplastic formed substrate according to D412-98 Standard Tensile Test Method for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers. In certain aspects, when the polyamide or polyether block amide is subjected to the tensile test according to the AS T test method as described below, the modulus of the polyamide or polyether block amide is about 20 MPa to 80 MPa. m The modulus of the polyamide or polyether block amide, when measured on a polyamide or polyether block amide thermoplastic formed substrate as specified in Test Method D412-98, Standard Tensile Test Method for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers, 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 any combination of these values, or any combination of these values.

[0387] In various aspects, when according to the AS T as described below m When tested according to D3418-97, the fiber or yarn contains a melting temperature (T m ) about 115 ℃ polyamide or polyether block acid low temperature processing polymer composition; when according to AS T as described below m When measured by D3418-97, the glass transition temperature (T g ) is about -10°C; when the AS T m When tested at 160°C using a 2.16 kg weight, the melt flow index of D1238-13 is approximately 25 cm 3 / 10min; When the polyamide or polyether block amide thermoplastic substrate is tested according to the low temperature Ross flex test described below, the low temperature Ross flex test result is about 150,0 ... m D412-98 Standard Tensile Test Method for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers When used on polyamide or polyether block amide thermoplastic molded substrates, the modulus is approximately 25 MPa to 70 MPa.

[0388] In various aspects, when according to the AS T as described below m When tested according to D3418-97, the fiber or yarn contains a melting temperature (T m ) about 96 ℃ of polyamide or polyether block acid low temperature processing polymer composition; when according to AS T as described below m When measured by D3418-97, the glass transition temperature (T g ) is about 20°C; when the thermoplastic formed 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 AS T is tested according to the AS T m D412-98 Standard Tensile Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers When measured on thermoplastic formed substrates, the modulus is less than or equal to 10 MPa.

[0389] In various aspects, when according to the AS T as described below m When tested according to D3418-97, the fiber or yarn contains a melting temperature (T m ) a low temperature processed polymer composition of about 115°C - a polyamide or polyether block amide mixture consisting of a polyamide or polyether block amide prepared first; when the AS T is as described below m When measured by D3418-97, the glass transition temperature (T g) is about -10°C; when the AS T m When tested at 160°C using a 2.16 kg weight, the melt flow index of D1238-13 is approximately 25 cm 3 / 10min; When the thermoplastic formed substrate is tested according to the low temperature Ross flexure test described below, the low temperature Ross flexure test result is about 150,0 ... m D412-98 Standard Tensile Test Method for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers When measured on thermoplastic formed substrates, the modulus is approximately 25 MPa to 70 MPa; when measured according to the AST as described below m When measured by D3418-97, the melting temperature (T m ) about 96 ° C; when the AS T m When measured by D3418-97, the glass transition temperature (T g ) is about 20°C; when the thermoplastic formed 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 AS T is tested according to the AS T m D412-98 Standard Tensile Test for Vulcanized Rubber, Thermoplastic Rubber, and Thermoplastic Elastomers When measured on thermoplastic formed substrates, the modulus is less than or equal to 10 MPa.

[0390] In various aspects, the yarn comprising the cryogenically processed polymer composition has a denier of about 750 to about 1100.

[0391] In various aspects, a yarn comprising a cryogenically processed polymer composition, as modified as described below, has a yarn tenacity greater than or equal to 1.5 g / denier as measured according to EN ISO 2062. In another aspect, a yarn comprising a cryogenically processed polymer composition, as modified as described below, has a yarn tenacity between 1.5 g / denier and 3.0 g / denier as measured according to EN ISO 2062. In yet another aspect, a yarn comprising a cryogenically processed polymer composition, as modified as described below, has a yarn tenacity between 1.7 g / denier and 1.8 g / denier as measured according to EN ISO 2062. In yet another aspect, a yarn comprising a cryogenically processed polymer composition, as modified as described below, has a yarn tenacity between 3.3 g / denier and 3.6 g / denier as measured according to EN ISO 2062. In some aspects, a yarn comprising a low temperature processed polymer composition, with the modifications described below, has a yarn tenacity of 1.5 g / denier, 1.6 g / denier, 1.7 g / denier, 1.8 g / denier, 1.9 g / denier, 2.0 g / denier, 2.1 g / denier, 2.2 g / denier, 2.3 g / denier, 2.4 g / denier, 2.5 g / denier, 2.6 g / denier, 2.7 g / denier, 2.8 g / denier, 2.9 g / denier, 3.0 g / denier, any range of tenacity values ​​subsumed therein, or any combination of the foregoing tenacity values, as measured in accordance with EN ISO 2062.

[0392] In various aspects, yarns comprising a low-processing temperature polymer composition have a yarn elongation of less than or equal to about 150% when tested in accordance with EN ISO 2062, as modified as described below. In another aspect, yarns comprising a low-processing temperature polymer composition, as modified as described below, have a yarn elongation of 30% to 130% when tested in accordance with EN ISO 2062. In yet another aspect, yarns comprising a low-processing temperature polymer composition, as modified as described below, have a yarn elongation of 115% to 120% when tested in accordance with EN ISO 2062. In yet another aspect, yarns comprising a low-processing temperature polymer composition, as modified as described below, have a yarn elongation of 120% to 140% when tested in accordance with EN ISO 2062. In yet another aspect, yarns comprising a low-processing temperature polymer composition, as modified as described below, have a yarn elongation of 35% to 45% when tested in accordance with EN ISO 2062 on thermoformed plaques of polyamide or polymer (ether-block-amide). In some aspects, a yarn comprising a low temperature processed polymer composition, with the modifications described below, has an elongation of about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 100%, about 105%, about 110%, about 115%, about 120%, about 125%, about 130%, any range of elongation values ​​inclusive of any of the foregoing values, or any combination of the foregoing elongation values, as measured in accordance with EN ISO 2062.

[0393] In various aspects, yarns comprising a cryogenically processed polymer composition have a yarn shrinkage of less than or equal to about 15% as measured at 50°C using the methods described herein. In another aspect, yarns comprising a cryogenically processed polymer composition have a yarn shrinkage of about 7% to about 13% as measured at 50°C using the methods described herein. In yet another aspect, yarns comprising a cryogenically processed polymer composition have a yarn shrinkage of about 9.5% to about 10.5% as measured at 50°C using the methods described herein. In yet another aspect, yarns comprising a cryogenically processed polymer composition have a yarn shrinkage of about 0% to about 5% as measured at 50°C using the methods described herein. In some aspects, the yarn comprising the low temperature processed polymer composition has a yarn shrinkage as measured at 50°C using the method 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 ​​subsumed therein, or any combination of the foregoing shrinkage values.

[0394] In various aspects, the yarn comprising the cryogenically processed polymer composition has a melting enthalpy (a measure of crystallinity) measured using the methods described herein of about 15 J / g to 50 J / g. In another aspect, the yarn comprising the cryogenically processed polymer composition has a melting enthalpy measured using the methods described herein of about 17 J / g to 23 J / g. In yet another aspect, the yarn comprising the cryogenically processed polymer composition has a melting enthalpy measured using the methods described herein of about 35 J / g to 42 J / g. In some aspects, the yarn comprising the cryogenically processed polymer composition has a melting enthalpy measured using 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 melting enthalpy values ​​encompassed by any of the foregoing values, or any combination of the foregoing melting enthalpy values.

[0395] In various aspects, yarns comprising a low temperature processed polymer composition, as modified as described below, have a yarn tenacity of about 2.0 to 2.2 g / d, as measured in accordance with EN ISO 2062; a yarn elongation of about 116% to 122%, as measured in accordance with EN ISO 2062; a yarn shrinkage of about 8% to 12%, as measured at 50° C., as measured by the method described herein; and a melting enthalpy of about 18 J / g to 22 J / g, as measured by the method described herein. Contemplated yarns include yarns having any value within the given ranges, including values ​​at or about the lower or upper limits of the given ranges.

[0396] In various aspects, yarns comprising a low temperature processed polymer composition, as modified as described below, have a yarn tenacity of about 3.2 to 3.6 g / d, as measured in accordance with EN ISO 2062; a yarn elongation of about 37% to 43% as measured in accordance with EN ISO 2062; a yarn shrinkage of about 0% to about 3% as measured at 50° C. as described herein; and a fusion enthalpy of about 35 J / g to about 42 J / g as measured in accordance with the methods described herein. Contemplated yarns include yarns having any value within the given ranges, including values ​​at or about the lower or upper limits of the given ranges.

[0397] In various aspects, yarns comprising a low temperature processed polymer composition include a first yarn, as modified as described below, having a yarn tenacity of about 2.0 to 2.2 g / denier as measured in accordance with EN ISO 2062; a yarn elongation of about 116% to 122% as measured in accordance with EN ISO 2062 as modified as described below; a yarn shrinkage of about 8% to 12% as measured at 50°C using the method described herein; and a melting enthalpy of about 18 J / g to 22 J / g as measured using the method described herein. Contemplated yarns include yarns having any value within the given range, including values ​​at or about the lower or upper limit of the given range; comprising a second yarn, as modified below, having a yarn tenacity of about 3.2 to 3.6 g / d, as measured in accordance with EN ISO 2062; a yarn elongation of 37% to 43% as measured in accordance with EN ISO 2062, as modified below; a yarn shrinkage of about 0% to about 3% as measured at 50°C using the method described herein; and a melting enthalpy of about 35 J / g to about 42 J / g as measured using the method described herein. Contemplated yarns include yarns having any value within the given range, including values ​​at or about the lower or upper limit of the given range.

[0398] Formed articles and films

[0399] As discussed above, disclosed film described herein and the selective incorporation of low treatment temperature polymer composition and / or the selective incorporation of high treatment temperature polymer composition can be included in the parts through forming.In some aspects, these low treatment temperature polymer compositions can comprise the film of low treatment temperature polymer composition or exist through the form of formed parts.In some aspects, the film comprising low treatment temperature polymer composition or the parts through forming are substantially free of high treatment temperature polymer composition.In other aspects, the film comprising low treatment temperature polymer composition or the parts through forming are substantially composed of low treatment temperature polymer composition.These parts through forming can be manufactured by any suitable means known in the art for making formed parts, such as polymer extrusion, polymer blow molding, injection molding and processing.These films can be manufactured by any suitable means known in the art for making films, such as polymer extrusion.

[0400] Similarly, the high treatment temperature polymer composition described above can comprise the film of high treatment temperature polymer composition or exist through the form of shaped parts.In some respects, the film that comprises the high treatment temperature polymer composition or the parts through being shaped do not contain low treatment temperature polymer composition basically.In other aspects, the film that comprises the high treatment temperature polymer composition or the parts through being shaped are made up of the high treatment temperature polymer composition basically.These shaped parts can be manufactured by any suitable means for making shaped parts known in the art, for example polymer extrusion, polymer blow molding, injection molding and processing.These films can be manufactured by any suitable means for making films known in the art, for example polymer extrusion.

[0401] In some aspects, the film or formed part comprising the low processing temperature polymer composition may further comprise a high processing temperature polymer composition. For example, the film or formed part may be a two-component material formed by co-extrusion or co-injection of the low processing temperature polymer composition and the high processing temperature polymer composition.

[0402] In certain aspects, the films or formed components described herein can be used to provide specific functionality. For example, in certain aspects, a film comprising a low processing temperature polymer composition can be thermoformed to form a film having waterproof or water-resistant properties. In these aspects, the film on the outer surface of the article can be provided by utilizing a film 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 the low processing temperature polymer composition is not colored and can be formed from a polymer composition that is substantially free of pigments, colorants, or dyes, which can result in the area comprising the low processing temperature polymer composition being clear or approximately transparent (e.g., non-yarn or non-fiber material after thermoforming).

[0404] In one or more aspects, the film comprising the low treatment temperature polymer composition or the parts through forming can show the modulus from about 1MPa to about 500MPa. In some aspects, the yarn comprising the low treatment temperature polymer composition can show the modulus from about 5MPa to about 150MPa. In one aspect, the yarn comprising the low treatment temperature polymer composition can show the modulus from about 20MPa to about 130MPa. In another aspect, the yarn comprising the low treatment temperature polymer composition can show the modulus from about 30MPa to about 120MPa. In another aspect, the yarn comprising the low treatment temperature polymer composition can show the modulus from about 40MPa to about 110MPa. As used herein, the term "modulus" refers to the corresponding test method described below in property analysis and characterization program part.

[0405] In one or more aspects, when a film or formed part comprising a low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, m and then brought to a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 1 MPa to about 500 MPa when tested at approximately 20°C and a pressure of 1 ATM. In several aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 1 MPa to about 500 MPa when tested at approximately 20°C and a pressure of 1 ATM. m and then brought to a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 5 MPa to about 150 MPa when tested at approximately 20°C and a pressure of 1 ATM. In one or more aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 5 MPa to about 150 MPa when tested at approximately 20°C and a pressure of 1 ATM. m and then brought to a temperature below the melting temperature T of the low processing temperature polymer composition. mWhen the temperature of the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 20 MPa to about 130 MPa when tested at approximately 20°C and a pressure of 1 ATM. In one or more aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 20 MPa to about 130 MPa when tested at approximately 20°C and a pressure of 1 ATM. m and then brought to a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature of the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 30 MPa to about 120 MPa when tested at approximately 20°C and a pressure of 1 ATM. In one or more aspects, when the yarn comprising the low processing temperature polymer composition is brought to a temperature above the melting temperature T of the low processing temperature polymer composition, the resulting thermoformed material (e.g., a melted yarn component) can exhibit a modulus of from about 30 MPa to about 120 MPa when tested at approximately 20°C and a pressure of 1 ATM. m and then brought to a temperature below the melting temperature T of the low processing temperature polymer composition. m When the temperature is 200C and the pressure is 1 ATM, the resulting thermoformed material (e.g., the melted yarn component) can exhibit a modulus from about 40 MPa to about 110 MPa.

[0406] As discussed above, in some aspects, the low processing temperature polymer composition and the high processing temperature polymer composition have different properties. In various aspects, these different properties allow the low processing temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from the structure before the thermoforming process (e.g., thermoforming from a film or formed part into a melted or partially melted film or formed part), while when the thermoforming process is performed at a temperature lower than the creep relaxation temperature, heat deformation temperature, or Vicat softening temperature of the high processing temperature polymer composition, the high processing temperature polymer composition cannot be deformed or melted during this process and can maintain its structure (e.g., as a film or formed part). In these aspects, the melted 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 part), which can provide a three-dimensional structure and / or other properties targeted at a particular point on a wearable article.

[0407] In various aspects, the film or formed part can be a coated film or formed part. In another aspect, the coated film or formed part can be any suitable film or formed part having a coating formed thereon, the coating comprising a thermoplastic coating composition or other suitable coating.

[0408] In certain aspects, the thermoplastic coating composition comprises a low processing temperature polymer composition and optionally comprises one or more additives. In 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 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 certain aspects, the thermoplastic coating composition comprises a high processing temperature polymer composition and optionally comprises one or more additives. In 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 certain aspects, the thermoplastic coating composition comprises a TPU. In some aspects, the TPU can be, for example, any of the materials described in the present disclosure, for example, a TPU prepared by polymerizing an aromatic or aliphatic isocyanate with a polyether polyol or polycaprolactone using short-chain diols (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of disclosed TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0411] In various aspects, the thermoplastic coating composition may further include additives, such as, but not limited to, one or more of a thickener, a processing aid, a dye, or a colorant. In another aspect, the additive is not optional and comprises at least one thickener. In another aspect, the additive is not optional and comprises at least one processing aid. In 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 silicon dioxide, talc, or calcium carbonate (CaCO ).

[0412] In certain aspects, as described herein, a thickener can be used during the preparation of the thermoplastic coating composition to improve productivity and matte properties. In another aspect, the thickener is silica powder, talc, or CaCO 3 . The thickener is used, at least in part, 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 / butylene styrene (SEBS) resin, a polyacetal resin (POM), or a styrene acrylonitrile resin (SAN), which can impart compatibility with the thermoplastic polyurethane.

[0413] In certain aspects, the thermoplastic coating composition may include a treatment agent to improve productivity. In another aspect, the treatment agent may be montan wax or a fatty acid ester (C5-C9) with pentaerythritol. Other treatment agents are known to those skilled in the art and may also be used in the disclosed thermoplastic composition. An exemplary commercially available treatment agent is ESTANE 58277 (Lubrizol).

[0414] In certain aspects, a coated film or formed part having a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound used to coat the film or formed part. In another aspect, a TPU compound used to coat the film or formed part having a desired hardness can be prepared by controlling the content of the raw materials.

[0415] In certain aspects, a coated film or formed part can be prepared by compounding a thermoplastic coating composition comprising a thermoplastic polymer (e.g., thermoplastic polyurethane) and optionally one or more additives in a conventional extruder, and then applying the compounded thermoplastic polyurethane coating composition to the surface of the film or formed part. In yet another aspect, a process for preparing a coated film or formed part comprises the steps of: 1) preparing formed thermoplastic pellets; and 2) producing the coated film or formed part. The formed 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.

[0416] The step of preparing the shaped thermoplastic pellets may include the following steps: 1) mixing a thermoplastic polymer with various additives (such as a thickener and / or a processing aid) and feeding the mixture into the hopper of a conventional compounding extruder; 2) melting, kneading and compounding the mixture in the barrel of the compounding extruder at a suitable temperature and pressure; 3) cutting the compounded thermoplastic coating composition discharged through the die of the compounding extruder in cooling water to form pellets; and 4) drying the shaped thermoplastic polyurethane pellets at a suitable temperature for about a period of time, and aging the dried pellets at a suitable temperature for a suitable period of time.

[0417] In a specific example, the step of preparing the shaped thermoplastic pellets includes at least the following steps: 1) mixing thermoplastic polyurethane with various additives (such as thickeners and / or processing aids) and feeding the mixture into the hopper of a conventional compounding extruder; 2) melting, kneading and compounding the mixture in the barrel of the compounding extruder at a temperature of about 150-250° C. and a pressure of about 50-150 kgf; 3) cutting the compounded thermoplastic polyurethane discharged through the die of the compounding extruder in cooling water to form pellets; and 4) drying the shaped thermoplastic polyurethane pellets at a temperature of 60-80° C. for about 4 to 6 hours, and aging the dried pellets at a temperature of 30-50° C. for about 7 days or more.

[0418] In various aspects, the formed part or film comprises a polyamide or poly(ether block amide), when formed according to the AS T described herein below. m D3418-97 has a melting temperature (T m In yet another aspect, the polyamide or poly(ether block amide) is prepared according to the AS T described herein as follows. m D3418-97 is determined to have a melting temperature (T m In yet another aspect, the polyamide or poly(ether block amide) is prepared according to the AS T described herein below. m D3418-97 was determined to have a melting temperature (T m In some aspects, the polyamide or poly(ether block amide) is prepared according to the AS T described herein as follows. m D3418-97 is determined to have a melting temperature of about 90°C, about 91°C, about 92°C, about 93°C, about 94°C, about 95°C, about 96°C, about 97°C, about 98°C, about 99°C, about 100°C, about 101°C, about 102°C, about 103°C, about 104°C, about 105°C, about 106°C, about 107°C, about 108°C, about 109°C, about 110°C, about 111°C, about 112°C, about 113°C, about 114°C, about 115°C, about 116°C, about 117°C, about 118°C, about 119°C, about 120°C, or a melting temperature encompassed by any of the foregoing values ​​(T m ) values, or the aforementioned melting temperature (T m ) values.

[0419] In various aspects, the formed part or film comprises a polyamide or poly(ether block ...

Claims

1. A method for manufacturing a combined upper and outsole for an article of footwear, the combined upper and outsole comprising a medial midfoot region, a lateral midfoot region, and a ground-facing outsole region, the method comprising: A first reflow material is provided, wherein the first reflow material is a melted and resolidified product of a first yarn and comprises a low processing temperature polymer composition, wherein the low processing temperature polymer composition comprises one or more first thermoplastic polymers and exhibits a melting temperature T of 135° C. or less. m ; A second yarn is provided, the second yarn comprising a high processing temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high processing temperature polymer composition exhibits a higher melting temperature T than the low processing temperature polymer composition. m At least one of the following: 1) creep relaxation temperature T cr ; 2) Thermal deformation temperature T hd ; or 3) Vicat softening temperature T vs ; 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 via at least a portion of the first reflow material, wherein the first yarn forms a third course interconnected with the first course and the second course; and At least a portion of the first reflow material is present on the large ground-facing bottom area. 2 . The method of claim 1 , wherein the at least a portion of the first reflow material is on at least 40% of the ground-facing outsole area. 3 . The method of claim 2 , wherein the at least a portion of the first reflow material is over at least 90% of the ground-facing outsole area.

4. The method of claim 1 , wherein the combined upper and outsole further comprises an exterior surface having at least a first zone, a second zone, and a third zone, the second zone being positioned between the first zone and the third zone, wherein the first zone 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 reflow material compared to the second zone. The method of claim 4 , wherein the third zone is in the ground-facing outsole area.

6. The method of claim 1 , wherein at least a portion of the ground-facing outsole area comprises at least one anchor yarn.

7. The method of claim 4, wherein at least one anchor yarn extends from the third region to the second region.

8. The method of claim 4, wherein the first zone is in the medial midfoot area or the lateral midfoot area or both.

9. The method of claim 1, wherein the combined upper and outsole further comprises a pullover area, and wherein at least a portion of the pullover area comprises the first reflow material.

10. The method of claim 1, wherein the combined upper and outsole further includes a heel area, and wherein the heel area contains the first reflow material.

11. The method of claim 1 , wherein the combined upper and outsole further comprises an ankle collar area, and wherein the ankle collar area is substantially free of the first reflow material.

12. The method of claim 1, further comprising providing one or more traction elements in the ground-facing outsole area.

13. The method of claim 12, wherein the one or more traction elements are applied to the ground-facing outsole area as part of a melting and resolidification process of the first yarn.

14. The method of claim 1, wherein the second yarn is a package dyed yarn.

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

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

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

18. The method of claim 1, wherein the high processing temperature polymer composition exhibits a melting temperature T greater than 140°C. m .

19. The method of claim 1, wherein the high processing temperature polymer composition exhibits a melting temperature Tm that is lower than that of the low processing temperature polymer composition. m At least 10°C higher melting temperature T m .

20. The method of claim 1, wherein the first yarn exhibits a tenacity of 1 gram per denier to 5 grams per denier, exhibits an elongation of less than 130%, and exhibits a shrinkage of less than 60%.

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