Knit components and articles for improved ball control and durability

Abstract

A knitted component has a surface that includes first and second regions having different relative coefficients of friction and forming an alternating pattern. The first region of the first surface comprises 40% to 80% of the total surface area of the first surface. The alternating pattern can be in the form of concentric shapes. The alternating pattern can have linear and curvilinear borders between the first and second regions. The first region can be formed from a first yarn having a core and a coating. The coating at least partially surrounds the core.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to knitted textiles, components of articles of manufacture, and articles of manufacture such as articles of footwear and methods of manufacturing the same. BACKGROUND

[0002] Various articles of manufacture, including footwear, are formed from textiles that are typically interwoven (e.g., knitted) by one or more yarns while being worn. In particular, uppers for articles of footwear can be formed from knitted textiles. To increase durability and / or water resistance, non-textile components can be added and secured (e.g., glued, stitched) to the textile. For example, cross-linked polyurethane can be used as a durable cover layer, synthetic leather textile, or composite film layer. However, the addition of any additional layer, even a film, reduces the ability of the article to conform to the wearer and provide proprioceptive feedback, which can be particularly important for articles in certain sporting activities. For example, in articles of footwear for soccer (also known as football in other geographic regions), it can be important for the wearer to be able to feel the ball through the textile and have a certain level of traction or grip for ball control and dribbling. At the same time, too much grip in the footwear can interfere with the wearer’s ability to perform quick touch and dribble maneuvers. BRIEF DESCRIPTION OF DRAWINGS

[0003] Other aspects of the present disclosure will be appreciated upon reading and understanding the detailed description of the disclosure set forth below with reference to the accompanying drawings.

[0004] Figure 1A is a lateral perspective view of an article of footwear according to aspects herein.

[0005] Figure 1B is a lateral perspective view of an article of footwear according to aspects herein. Figure 1A is a medial perspective view of an article of footwear.

[0006] Figure 1C is a medial perspective view of an article of footwear having an alternative pattern according to aspects herein. Figure 1A is a medial perspective view of an article of footwear having an alternative pattern according to aspects herein.

[0007] Figure 2A is a schematic view of three interconnected courses of loops of a loop according to aspects herein, wherein the middle course of loops is formed from a first yarn and the outer courses of loops of the loop are formed from a second yarn.

[0008] Figure 2B is a schematic view of an interconnected course of loops of Figure 2A after exposure to a thermoforming process.

[0009] Figures 3A-3C depicts an exemplary perspective view of various protrusions and ridges molded into an outward-facing surface of a knitted component according to aspects herein.

[0010] Figure 4 is a medial side perspective view of another article of footwear according to aspects herein.

[0011] Figure 5A is a lateral side perspective view of yet another alternative article of footwear according to aspects herein.

[0012] Figure 5B is a medial side perspective view of an article according to aspects herein. Figure 5A is a medial side perspective view of an article according to aspects herein.

[0013] Figure 6 depicts a flowchart of a method of forming a knitted component according to the present disclosure. DETAILED DESCRIPTION

[0014] The subject matter of the present application is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps in order to achieve the same goals. Furthermore, although the terms “step” and / or “block” might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

[0015] Various articles of footwear, including footwear, are formed from textiles that are typically formed by interlacing (e.g., knitting) one or more yarns. In particular, uppers for articles of footwear can be formed from knitted textiles. To increase durability and / or water resistance, non-textile components can be added and secured (e.g., adhered, stitched) to the textile. For example, polyurethane (e.g., cross-linked polyurethane), synthetic leather textiles, or composite film layers can be used as a durable cover layer. However, the addition of any additional layer, even a film, reduces the ability of the article to conform to a wearer and provide a sense of proprioceptive feedback, which can be particularly important for articles in certain sporting activities. For example, in articles of footwear for soccer, it can be important for a wearer to be able to feel the ball through the textile and have a certain level of traction or grip for ball control and dribbling. At the same time, too much grip in the footwear can interfere with a wearer’s ability to perform quick touch and dribble maneuvers. Furthermore, as different portions of the footwear can be used for different types of movements, it can be desirable to have uppers with textiles that have different properties (e.g., patterns) in different portions.

[0016] As will be discussed in detail below, grip or traction for object (e.g., ball) control is achieved through alternating patterns of first and second regions having different grip. These alternating patterns help fine-tune ball control such that a desired amount of grip is achieved. For example, the textiles described herein, such as a knit component or a footwear upper, can include an alternating pattern of first regions having a first coefficient of friction and second regions having a second coefficient of friction that is different from or lower than the first coefficient of friction. This alternating between first and second regions on the surface of a footwear upper enables an interaction between the footwear upper and an object, such as a ball, that can enhance a wearer’s sense of control of the footwear upper. Moreover, it is contemplated that a surface of a footwear upper having an alternating pattern of first and second regions, where the first regions make up 40% to 80% of the total surface area of the outward-facing surface of a portion of the footwear upper (e.g., a ball contact zone), is effective for achieving a potentially enhanced sense of control for a wearer of the footwear upper.

[0017] It has been determined that thermoplastic elastomers can be incorporated into polymeric compositions that provide a level of abrasion resistance, traction (which can also be referred to as grip), or both, such that they are suitable for use in articles (e.g., apparel articles, footwear, and sports equipment) in which abrasion resistance or traction is desired. In many cases, the level of abrasion resistance, traction, or both, provided by these polymeric compositions is equal to or better than standard vulcanized rubber compositions used to make footwear, apparel, and sports equipment. Unlike vulcanized rubber, due to the thermoplasticity of these polymeric compositions and their properties in both solid and molten states, they can be readily formed into coated yarns having properties suitable for use in industrial scale knitting or weaving equipment. These properties enable the yarns to be readily incorporated into a variety of articles, including textiles using conventional manufacturing processes such as knitting and weaving, as well as industrial scale processes used to make nonwoven textiles. Moreover, unlike vulcanized rubber, these textiles and the articles into which these textiles are incorporated can then be thermoformed in such a way that the polymeric composition of the coated yarns is reflowed and creates an abrasion resistant or high grip surface on the textile or article without compromising other components of the textile or article, such as, for example, other yarns, other textiles, foams, molded resin components, etc.

[0018] At a high level, various aspects of the present disclosure relate to incorporating these thermoplastic elastomers into a textile in an article to maximize certain desired functionalities, such as ball control and durability. Specifically, a knitted component can include a first yarn having a first core yarn (also referred to herein as a “core”) and a first coating (also referred to herein as a “coating”) that includes a thermoplastic elastomer. The thermoplastic composition includes one or more thermoplastic elastomers that at least partially surround the first core yarn. The knitted component further includes a second yarn that is different from the first yarn. On a first surface of the knitted component (e.g., an outward-facing surface of an article formed from the knitted component), a first region is formed from the first yarn while a second region is formed from the second yarn. Due at least in part to the materials of the first yarn and the second yarn, the first region and the second region have different coefficients of friction relative to a common material. Specifically, the first region can have a higher coefficient of friction than the second region to provide increased grip in the first region relative to the second region. For example, the first region has a higher coefficient of friction with a ball surface than the coefficient of friction between the second region and the same ball surface. Further, the first region and the second region can form an alternating pattern, where the first region occupies 40% to 80% of the total surface area of the first surface (e.g., a ball-contacting portion of a footwear upper), which can provide an improved level of grip for the knitted component.

[0019] When the knitted component is integrated into an upper of an article of footwear, such as a soccer shoe, the alternating pattern of the first region and the second region can improve ball control and dribbling as well as provide durability. In some aspects, the alternating pattern includes a concentric shape pattern (e.g., a curvilinear boundary between the first region and the second region) on a medial side of the upper. In some aspects, the first region and the second region can form a different alternating striated pattern (e.g., a linear boundary between the first region and the second region). In examples, the striations generally extend from a bite line to a throat line, such as on a lateral side of the upper. While the concentric shape pattern of the first region and the second region on the medial side can be desirable for passing, receiving, and kicking motions, the more linear pattern on the lateral side can be desirable for drag or push motions of the ball.

[0020] Further, in some aspects, the knitted component can be thermoformed such that the first coating flows and occupies at least a portion of the space between courses of the first yarn or courses of the first core yarn. This arrangement can advantageously integrate 360-degree ball control directly into the knitted component without the need for a laminated skin, thereby streamlining the surface into a single functional layer. When the textile is used in an upper for a shoe or soccer shoe, this single functional layer can help to bring the wearer closer to the ball by removing layers therefrom, which in turn increases the proprioceptive feedback to the wearer and also improves ball control. Additionally, not including a laminated skin improves manufacturing efficiency by reducing post-knitting processes.

[0021] Aspects of the present disclosure can also include methods of manufacturing a knitted component. The method can include knitting a knitted component with a first yarn integrally knitted with a second yarn. As described above, the first yarn can include: a first core spun yarn; and a first coating at least partially surrounding the first core spun yarn and including a polymeric composition including one or more thermoplastic elastomers, the coating at least partially surrounding the first core spun yarn. Further, within the knitted component, the first yarn forms a first region on a first surface of the knitted component and the second yarn forms a second region on the first surface of the knitted component, where the first region has a different coefficient of friction than the second region. Further, as described above, the first region can form an alternating pattern with the second region.

[0022] Aspects also include methods of manufacturing a knitted component for an upper. As described above, a knitted component having a first yarn integrally knitted with a second yarn can be thermoformed such that the first coating can reflow and resolidify to create a thermoformed network of interlaced yarns. The thermoformed network includes: the first core spun yarn; and the first coating surrounding at least a portion of the first core spun yarn and occupying a space between at least some portions of the yarns in the thermoformed network. The method can also include molding the first surface to create a raised portion of the thermoformed network, where the raised portion can form a concentric pattern within the knitted component. Other aspects of the present disclosure can include methods of manufacturing an article of footwear by attaching an upper including a thermoformed knitted component to a sole structure.

[0023] As described above, certain aspects relate to one or more knitted components or thermoformed knitted components. In certain aspects, such knitted components or thermoformed knitted components form at least a portion of an athletic equipment article or an apparel article, including an article of footwear. In illustrative examples, aspects relate to an upper for an article of footwear formed from a knitted component. An article of footwear generally includes an upper and a sole structure. The upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot. As used herein, the term “upper” refers to a footwear component that extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot to form a void for receiving a wearer’s foot. Illustrative, non-limiting examples of uppers can include uppers incorporated into basketball shoes, cycling shoes, cross-training shoes, soccer (football) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. Further, in other aspects, the upper can also be incorporated into non-athletic shoes (e.g., dress shoes, loafers, and sandals). Thus, the concepts disclosed with respect to articles of footwear apply to a variety of footwear types.

[0024] Positional terminology used in describing uppers (e.g., top, bottom, front, side, back, upper, lower, lateral, medial, right, left, inward-facing, outward-facing, etc.) is used with respect to an upper as intended to be worn with the wearer standing upright such that the wearer’s feet are in the foot-receiving cavities and the wearer’s ankles or legs extend through the ankle openings. It will be appreciated, however, that the use of positional terminology does not depend on the actual presence of a person for purposes of explanation.

[0025] The term “knit component” refers to a piece of textile formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of interlooped loops that define courses and wales. As used herein, the term “course” refers to a primary horizontal row of knitted loops (in an upright textile as a knitted textile) produced by an adjacent needle during the same knitting cycle. A course can include one or more stitch types, such as knit stitches, held stitches, float stitches, tuck stitches, transfer stitches, rib stitches, and the like, which are known in the knitting arts. As used herein, the term “knit stitch” refers to a basic stitch type in which the loop of yarn is cleared from the needle after it has been drawn from the back to the front of the textile by a previous stitch. As used herein, the term “wale” refers to a primary vertical column of interlooped or interwoven knitted loops, typically produced by the same needle in successive (but not necessarily all) courses or knitting cycles. The knit components described herein can include weft-knit components or warp-knit components.

[0026] As used herein, the term “integral knit” can refer to a knitted textile in which the yarn from one or more knitted courses of one area is interwoven with one or more knitted courses of another area. The interweaving can be through simple knit stitches, tuck stitches, held stitches, float stitches, or the like. In this manner, the areas that are integral knit together have a seamless transition.

[0027] As used herein, the term“double knit construction” refers to a textile or textile portion that is knitted on a machine having two sets of needles in two needle beds or needle cylinders. Some aspects herein contemplate machines including weft-knitting (flat-knitting) machines. When describing flat-knitting machines, the term“needle bed” is often used. However, it should be appreciated that aspects herein can also relate to warp-knitting components. For purposes of describing in different ways, the term double knit construction refers to a textile having a front course of loops formed on a first needle bed and a back course of loops formed on a second needle bed. The front course of loops of the textile of the double knit construction is a course of loops of interlaced stitches that form a front layer of the textile, and the back course of loops is a course of loops of interlaced stitches that form a back layer of the textile such that the front and back layers of the textile can be formed substantially simultaneously. As used herein, the term“front layer” refers to a layer of the textile that is configured to face outward when an article incorporating the textile (such as an upper) is worn, and the term“back layer” refers to a layer of the textile that is configured to face a wearer’s skin surface when the article is worn.

[0028] Additionally, various measurements are provided herein. Unless otherwise indicated, the terms“about” or“substantially” with respect to a measurement means within ±10% of the indicated value.

[0029] Turning now to the drawings, and in particular Figure 1A and Figure 1B , an article of footwear 100 is depicted as one example wearing article. While Figure 1A and Figure 1B depict an article of footwear 100, it should be appreciated that the present disclosure also contemplates other wearing articles, including but not limited to apparel (e.g., shirts, jerseys, pants, shorts, gloves, eyewear, socks, hats, caps, jackets, undergarments) and containers (e.g., backpacks, bags). Figure 1A and Figure 1B The article of footwear 100 can generally include a ground-facing outsole region 110, an ankle collar region 112, a lateral midfoot region 114a, a medial midfoot region 114b, a forefoot region 116, and a heel region 118. In addition, the article of footwear 100 can include a plurality of eyelets 120, a tongue 124, and a throat region 126. As Figure 1A and Figure 1B depict, the article of footwear 100 is intended for use with a right foot; however, it should be appreciated that the following discussion can also apply to a mirror image of the article of footwear 100 intended for use with a left foot.

[0030] In some aspects, the article of footwear 100 includes a sole structure 104 and an upper 102. The sole structure 104 is secured to the upper 102 and extends between the foot and the ground when the article of footwear 100 is worn. In some aspects, the sole structure 104 includes a midsole 107 and an outsole 109. The midsole 107 can be secured to a lower region of the upper 102, such as a bottom cloth (not shown), and can include a cushioning element that includes a resilient material, such as a polymer foam or other suitable material. In other configurations, the cushioning element of the midsole 107 can incorporate further elements that attenuate forces, enhance stability, or influence foot motion, including fluid-filled chambers, plates, moderators, and / or other elements. The outsole 109 can be secured to a lower surface of the midsole 107 and can include a wear-resistant elastomeric material, such as a natural rubber material or a synthetic rubber material. The outsole 109 can be textured to impart traction, or can include one or more traction elements. The traction elements can be separate elements that are affixed to the outsole 109, or can be integrally formed with the outsole 109.

[0031] The upper 102 can be formed from various elements (e.g., a lace stay, a tongue collar, a medial side, a lateral side, a front, a head, a heel counter) that combine to provide a structure for securely and comfortably receiving a foot. While the configuration of the upper 102 can vary significantly, the various elements generally define a void within the upper 102 for receiving and securing a foot relative to the sole structure 104. The surfaces of the void within the upper 102 are shaped to accommodate the foot, and can extend over instep and toe areas of the foot, along medial and lateral sides of the foot, under the foot, and around a heel region of the foot.

[0032] At least a portion of the upper 102 can be formed from at least one knitted component 130, for example, by a weft knitting process or a warp knitting process on a flat knitting machine. The knitted component 130 can be formed as a single, unitary, integral element during a knitting process, such as weft knitting, warp knitting, or any other suitable knitting process. In some aspects, the knitted component 130 is formed by a knitting process that is different from a knitting process used to form other elements of the upper 102. Figure 1A and Figure 1B In the depicted example, the knitted component 130 forms an outer shell of the upper 102 that forms at least exterior surfaces of the lateral midfoot region 114a, the medial midfoot region 114b, the forefoot region 116, and at least a portion of the throat region 126 of the upper 102. In some aspects, the knitted component 130 also forms interior surfaces of the upper 102.

[0033] The upper 102 can also include one or more additional components, such as a textile component 140, which can be knitted, woven, non-woven, or other types of textiles. The textile component 140 can form at least a portion of the heel region 118, the ankle collar region 112, and the tongue 124. The textile component 140 can be a single textile component or can be formed from multiple textile components that are secured together. Further, in aspects where the textile component 140 can be integrally knitted with the knit component 130. Alternatively, the textile component 140 can be secured to the knit component 130 via at least one of stitching, adhesives, or the like.

[0034] The knit component 130 can include one or more different types of yarns for imparting different functionality. For example, the knit component 130 can include a first yarn and a second yarn. The first yarn (also referred to herein as a first coated yarn or a coated yarn) includes a first core yarn and a first coating that provides a first set of properties to the first yarn. The second yarn can have a different material composition than the first yarn. For example, the second yarn can include at least a coating that is different from the first coating of the first yarn, such that the second yarn exhibits different properties than the first yarn.

[0035] Further, within the first yarn, the first core yarn and the first coating can have different material compositions to provide different properties. For example, as described herein, the first coating can include a low processing temperature polymer composition, while the first core yarn can include a high processing temperature polymer composition, such that the first coating can melt or deform at a temperature at which the core yarn remains intact. In one aspect, the deformation temperature of the polymer composition of the core yarn of the first yarn is at least 20 °C higher than the melting temperature of the polymer composition of the first coating, such as a polymer composition including a thermoplastic composition. This allows the core yarn to be coated by the coating while the coating is in a molten state.

[0036] The first core yarn of the first yarn can include a monofilament yarn or a multifilament yarn, such as commercially available polyester or polyamide yarns, having properties such as denier and tenacity sufficient for the yarn to be manipulated by industrial scale knitting equipment. Further, the core yarn can be based on natural or man-made fibers, including polyester, high tenacity polyester, polyamide yarns, metal yarns, stretch yarns, carbon yarns, glass yarns, polyethylene yarns or polyolefin yarns, bi-component yarns, PTFE yarns, ultra-high molecular weight polyethylene (UHMWPE) yarns, liquid crystal polymer yarns, specialty effect yarns, or reflective yarns, or multi-component yarns containing one or more of these yarns. In example aspects, the core yarn includes a thermoplastic material including polyester.

[0037] In various aspects, the first core yarn can be coated by any method known in the art. In one aspect, the polymer composition disclosed herein for the first coating is suitable for manufacture by pultrusion and / or pulling through a bath of liquid polymer material. In yet another aspect, regardless of the coating process, sufficient coating material is provided on the first yarn such that, when knitted alone or with one or more other yarns in various configurations and subsequently thermoformed and allowed to reflow and resolidify, depending on the placement of the first yarn within the knitted structure, the coating material (e.g., the polymer composition including the thermoplastic elastomer) forms a structure having sufficient concentration of the coating material on one or more surfaces and / or within the first core yarn.

[0038] The first coating of the first yarn includes a polymer composition including a thermoplastic composition including a thermoplastic elastomer. While the polymer composition can be extruded as a thermoplastic elastomer composition and directly formed into fibers, filaments, yarns, or films from that polymer composition, due to the elastomeric nature of the polymer composition, these forms of the polymer composition would have a high level of stretch and thermal shrinkage. This means that the fibers, filaments, yarns, or films can tend to stretch around machine guides rather than slide over them, and can tend to shrink at temperatures typically encountered in industrial scale knitting and weaving equipment. However, by applying the polymer composition as a coating to a core yarn suitable for mechanical manipulation, the resulting coated first yarn retains the tenacity and resistance to stretch of the core yarn while also providing an outward facing surface with excellent resistance to drag and abrasion provided by the elastomeric nature of the polymer composition of the coating. For example, it has been found that a 150 denier core yarn having a tensile strength of at least 1 kilogram force and less than 20% strain at break and less than 20% thermal shrinkage can be coated with the polymer composition up to a nominal average outer diameter of about 1.0 millimeter and still retain its ability to be knitted or inlaid using commercial flat knitting equipment. Due to the ability to use such yarns on industrial scale equipment, such first yarns can also allow for new manufacturing methods that will allow for different placement of the polymer composition within a textile and article including the textile at a greater level of specificity in both location and amount as compared to conventional manufacturing processes.

[0039] Additionally, when the melting temperature of the polymeric composition is sufficiently below the deformation temperature of the first core spun yarn, the thermoplastic nature of the polymeric composition allows the composition to be melted and used to coat the first core spun yarn, and subsequently the knitted component 130 to be thermoformed to produce a thermoformed network comprising the first core spun yarn and the reflowed and re-solidified polymeric composition that solidifies the first core spun yarn. In one aspect, the thermoplastic elastomer of the coating polymeric composition has a glass transition temperature below -20 °C, which allows the thermoplastic elastomer present in the polymeric composition to be in its “rubbery” state even when the knitted component 130 is used in cold environments. In another aspect, the melting temperature of the coating polymeric composition is at least 100 °C, which can ensure that the polymeric composition does not melt when the knitted component 130 is transported or stored in hot conditions. In another aspect, the melting temperature of the coating polymeric composition is at least 130 °C, which ensures that the polymeric composition does not melt when the knitted component 130 is subjected to conditions that textiles often encounter during the manufacturing process of an article of footwear, apparel, or sporting equipment. In another aspect, the melting temperature of the coating polymeric composition is less than 170 °C, which ensures that the knitted component 130 can be thermoformed at temperatures that do not negatively affect other textiles or components that can form part of the upper 102. In another aspect, the melting enthalpy of the thermoplastic elastomer of the coating polymeric composition can be less than about 30 Joules / gram or 25 Joules / gram, which means that less heat and shorter heating times are needed to completely melt the polymeric composition and achieve good flow of the molten polymeric composition during the thermoforming process to better consolidate the network of yarns in the knitted component 130. In another aspect, the recrystallization temperature of the thermoplastic elastomer of the coating polymeric composition can be higher than 60 °C, or higher than 95 °C, which can facilitate the fast re-solidification of the polymeric composition after thermoforming, which can reduce the amount of time needed to cool the textile after thermoforming and can avoid the need to provide active cooling of the textile, thereby reducing cycle time and energy consumption.

[0040] Because the knitted component 130 includes the second yarn in addition to the first yarn (i.e., the coating yarn), the thermoformed network of yarns (i.e., the core spun yarn from the first yarn and the second yarn) is consolidated by the reflowed and re-solidified polymeric composition. The presence of the reflowed and re-solidified polymeric composition can serve one or more functions within the thermoformed textile, such as controlling the level of stretch within the entire knitted component 130 or only in regions thereof, forming a skin with high abrasion resistance and / or traction across the entire surface of the knitted component 130 or only in regions thereof, improving the water resistance of the entire surface of the knitted component 130 or only in regions thereof, or bonding all or only regions of the knitted component 130 to a substrate.

[0041] The use of the first yarn in the knitted component 130 can also reduce the number of different materials required to form the article. The coating of the first yarn can form a skin on the surface of the knitted component 130 upon thermoforming. Alternatively or additionally, the coating of the first yarn can act as an adhesive upon thermoforming to bond the yarns within the knitted component 130 together or to bond other elements to the surface of the knitted component 130. The use of the thermoformed knitted component 130 described herein can replace one or more of the conventionally added separate elements to increase abrasion resistance or create traction, thereby reducing waste and simplifying the manufacturing process while improving the recyclability of the article. Additionally, creating these properties within the knit structure of the knitted component 130, rather than as an added layer, facilitates the knitted component 130 to form to the shape of the wearer’s foot and enables more proprioceptive feedback to be achieved when, for example, playing soccer. It is noted that other balls can be used with the articles of footwear described herein without departing from the scope of the technology herein.

[0042] The thermoformed network of the thermoformed textile can form an outer-facing surface of the upper, such as Figure 1A and Figure 1B the first surface 105 of the knitted component 130. Surprisingly, the thermoformed network created by thermoforming the textile has superior ball contact properties in that the properties of the thermoformed network can equal or outperform those of kangaroo leather in terms of the rate of spin imparted to the ball by the upper when kicking the ball. For example, it has been found that the use of a polymer composition having a hardness (Shore A) of about 65 to about 85 results in an upper having improved ball spin rate. It has also been found that an upper comprising the textile described herein is equivalent to or outperforms a synthetic leather coated with a skin or a knitted upper in terms of traction in wet and dry conditions.

[0043] As described herein, the second yarn can be integrally knitted with the first yarn to form a thermoformed network in at least some regions of the knitted component 130. In particular, the knitted component 130 can have a first surface 105 that forms an outer-facing surface of the upper 102, as shown in Figure 1A and Figure 1B The knitted component 130 can also include an opposing second surface that can form an inner-facing surface of the upper 102 and is not visible in Figure 1A and Figure 1B The first surface 105 can include a plurality of first regions and a plurality of second regions (e.g., first regions 108 and second regions 106). To distinguish between these regions in Figure 1A and Figure 1B the first regions 104 are depicted with lighter shading than the second regions 106. However, it should be understood that the shading should not necessarily limit the relative coloring of these regions 104 and 106.

[0044] The first region 108 on the first surface 105 includes the first yarn, and the second region 106 on the first surface 105 includes the second yarn. In various aspects, the second region 106 does not include the first yarn at all or substantially. In some aspects, the first region 108 does not include the second yarn at all or substantially. In other aspects, the first region 108 can have a trace amount of the first yarn, and / or the second region 106 can have a trace amount of the second yarn, without departing from the technology described herein. A "trace amount" is defined herein as approximately less than 10% by weight of a particular yarn. For example, less than 10% by weight of the first yarn or less than 10% by weight of the second yarn.

[0045] As described above, the first yarn can have a first core-spun yarn and a first coating including a thermoplastic polymer composition. The thermoplastic polymer composition can include one or more thermoplastic elastomers at least partially surrounding the first core-spun yarn. The second yarn can include filaments of a thermoplastic material including a polyester. However, in examples, the second yarn does not include the thermoplastic polymer composition that makes up the first coating.

[0046] As described previously, the first yarn and the second yarn can have different physical properties. For example, the first coating of the first yarn has a first deformation temperature, and the second yarn has a second deformation temperature that is greater than the first deformation temperature. In certain aspects, the second deformation temperature is lower than the second melting temperature or the second decomposition temperature. In this way, the first yarn or at least the coating of the first yarn can melt, flow, or become molten to create the thermoformed network described herein, while the structure of the second yarn remains intact. In various aspects, the deformation temperature of the coating is at least 20 °C lower than the second deformation temperature of the second yarn. For example, in various aspects, the melting temperature of the coating of the first yarn is at least 100 °C, at least 130 °C, or at least 170 °C, and in each case, the second deformation temperature can be at least 20 °C higher than the melting temperature of the coating of the first yarn.

[0047] At least in part due to the selective use of the first and second yarns, the first region 108 has a different coefficient of friction than the second region 106. When referring to a relative coefficient of friction herein, the common test standard is applied to both the first and second regions. For example, the ASTM D1894 test can be used on a sample having only the first region to determine the static or dynamic coefficient of friction of the first region described herein. Likewise, the ASTM D1894 test can be used on a sample having only the second region to determine the static or dynamic coefficient of friction of the second region described herein. However, as described below, as long as the common test standard is applied to both the first and second regions, modified versions of the ASTM D1894 or other tests can be used without departing from the technology herein. In other words, when the first region has a higher coefficient of friction than the second region, a unique first region sample and a unique second region sample are measured using the same test (e.g., the same test standard and / or process) and the same conditions (e.g., wet, dry, temperature) such that the only variable in this example is the change in material for which the coefficient of friction is determined (e.g., the first region and the second region). Thus, the relative coefficient of friction between the first region and the second region can be determined (e.g., the first region has a higher coefficient of friction than the second region).

[0048] In some aspects, the first region 108 has a higher coefficient of friction than the second region 106. The coefficient of friction can be based on wet conditions or dry conditions. In various aspects, the first region 108 has a higher coefficient of friction than the second region in both wet conditions and dry conditions. In one aspect, the dry dynamic coefficient of friction of the first region 108 tested on a dry sample of soccer material is about 0.90 to about 1.50. Additionally, the wet dynamic coefficient of friction of the first region 108 tested on a wet sample of soccer material can be about 0.50 to about 0.80. Further, in some aspects, the difference between the dynamic coefficient of friction of the first region 108 on a dry sample of soccer material and the dynamic coefficient of friction of the first region 108 on a wet sample of soccer material is less than 40%. In this way, the first yarn forming the first region 108 can enable the first region 108 to have traction or grip on an object such as a soccer ball in both dry conditions and wet conditions. In this way, the first yarn can enable a wearer to have good ball control in various weather conditions and can reduce slippage of the soccer ball when wet. All of the coefficient of friction values disclosed herein can be obtained using the Textile-Ball Coefficient of Friction Test described below.

[0049] While grip, which can be represented by a coefficient of friction, aids in ball control, too much grip can slow the wearer's speed of maneuvering the ball. In some activities, such as soccer, a light, quick touch is sometimes desired, and thus, having an area that counteracts the coefficient of friction from the first area 108 can help provide an optimal level of overall grip and ball control. As such, the second area 106, which does not include the first yarn, has a lower coefficient of friction than the first yarn in wet conditions and dry conditions. For example, the coefficient of friction (wet or dry) of the second area 106 can be about 10% to about 75% less than the coefficient of friction (wet or dry) of the first area 108, about 15% to about 60% less than the coefficient of friction (wet or dry) of the first area 108, or about 20% to about 50% less than the coefficient of friction (wet or dry) of the first area 108.

[0050] The first area 108 and the second area 106 can also have other different physical properties. For example, the first yarn or the first coating of the first yarn and the second yarn can differ based on at least one of a hue, a value, and a chroma of their color. As such, the first area 108 and the second area 106 can differ based on at least one of a hue, a value, and a chroma of their color. Other visual differences between the first yarn and the second yarn and between the first area 108 and the second area 106 can be used without departing from the scope of the technology herein. However, in some aspects, the visual differences between the first area 108 and the second area 106 can be minimal or non-existent, while the differences in other physical properties remain.

[0051] As Figure 1A and Figure 1BAs shown, the first regions 108 and the second regions 106 form an alternating pattern on the surface of the upper 102. For example, one of the first regions 108 can be located between two of the second regions 106, or in other words, one of the second regions 106 can be located between two of the first regions 108. Alternating the first regions 108 and the second regions 106 in this manner can provide optimal grip within the regions of the upper 102 to improve ball control. In various aspects, the size and dimensions of each of the first regions 108 and the second regions 106 can vary depending on the amount of grip and / or ball control desired. For example, the size and dimensions of the first regions 108 can be similar to or different from the size and dimensions of the second regions 106, however, the ratio of the total surface area of the first regions 108 to the total surface area of the second regions 106 depends on the amount of grip and / or ball control desired. For example, where more grip and / or ball control is desired, the ratio of the total surface area of the first regions 108 to the total surface area of the second regions 106 can be greater, and where less grip is desired, the ratio of the total surface area of the first regions 108 to the total surface area of the second regions 106 can be less. In some aspects, the percentage of the total surface area within the regions of the first surface 105 of the knit component 103 that is occupied by the first regions 108 is in the range of about 40% to about 80%, in the range of about 50% to about 70%, and / or in the range of about 55% to about 65%. The ranges provided herein include the values at either end of the range. For example, the range of 40% to 80% includes 40% and 80%. As such, the percentage of the total surface area of the first surface 105 of the knit component 103 that is occupied by the second regions 106 can be in the range of about 20% to about 60%, in the range of about 30% to about 50%, and / or in the range of about 55% to about 65%.

[0052] Figure 1A The lateral side of the upper 102 depicted includes first regions 108 and second regions 106 arranged in an alternating stripe pattern that extends generally vertically when the upper 102 is in an as-worn condition with the sole structure 104 in contact with the ground. As such, the first regions 108 and the second regions 106 can generally extend from the bottom edge 150 of the knit component 130 toward the throat area 126. At least a portion of the bottom edge 150 of the knit component 130 can be aligned with the bite line 152 of the upper 102 that engages the sole structure 104. The stripes formed by alternating the first regions 108 and the second regions 106 on the lateral side can extend in the midfoot region 114a and the forefoot region 116. Further, in aspects where the knit component 130 extends into the heel region 118, the stripes can also extend in the heel region 118. The stripes are an example of an alternating pattern that includes linear boundaries between the first regions 108 and the second regions 106.

[0053] At least some of the stripes can have a zigzag configuration, a wavy line configuration, a parallel line configuration, and / or any other stripe configuration, such as stripes along the curvature of the knitted component 130. Additionally or alternatively, at least some of the stripes can have a varying width along their length. For example, the varying width can range from narrow to 3 millimeters to wide to 1 centimeter. Any number of stripes formed via the alternation of the first regions 108 and the second regions 106 can be included on the knitted component 130. In some aspects, the first regions 108 form 10 to 40 stripes on the first surface 105 of the knitted component 130, while in other aspects, the first regions 108 form 25 to 35 stripes on the first surface 105 of the knitted component 130. However, the number and configuration of the stripes depends on the amount of grip and / or ball control desired, and in turn, on the ratio of the total surface area of the first regions 108 to the total surface area of the second regions 106 as described above.

[0054] In Figure 1B The depicted medial side of the upper 102, the first regions 108 and the second regions 106 alternate to form a concentric shape pattern, or in other words, a “swirl” or “whirl” pattern. In this example, the concentric pattern of the first regions 108 and the second regions 106 includes irregularly shaped circles. The swirl or whirl pattern is an example of an alternating pattern with curvilinear boundaries between the first regions 108 and the second regions 106. Additionally or alternatively, the concentric shapes can be triangles, circles, ovals, parallelograms, pentagons, hexagons, stars, hearts, combinations thereof, or any combination of concentric shapes without departing from the scope of the technology described herein. The pattern is concentric in that at least the first regions 108 and the second regions 108 that are part of the concentric pattern are coaxial and share a common center. Figure 1B The center of the concentric pattern in the medial midfoot region 114b is located within the medial midfoot region 114b in the medial side and helps impart spin on a ball, such as a soccer ball, when kicking the ball. Within the zones of the concentric pattern closer to the center of the medial midfoot region 114b, the second regions 106 can cover more of the first surface 105 in this region of the upper than the first regions 108.

[0055] In some aspects, the concentric pattern within the medial midfoot region 114b can be nested between a series of stripes formed by alternating additional first regions 108 and additional second regions 106. One or more of these stripes adjacent to the concentric pattern can have a curvature or angle that corresponds to the curvature or angle of the shapes forming the concentric pattern, as Figure 1B shown.

[0056] Figure 1CAnother aspect depicts an alternating pattern of first regions 108 and second regions 106 on the medial side of the upper 102. In this configuration, the first regions 108 and second regions 106 can still generally form a pattern of concentric shapes, but these shapes can be formed by dashed lines of different lengths and curvatures that cooperatively form the shapes within the concentric pattern.

[0057] The use of different types of alternating patterns of first regions 108 and second regions 106 on the lateral and medial sides of the upper 102 reflects the different types of motions that can be performed in certain activities. For example, in soccer, the medial side of the foot is often used for passing, receiving, and / or kicking the ball, while the lateral side of the foot is used for other ball manipulations, such as dribbling or nudging the ball. As such, different ratios and patterns of first regions 108 and second regions 106 can provide different grip patterns that are suitable for particular activities. For example, the concentric pattern in the foot region 114b in the medial side provides a more omnidirectional variation in the coefficient of friction between the first regions 108 and the second regions 106, which can enable better ball control for passing, receiving, and / or kicking motions. As described above, the concentric pattern can also enable the wearer to impart more or less spin on the ball when kicking. Conversely, the striped pattern on the lateral side provides a variation in the coefficient of friction of the first regions 108 and the second regions 107 in a more longitudinal direction (i.e., a direction extending from the forefoot region 116 to the heel region 118), which enables better control of the ball when dribbling or nudging.

[0058] While aspects described herein feature concentric and striped patterns located on the upper of an article of footwear, it should be noted that such patterns can additionally or alternatively be placed on the sole or bottom of an article of footwear to reflect different types of motions that can be performed in certain activities. In particular, the patterns can be tailored to include different variations in the coefficient of friction of the first and second regions on the front or toe region of the outsole 109 versus the coefficient of friction on the back or heal region of the outsole 109.

[0059] As described above, some aspects of the knitted component 130 are double knit structures formed on two needle beds. Both the first and second yarns can be used to form knitted loops within the courses and / or along the wales on the front needle bed and loops on the back needle bed such that the first and second yarns can alternately form the first surface 105 of the knitted component 105. For example, the first yarn can form loops on the needles of the front needle bed to form the first regions 108, while the second yarn floats or forms loops on the needles of the back needle bed. While the second regions 106 can be formed when the second yarn forms loops on the needles of the front needle bed while the first yarn floats or forms loops on the needles of the back needle bed.

[0060] In some aspects, the knitted component 130 includes a third yarn that includes an elastomeric fiber or an elastomeric polyurethane material. In example aspects, the third yarn is knitted on a second surface of the knitted component 130 opposite the first surface 105. Specifically, the third yarn can be knitted on the second surface in areas opposite the first region 108 and the second region 106 on the first surface 105. In some aspects, the third yarn is knitted on only one needle bed, such as the back needle bed, so that the third yarn is only on the second surface and not on the first surface 105. Including the third yarn with an elastomeric fiber or an elastomeric polyurethane material on the second surface (e.g., the inward-facing surface) of the knitted component 130 provides some elasticity to the knitted component 130, which enhances proprioceptive feedback to the wearer when the knitted component 130 on the upper 102 comes into contact with an object, such as a ball.

[0061] As described above, the first yarn has a coating that can melt or deform and then solidify through the thermoforming process to form a thermoformed network with portions of the core yarn of the first yarn and one or more other yarns, such as the second yarn and, in some aspects, the third yarn. In this way, the thermoforming process can change at least a portion of the knit structure of the knitted component 130. For example, after knitting, the knitted component 130 can include interlinked courses of loops of the first yarn and the second yarn, and after thermoforming, the knitted component 130 can not include interlinked courses of loops of the first yarn and the second yarn in the thermoformed portion at least partially due to the deformation or melting of the coating of the first yarn. Meanwhile, the core yarn of the first yarn can still form interlinked loops with the second yarn, and the remaining loops can still be connected via the melted and re-solidified coating material.

[0062] Figure 2A A portion 200 of an example knitted component is schematically depicted prior to a thermoforming process, which can be the knitted component 130 of Figures 1A-1C . The portion 200 includes interlinked courses of loops of a first yarn 210, which can be a first coated yarn described herein, and a second yarn 208, which can be a second yarn described with respect to Figures 1A-1C . The portion 200 includes a first course of loops 202 and a second course of loops 204 with the second yarn 208, and a third course of loops 206 of the first yarn 210. In such aspects, the third course of loops 206 of the turns of the first yarn 210 can be interlinked (e.g., intermeshed) to the first course of loops 202 and the second course of loops 204 with the second yarn 208.

[0063] Figure 2B The portion 200 is depicted after being exposed to a thermoforming process. By comparing Figure 2A and Figure 2BAs can be seen, the first yarn 210, comprising the thermoplastic polymer composition as described herein, is thermoformed from a solid yarn structure into a molten yarn component 212, wherein the core-spun yarns 214 of the first yarn 210 retain their overlapping configuration. In some respects, the heating step of the thermoforming process causes at least partially the coating in the first yarn 210 to melt and flow, and is then subsequently cured into the molten yarn component 212 by completing the thermoforming process. This molten yarn component 212 is the coating surrounding the core-spun yarns 214 of the first yarn 210 after the coating has been melted, flowed, and re-cured. Figure 2B The molten yarn component 212 is depicted as contacting and at least partially surrounding the core-spun yarn 214 of the first yarn 210, and contacting and at least partially surrounding a portion of the second yarn 208, at least on the portions of the first and second loop rows 202 and 204 that interweave with or are close to the third loop row 206 forming the network. However, the molten yarn component 212 can be thermoformed to be more... Figure 2B The extensions described herein may be expanded to a greater or lesser extent without departing from the techniques described herein.

[0064] Compared to areas with molten yarn component 212 produced by thermoforming, areas with molten yarn component 212 produced by thermoforming can have increased abrasion resistance and increased water resistance. Furthermore, because these properties are provided through the knitted structure rather than applied as an additional layer or film, portions 200 of the knitted part can remain relatively thin and flexible. Thus, the molten yarn component 212 can be used in high-flex areas of the upper (such as the area between the throat and the forefoot) without premature wear or breakage.

[0065] Notice, Figure 2A and Figure 2B These are merely examples of knitting and thermoforming as described herein. Other knitted patterns, consisting primarily of the first yarn 210 or primarily of the second yarn 208, having any number of adjacent rows and / or any number of adjacent loops, can be used to form a first region (e.g., on the surface of a knitted part as described herein) on the surface of a knitted part. Figures 1A-1C First region 108) or second region (e.g. Figures 1A-1C The portion 200 shown is a single knitted layer, without departing from the scope of the invention. For example, for simplicity, the portion 200 shown has only a single knitted layer. However, it is conceivable that some aspects of this disclosure may include knitted parts with a double-knitted structure formed using needles on two needle beds. For example, a first yarn 210 may be knitted on the front needle bed to... Figure 2AIn the third course of loops 206, loops can be formed, which can form a first surface of the knitted component, and in another course of loops, such as in a course of loops that is knitted simultaneously with the first course of loops 202, the first yarn 210 can be knitted on the back needle bed to form at least a portion of a second surface of the knitted component. Similarly, the second yarn 208 can be knitted on the front needle bed to form at least a portion of the second surface of the knitted component in Figure 2A In the first course of loops 202 and the second course of loops 204, loops can be formed, which can form a first surface of the knitted component, and in another course of loops, such as in a course of loops that is knitted simultaneously with the third course of loops 206, the second yarn 208 can be knitted on the back needle bed to form at least a portion of a second surface of the knitted component. In some aspects, the first yarn 210 and / or the second yarn 208 can be moved back and forth between the front needle bed and the back needle bed within a single course of loops. Additionally, in some aspects where the portion 200 is part of a double knit structure, the loops of the course of loops for the second surface can be formed from a third yarn having an elastic fiber or an elastic polyurethane material. Further, in some aspects having a double knit structure, the fused yarn component 212 can extend between the knitted layers, but not fully through the back layer to form the second surface. In alternative configurations, the fused yarn component 212 can still fully extend through both knitted layers of the double knit structure.

[0066] Figures 3A-3CEach depicts an example of an outward-facing surface of a knitted part thermoformed with various textures or patterns. The knitted part can be, for example, knitted part 130 as described herein, having alternating first regions 108 and second regions 106, wherein the first region 108 is made of a first yarn and the second region 106 is made of a second yarn. Thermoforming of such a knitted part can be used to reflow and re-cur the coating of the first yarn as described herein, such that the coating material then occupies at least a portion of the space between the yarns in the thermoformed network of the yarn. As further described below, pressure can be applied during thermoforming when the knitted part 130 contacts a molding surface (such as a flat plate or a conventional two-piece mold). In some aspects, the molding surface may include recesses and / or protrusions to texture the protrusions on the first surface 105 of the knitted part 130. The protrusions molded into the knitted structure of the knitted part 130 can advantageously be used to adjust the grip of the knitted part, for example, the amount of grip between the first surface of the knitted part 130 (which may be the outer surface of a shoe upper) and a soccer ball. Specifically, due to the first yarn, the raised elements reduce the higher coefficient of friction (i.e., greater grip) of the first region 108. Thus, the raised elements can be placed in portions of the knitted part 130, where the first region 108 forms a larger portion of the surface area. Additionally, in some aspects, the raised elements may be located on the outer side of the upper rather than the inner side, or the inner side of the upper may have fewer raised elements than the outer side.

[0067] The protruding element 160 can have various shapes, sizes, and arrangements within the knitting part 130. Figure 3A In this example pattern, the raised elements 160 form elongated ridges or grooves that are closely spaced together and extend parallel to each other. The ridges may have different lengths. Additionally, Figure 3A The ridges extend across the first region 108 and the second region 106. Furthermore, the ridges can extend substantially perpendicular to the longitudinal direction of the first region 108 and the second region 106. Since the ridges can form recessed areas similar to grooves between themselves, they can also be operated to allow moisture and other small debris to escape from the first surface 105 of the knitted component 130. This allows for a better contact surface with the ball and, consequently, better grip and / or ball control in wet and / or dirty conditions. Additionally, elongated parallel grooves on the outer side of the upper can be particularly advantageous for dragging, pushing, and other such techniques. In some respects, the width of the grooves or recesses between the ridges and / or the spacing between them is in the range of 1 mm to approximately 1 cm. However, as described above, the pattern, width, and / or spacing of the ridges can be adjusted to adjust grip and / or ball control as desired.

[0068] exist Figure 3BIn some aspects, the raised elements 160 are in the form of tetrahedrons or pyramid-shaped protrusions extending from the first surface 105 of the knitted component 130. Figure 3B The protrusions in Figure 3B may be located in the first region 108 and the second region 106. In other aspects, the protrusions are located only in the first region 108. Additionally, the protrusions can be arranged in a generally linear pattern as shown in or can be arranged in a more clustered or random pattern.

[0069] In Figure 3C , the raised elements 160 form elongated ridges that are closely spaced together. These ridges can be spaced substantially equidistant from one another. Additionally, each groove can be curved or arched. Within this example pattern, the ridges can have different lengths and can cooperatively form slightly curved or curvilinear tracks of multiple rows and / or columns of elongated ridges or grooves. Similar to Figure 3A the raised elements 160 in Figure 3C , the ridges extend across the first region 108 and the second region 106. Further, the ridges can extend nearly perpendicular to the longitudinal direction of the first region 108 and the second region 106. As the ridges can form recessed regions between the ridges similar to grooves, the ridges are also operable to allow moisture and other small debris to escape the first surface 105 of the knitted component 130, which allows for a better contact surface with a ball. In some aspects, the width of the grooves or recesses between the ridges and / or the spacing from one another is in or about the range of 1 millimeter to 1 centimeter. Note that Figures 3A-3C the raised elements 160 depicted in are merely example patterns, and the first surface 105 of the knitted component 130 can be thermoformed to have a flat, shiny, uneven, or matte texture or pattern without departing from the scope of the technology described herein.

[0070] Figure 4 and Figures 5A-5B depict aspects of a knitted component for an article of footwear having an alternating pattern of first and second regions that is different than shown in Figures 1A-1C . Figure 4 An article of footwear 400 is depicted having a sole structure 404 and an upper 402. Aspects of the sole structure 404 can have generally the same configuration as described with respect to the sole structure 104 of Figures 1A-1B . Additionally, aspects of the upper 402 can have generally the same configuration as described with respect to the upper 102 of Figures 1A-1B . As such, the upper can be formed at least partially from a knitted component 430, and aspects of the knitted component 430 can have generally the same configuration as described with respect to the knitted component 130 of Figures 1A-1B , except as noted below.

[0071] The knitted component 430 is formed at least from first and second yarns having different material compositions and different properties. The knitted component 430 can be formed with the materials and techniques discussed above in connection with the component 130 of Figures 1A-1B The first surface 405 of the knitted component 430 can form an outward-facing surface of an upper, and have a first plurality of regions (first regions 408) formed from the first yarn and a second plurality of regions (second regions 406) formed from the second yarn.

[0072] Similar to the first regions 108 and the second regions 106 of Figures 1A-1B The first regions 408 and the second regions 406 can have different coefficients of friction. For example, the wet and dry coefficients of friction of the first regions 408 can be greater than the wet and dry coefficients of friction of the second regions 406. Further, the first regions 408 and the second regions 406 can be arranged in an alternating pattern at least on the medial side of the upper 402. In particular, the first regions 408 and the second regions 406 can alternate to form a pattern of concentric shapes, such as irregularly shaped circles and / or ellipses. A central zone of the concentric pattern can be located within the medial midfoot region 414. Unlike the knitted component 130 of Figure 1A and Figure 1B In the concentric shapes proximate the central zone, the second regions 406 can not have a substantially greater width than the first regions 408. Rather, the concentric circles or ellipses forming the first regions 408 in the central zone can have a similar surface area to the surface area of the concentric circles or ellipses forming the second regions 406 in the central zone. Thus, the central zone of the concentric pattern on the medial midfoot region 414 can provide a greater grip than the central zone of the concentric pattern on the medial midfoot region 114a of Figure 1B

[0073] It should be appreciated that the first regions 408 and the second regions 406 can also form an alternating pattern on the lateral side of the upper, similar to the pattern described in connection with Figure 1A It should be further appreciated that at least some of the first regions 408 on the first surface 405 of the knitted component 430 can be subjected to heat forming to create a network of heat-formed regions similar to the heat-formed network described in connection with the knitted portion 200 of Figure 2A and Figure 2B Additionally, in some aspects, the heat-formed first surface 405 can be molded to include raised structures within the first regions 408 and / or the second regions 406. These raised structures can include any of the patterns described in connection with Figures 3A-3C

[0074] Figure 5A and Figure 5B depicts another configuration of an alternating pattern in accordance with some aspects herein. Figure 5A and Figure 5B ​​An article of footwear 500 is depicted having a sole structure 504 and an upper 502. Aspects of the sole structure 504 can have substantially the same configuration described with respect to the sole structure 104 of Figures 1A-1B Additionally, aspects of the upper 502 can have substantially the same configuration described with respect to the upper 102 of Figures 1A-1B As such, the upper can be formed at least partially from a knit component 530, and aspects of the knit component 530 can have substantially the same configuration, materials, and / or properties described with respect to the knit component 130 of Figures 1A-1B

[0075] A first surface 505 of the knit component 530 can form an outward-facing surface of the upper (similar to the first surface 105 of Figures 1A-1B and have a first plurality of regions (first regions 508) formed from the first yarn and a second plurality of regions (second regions 506) formed from the second yarn. Similar to the first regions 108 and the second regions 106 of Figures 1A-1B the first regions 508 and the second regions 506 can have different coefficients of friction. For example, the wet and dry coefficients of friction of the first regions 508 can be greater than the wet and dry coefficients of friction of the second regions 506.

[0076] Further, the first regions 508 and the second regions 506 can be arranged in an alternating pattern on concentric shapes formed on a medial side of the upper 502. Specifically, the first regions 508 and the second regions 506 can alternate to form a pattern of concentric triangles in a medial forefoot region 514 of the medial side, as at least Figure 5B illustrated. In some aspects, the concentric triangles can have rounded or pointed corners. In some aspects, the concentric pattern within the medial midfoot region 514 can be nested within a zigzag pattern formed on the remainder of the knit component 530, such as in the forefoot region 516, the heel region 518, and the lateral midfoot region 512 (as shown in Figure 5A

[0077] The zigzag pattern of the first regions 508 and the second regions 506 can be located on a lateral side of the upper 502. Within this pattern, the first regions 506 and the second regions 508 can generally extend from a bottom edge 550 of the knit component 530 toward a throat area 526 of the upper 502. At least a portion of the bottom edge 550 of the knit component 530 can align with a bite line 552 of the upper 502 engaging the sole structure 454. The zigzag stripes formed by alternating the first regions 508 and the second regions 506 on the lateral side can extend in the lateral midfoot region 512, as well as the forefoot region 516. Further, in aspects where the knit component 530 extends into the heel region 518, the stripes can also extend in the heel region 518. ​​

[0078] The zig-zag pattern can have various sizes. In some aspects, the streaks within the zig-zag pattern can be generally parallel to each other. Further, in some aspects, at least some points or corners of at least some of the streaks having the zig-zag pattern on the medial side can align with at least one point or one corner of the outermost one of the concentric triangles in the foot region 514 on the medial side, such that the outermost triangle is nested at the corner of one of the streaks of the zig-zag pattern.

[0079] Additionally, in Figure 5A and Figure 5B In described aspects, the upper 502 includes a textile component 556 that forms an exterior of the throat region 526. This textile component 556 can act as an outer cover to cover the laces and eyelets (similar to that shown in Figure 1A and Figure 1B The textile component 556 can be integrally knit and have an integral knit construction with the knit component 530 having the first region 508 and the second region 506. Alternatively, the textile component can be formed separately from the knit component 503 and secured to the knit component 530 at one or more locations via stitching, adhesion, or the like.

[0080] Figure 6 includes a flowchart depicting an example method 600 of manufacturing a knit component, such as the knit components 130, 430, and / or 530 described above. The steps provided in the method 600 are merely illustrative, and the method 600 can include additional steps that are not illustrated. At least some of the steps of the method 600 are indicated as being performed on a knitting machine, which can be an automatic knitting machine. As such, one or more of these steps can be performed and / or controlled using a control unit having a processor or computer communicatively coupled to or integrated into the knitting machine. In example aspects, the knitting machine used to perform the steps of the method 600 is a V-bed flat knitting machine having two needle beds (a front needle bed and a back needle bed) that are angled relative to each other to form a V-bed. However, it should be understood that this is one example, and other knitting machines can be used to form the knit component or a portion thereof. Similarly, in example aspects, the knitting steps within the method 600 can be a weft knitting process, but in alternative aspects, a warp knitting process can be used.

[0081] At block 602, the method 600 includes knitting a knitted component with a first yarn knit integrally with a second yarn. As described above, the first yarn can include: a first core spun yarn; and a first coating including a polymeric composition including one or more thermoplastic elastomers at least partially surrounding the first core spun yarn. The knitting of the knitted component at block 602 can include: knitting the first yarn such that the first yarn forms a first region on a first surface of the knitted component, and knitting the second yarn such that the second yarn forms a second region on the first surface of the knitted component. To form the first region, the first yarn can loop around a needle on a first (i.e., front) needle bed as the second yarn floats behind loops of the first yarn and / or forms loops around needles on a second (e.g., back) needle bed. To form the second region, the second yarn can loop around a needle on the first needle bed as the first yarn floats behind loops of the second yarn and / or forms loops around needles on the second needle bed. Example aspects of the first region and the second region formed at block 602 can be with respect to any of the first region and the second region described above. Figures 1A-5B Additionally, the method 600 can further include: knitting a third yarn having an elastic fiber or an elastic polyurethane material on the second needle bed such that the third yarn forms a second (i.e., back or inward-facing) surface of the knitted component.

[0082] At block 604, the method 600 includes thermoforming at least the first region of the knitted component such that the first coating of the first yarn flows and occupies at least a portion of a space between courses of loops of the first yarn or courses of loops of the first core spun yarn. Additionally or alternatively, the thermoforming can allow the first coating to flow and occupy at least a portion of a space between courses of loops of the first core spun yarn and the second yarn. The thermoforming can cause the polymeric composition of the coating to create a thermoformed network of interlaced yarns including the first core spun yarn and the first polymeric composition surrounding at least a portion of the first core spun yarn and occupying a space between at least some portions of the yarns in the thermoformed network. The thermoformed network can primarily extend through the first region on the first surface of the knitted component, but it should be understood that at least portions of the second region of the knitted component formed by the second yarn can contact and at least partially surround the melted and re-solidified thermoplastic polymeric composition, thereby creating the thermoformed network.

[0083] Further, the thermoforming step at block 604 includes raising a temperature of the thermoplastic polymeric composition (i.e., the coating of the first yarn) to a temperature that causes at least a portion of the thermoplastic polymeric composition as described herein to melt and flow or deform. Further, the thermoforming process includes subsequently lowering the temperature of the thermoplastic polymeric composition to solidify the reflowed thermoplastic polymeric composition as described herein into a desired configuration and / or shape, such as an article of footwear.

[0084] The knitted component can be thermoformed using a molding surface such as a plate or two-piece mold. The knitted component can be heated prior to contacting the molding surface or can be heated simultaneously with contacting the molding surface. In certain aspects, the temperature of the thermoplastic polymer composition can be increased for a period of about 10 seconds to about 5 minutes. In aspects, the temperature of the thermoplastic polymer composition can be increased for a period of about 30 seconds to about 5 minutes. In one aspect, the temperature of the thermoplastic polymer composition can be increased for a period of about 30 seconds to about 3 minutes. Further, in some aspects, the thermoplastic polymer composition can be exposed to the heating temperature multiple times prior to being subjected to cooling.

[0085] For cooling, the knitted component can be moved to a cooling zone of reduced temperature. Cooling allows the thermoplastic polymer composition to re-solidify in locations where it is in a state of flow, at which the thermoplastic polymer composition occupies at least a portion of the space between courses of the first yarn and / or courses of the first core spun yarn. Further, the first polymer composition (e.g., a polymer composition including a thermoplastic composition including a thermoplastic elastomer) can be cooled to re-solidify in locations where it is in a state of flow, at which the thermoplastic polymer composition occupies at least a portion of the space between courses of the first core spun yarn and courses of the second yarn.

[0086] Further, in some aspects, pressure can be applied during or after the application of heat. In certain aspects, the thermoforming exposes the material on the mold surface to a pressure of about 50 kPa to about 300 kPa. In aspects, the thermoforming exposes the material on the mold surface to a pressure of about 50 kPa to about 250 kPa. In one aspect, the thermoforming exposes the material on the mold surface to a pressure of about 100 kPa to about 300 kPa.

[0087] In some aspects of the method 600, the textured molding surface can be used to impart a three-dimensional texture on the first surface of the knitted component. For example, by applying heat and optionally pressure, the textured molding surface can cause the molten thermoplastic polymer composition to form raised elements in the first surface. The raised elements can be of any form or pattern described. The textured molding surface can be used for the first application of heat or a subsequent application of heat during thermoforming. Figures 3A-3C The described any form or pattern. The textured molding surface can be used for the first application of heat or a subsequent application of heat during thermoforming.

[0088] By selectively incorporating the first yarn (having a coating including a thermoplastic polymer) into the first region of the knitted component via knitting prior to thermoforming, the manufacturing process can be streamlined. Specifically, it enables the entire knitted component to be exposed during thermoforming without the need to mask or protect certain regions (i.e., the second region) while maintaining the selective arrangement of the thermoforming network, resulting in a more time and energy efficient manufacturing process.

[0089] In some aspects, the method 600 includes forming the knitted component into an upper at block 606. The knitted component can already be knitted into the shape of an upper, and can form the upper by folding one or more portions and / or joining one or more edges to create a foot-receiving void. In some aspects, the knitted component can be a larger piece of textile that is cut into the shape of an upper or a component of an upper, such as an outer shell. In some aspects, block 606 includes securing the thermoformed knitted component to one or more textile components by stitching, adhesion, or the like.

[0090] In some aspects, the method 600 can include a step of attaching the upper or another such thermoformed knitted component to a sole structure, as shown at block 608. The attachment can be achieved via thermoforming the upper or knitted component and the sole structure together, and / or can be achieved by mechanical techniques or other attachment techniques known in the art.

[0091] Exemplary properties of first yarns

[0092] As described above, the textiles and shaped components can include the selective incorporation of the described yarns (referred to above as first yarns) alone or in combination with other materials (e.g., second yarns that do not fall under the fibers, filaments, and yarns described herein). In certain aspects, the yarns and / or fibers described herein can be used to provide specific functionality. For example, in certain aspects, the yarns as described herein can be thermoformed to form a membrane having waterproof or water-resistant properties.

[0093] In one aspect, the coated yarns described herein, such as the first yarns, have a breaking strength of about 0.6 kilograms to about 0.9 kilograms of applied force, or about 0.7 kilograms to about 0.9 kilograms of applied force, or about 0.8 kilograms to about 0.9 kilograms of applied force, or greater than 0.9 kilograms of applied force.

[0094] In one aspect, the yarns described herein are produced from fibers or filaments that include only a single thermoplastic elastomer. In other aspects, the fibers include a blend of two or more different thermoplastic elastomers.

[0095] In one aspect, the yarn is a coated yarn, wherein the core yarn includes a second polymeric composition and a coating disposed on the core yarn, the coating including the first polymeric composition, wherein the first polymeric composition has a first melting temperature. In one aspect, the second polymeric composition is a second thermoplastic composition having a second deformation temperature, and the second deformation temperature is at least 20 °C greater, at least 50 °C greater, at least 75 °C greater, or at least 100 °C greater than the first melting temperature of the first polymeric composition. In another aspect, the second polymeric composition is a second thermoplastic composition having a second melting or deformation temperature, and the second deformation temperature is about 20 °C greater, about 50 °C greater, about 75 °C greater, or about 100 °C greater than the first melting temperature of the first polymeric composition.

[0096] In one aspect, the first polymeric composition includes a polymeric component. In one aspect, the first polymeric composition can include a single polymeric component (e.g., a single thermoplastic elastomer). In other aspects, the first polymeric composition can include two or more polymeric components (e.g., two or more different thermoplastic elastomers).

[0097] In one aspect, the second polymeric composition is a first thermoset composition. In one aspect, the second polymeric composition includes a second thermoset composition. The core yarn can be any material that retains its strength at the temperature at which the first polymeric material is extruded during the coating process. The core yarn can be a natural or regenerated fiber or filament, or a synthetic fiber or filament. In one aspect, the core yarn can include a cotton, silk, wool, rayon, nylon, spandex, polyester, polyamide, polyurethane, or polyolefin. In one aspect, the core yarn includes polyethylene terephthalate (PET). In one aspect, the second polymeric composition has a deformation temperature greater than 200 °C, greater than 220 °C, greater than 240 °C, or in a range between about 200 °C and about 300 °C.

[0098] In one aspect, the core yarn is a spun yarn, a multifilament yarn, or a monofilament yarn. In one aspect, the core yarn is multi-twisted. In one aspect, the core yarn has a linear density of about 100 denier to about 300 denier, or about 100 denier to about 250 denier, or about 100 denier to about 200 denier, or about 100 denier to 150 denier, or about 150 denier to 300 denier, or about 200 denier to 300 denier, or about 250 denier to 300 denier. In one aspect, the core yarn has a thickness of about 60 microns to 200 microns, about 60 microns to 160 microns, about 60 microns to 120 microns, about 60 microns to 100 microns, about 100 microns to 200 microns, or about 140 microns to 200 microns.

[0099] In an aspect, the core yarn is polyethylene terephthalate having a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to 160 denier. In an aspect, the core yarn is polyethylene terephthalate having an elongation of about 20% to about 30%, about 22% to about 30%, about 24% to about 30%, about 20% to about 28%, or about 20% to about 26%. In an aspect, the core yarn is polyethylene terephthalate having a tenacity of about 1 gram / denier to about 10 grams / denier, about 3 grams / denier to about 10 grams / denier, about 5 grams / denier to about 10 grams / denier, about 1 gram / denier to about 7 grams / denier, or about 1 gram / denier to about 5 grams / denier.

[0100] In an aspect, the coated yarn can be produced by extruding the coating layer (i.e., the first polymeric composition) onto the core yarn through an annular die or orifice such that the coating layer is axially centered around the core yarn. The thickness of the coating layer applied to the core yarn can vary depending on the application of the yarn. In an aspect, the coated yarn is used to produce a knit textile. In an aspect, the coated yarn has a nominal average outer diameter of at most 1.00 millimeter, or at most about 0.75 millimeter, or at most about 0.5 millimeter, or at most about 0.25 millimeter, or at most about 0.2 millimeter, or at most about 0.1 millimeter. In another aspect, the coating layer has a nominal average outer diameter of about 0.1 millimeter to about 1.00 millimeter, or about 0.1 millimeter to about 0.80 millimeter, or about 0.1 millimeter to about 0.60 millimeter. In another aspect, the coating layer on the yarn has an average radial coating thickness of about 50 micrometers to about 200 micrometers, or about 50 micrometers to about 150 micrometers, or about 50 micrometers to about 125 micrometers.

[0101] In an aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier and the coating layer has a nominal average outer diameter of about 0.10 millimeter to about 0.50 millimeter, or about 0.10 millimeter to about 0.25 millimeter, or about 0.10 millimeter to about 0.20 millimeter. In an aspect, the core yarn is polyethylene terephthalate having a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier and the coating layer has a nominal average outer diameter of about 0.10 millimeter to about 0.50 millimeter, or about 0.10 millimeter to about 0.25 millimeter, or about 0.10 millimeter to about 0.20 millimeter.

[0102] In further aspects, the coated yarn has a net overall diameter of about 0.2 millimeters to about 0.6 millimeters, or about 0.3 millimeters to about 0.5 millimeters, or about 0.4 millimeters to about 0.6 millimeters. In some aspects, a lubricating oil, including but not limited to mineral oil or silicone oil, is present on the yarn at about 0.5 weight percent to about 2 weight percent, or about 0.5 weight percent to about 1.5 weight percent, or about 0.5 weight percent to about 1 weight percent. In some aspects, the lubricating composition is applied to the surface of the coated yarn prior to or during the process of forming the textile. In some aspects, the thermoplastic composition and the lubricating composition are miscible when the thermoplastic composition is reflowed and resolidified in the presence of the lubricating composition. After reflowing and resolidifying, the reflowed and solidified composition can include the lubricating composition.

[0103] In one aspect, the core-spun yarn has an elongation of about 8% to about 30%, about 10% to about 30%, about 15% to about 30%, about 20% to about 30%, about 10% to about 25%, or about 10% to about 20%. In one aspect, the core-spun yarn has a tenacity of about 1 gram per denier to about 10 grams per denier, about 2 grams per denier to about 8 grams per denier, about 4 grams per denier to about 8 grams per denier, or about 2 grams per denier to about 6 grams per denier.

[0104] In one aspect, the polymeric composition of the first coating has a melting temperature of about 100 °C to about 210 °C, optionally about 110 °C to about 195 °C, about 120 °C to about 180 °C, or about 120 °C to about 170 °C when thermoformed. In another aspect, the first polymeric composition has a melting temperature greater than about 120 °C and less than about 170 °C, and optionally greater than about 130 °C and less than about 160 °C.

[0105] In further aspects, when the melting temperature is greater than 100 °C, the integrity of an article formed from or incorporating the first polymeric composition is maintained if the article is briefly exposed to a similar temperature, for example during shipping or storage. In another aspect, when the melting temperature is greater than 100 °C or greater than 120 °C, an article formed from or incorporating the first polymeric composition can be subjected to steam treatment without melting or uncontrolled fusing of any polyester components included in the article for purposes such as filling, banded surfaces, or comfort features, and for stretch yarns for comfort and fit features.

[0106] In one aspect, when the melting temperature is greater than 120 °C, the material incorporating the first or second polymer composition disclosed herein is unlikely to soften and / or become tacky during use on a hot-paved surface, a court surface, an artificial or natural soccer field or similar playing surface, a track or a field during a sporting event. In one aspect, the higher the melting temperature of the first or second polymer composition and the greater its melting enthalpy, the greater the ability of the article of footwear or sporting equipment incorporating or constructed from the first or second polymer composition to withstand a heat- inducing excursion, a frictional surface heat- inducing event, or an environmental heat- inducing excursion. In one aspect, such heat excursions can occur when the article contacts a hot ground, court or turf surface, or frictional heat due to friction or abrasion can occur when the article contacts another surface such as the ground, another shoe, a ball, etc.

[0107] In another aspect, when the melting temperature is less than about 210 °C, or less than about 200 °C, or less than about 190 °C, or less than about 180 °C, or less than about 175 °C, but greater than about 120 °C, or greater than about 110 °C, or greater than about 103 °C, the polymer-coated yarn can be melted for the purpose of molding and / or thermoforming a given zone of a textile knitted therefrom in order to impart the desired design and aesthetic features in a short period of time.

[0108] In one aspect, a melting temperature below 140 °C prevents or mitigates the risk of dye migration from the polyester yarn incorporated in the article of footwear or other article. In a further aspect, dye migration from a packaged dyed polyester yarn or filament is a diffusion-limited process, and short-term exposure to temperatures greater than 140 °C (e.g., in a thermoforming process) does not extensively damage, discolor, or otherwise render the appearance of the article of footwear or other article unacceptable. However, in another aspect, if the melting temperature of the polymer coating is greater than about 210 °C, thermal damage and dye migration can occur.

[0109] In one aspect, a high melting enthalpy indicates that a longer heating time is required to ensure that the polymer is completely melted and will flow well. In another aspect, a low melting enthalpy requires less heating time to ensure complete melting and good flow.

[0110] In a further aspect, a high cooling exotherm curve indicates a fast transition from molten to solid. In another aspect, a higher recrystallization temperature indicates that the polymer is able to solidify at a higher temperature. In one aspect, a high temperature solidification is beneficial for thermoforming. In one aspect, a recrystallization above 95 °C promotes fast solidification after thermoforming, reduces cycle time, reduces cooling requirements, and improves the stability of the shoe component during assembly and use.

[0111] In one aspect, the viscosity of the coating compositions disclosed herein affects the properties and handling of the coating compositions. In a further aspect, a high viscosity at low shear rates (e.g., less than 1 reciprocal second) indicates fluidic resistance, displacement, and more solid-like behavior. In another aspect, a low viscosity at higher shear rates (e.g., greater than 10 reciprocal seconds) lends itself to high speed extrusion. In one aspect, as the viscosity increases, the ability to flow and deform sufficiently to coat a core spun yarn substrate becomes challenging. In another aspect, materials that exhibit a high shear thinning index (e.g., where the viscosity at 10 or 100 reciprocal seconds is lower than the viscosity at 1 reciprocal second) can be difficult to extrude, and the melt can break if coated or extruded at too high a speed.

[0112] In one aspect, the composition forming the first region has a durometer Shore A hardness of about 50 to about 90 Shore A, optionally about 55 to about 85 Shore A, about 60 to about 80 Shore A, about 60 to about 70 Shore A, or about 67 to about 77 Shore A.

[0113] In various aspects, the first polymer composition for coating a yarn has a cold ross flex test result of about 120,000 to about 180,000, or about 140,000 to about 160,000, or about 130,000 to about 170,000 when tested on a thermoformed plaque of the first polymer composition for coating a yarn according to the cold ross flex test described below.

[0114] In one aspect, the polymer composition or coating of the first yarn or first region has two or more of the first properties provided above, or optionally three or more, four or more, five or more, six or more, seven or more, or all ten of the first properties.

[0115] In addition to the first property, the first yarn or the first coating or polymeric composition of the first region has one or more second properties when thermoformed. In one aspect, the first yarn or the first coating or polymeric composition of the first region has a glass transition temperature of less than 50 °C, alternatively less than 30 °C, less than 0 °C, less than -10 °C, less than -20 °C, or less than -30 °C when thermoformed. In one aspect, the first yarn or the first coating or polymeric composition of the first region has a stress at break of greater than 7 MegaPascals, alternatively greater than 8 MegaPascals, as determined using the Modulus, Tenacity and Elongation Test at 25 °C when thermoformed. In one aspect, the first yarn or the first coating or polymeric composition of the first region has a tensile stress at 300% modulus of greater than 2 MegaPascals, alternatively greater than 2.5 MegaPascals, or greater than 3 MegaPascals, as determined using the Modulus, Tenacity and Elongation Test at 25 °C when thermoformed. In one aspect, the first yarn or the first coating or polymeric composition of the first region has an elongation at break of greater than 400%, alternatively greater than 450%, alternatively greater than 500%, or greater than 550%, as determined using the Modulus, Tenacity and Elongation Test at 25 °C when thermoformed. In another aspect, the first yarn or the first coating or polymeric composition of the first region has two or more of the second properties, or alternatively three or more, or all four of the second properties when thermoformed.

[0116] In certain aspects, the films, fibers, and yarns described herein can exhibit a tenacity of greater than 1 gram per denier. In one aspect, the films, fibers, and yarns described herein can exhibit a tenacity of from about 1 gram per denier to about 5 grams per denier. In one or more aspects, the films, fibers, and yarns described herein can exhibit a tenacity of from about 1.5 grams per denier to about 4.5 grams per denier. In one aspect, the films, fibers, and yarns described herein can exhibit a tenacity of from about 2 grams per denier to about 4.5 grams per denier. As used herein, “tenacity” refers to a property of a fiber or yarn and is determined using the corresponding test method and sampling procedure as described below. Specifically, the tenacity and elongation of a yarn sample is determined according to the test method detailed in EN ISO 2062, wherein the pre-load is set to 5 grams. The elongation is recorded at the maximum tensile force value applied before break. The tenacity can be calculated as the ratio of the load required to break the sample to the linear density of the sample.

[0117] In certain aspects, it can be desirable to use yarns that are suitable for use on commercial knitting equipment. The free standing shrinkage of a yarn at 50 °C is one property that can be predictive of a suitable yarn for use on commercial knitting machines. In certain aspects, the films, fibers, filaments, and yarns described herein can exhibit a free standing shrinkage of less than 15% when heated from 20 °C to 70 °C. In various aspects, the films, fibers, and yarns described herein can exhibit a free standing shrinkage of from about 0% to about 60%, from about 0% to about 30%, or from about 0% to about 15% when heated from 20 °C to 70 °C. The term "free standing shrinkage" as used herein refers to a property of a yarn and the corresponding test method as described below:

[0118] Yarn shrinkage test The free standing shrinkage of a yarn can be determined by the following method. A yarn sample is prepared according to the yarn sampling procedure described below and is cut to a length of about 30 millimeters with minimal tension at about room temperature (e.g., 20 °C). The cut sample is placed in an oven at 50 °C or 70 °C for 90 seconds. The sample is removed from the oven and measured. Using the pre-oven measurement and the post-oven measurement of the sample, the percent shrinkage is calculated by dividing the post-oven measurement by the pre-oven measurement and multiplying by 100.

[0119] Yarn sampling procedure The yarn to be tested is stored at room temperature (20 °C to 24 °C) for 24 hours prior to testing. The first 3 meters of material are discarded. The sample yarn is cut to a length of about 30 millimeters with minimal tension at about room temperature (e.g., 20 °C).

[0120] In one or more aspects, the free standing shrinkage of a yarn at 70 °C can be a useful indication of the ability of the yarn to withstand certain environmental conditions without any substantial change in the physical structure of the yarn. In certain aspects, a yarn comprising a low processing temperature polymer composition can exhibit a free standing shrinkage of from about 0% to about 60% when heated from 20 °C to 70 °C. In one or more aspects, a yarn comprising a low processing temperature polymer composition can exhibit a free standing shrinkage of from about 0% to about 30% when heated from 20 °C to 70 °C. In one aspect, a yarn comprising a low processing temperature polymer composition can exhibit a free standing shrinkage of from about 0% to about 20% when heated from 20 °C to 70 °C.

[0121] As described above, in certain aspects, the first and second polymeric compositions as described herein have different properties. In various aspects, these different properties allow the coated fibers as described herein to melt and flow during a thermoforming process and subsequently cool and solidify into a structure that is different from the structure prior to the thermoforming process (e.g., from a yarn to a melted yarn component), while the uncoated fibers are unable to deform or melt during such a process and can maintain their structure (e.g., as a yarn) when the thermoforming process is performed at a temperature that is below the melting temperature of the uncoated fibers. In these aspects, the melted yarn component formed from the coated fibers described herein during the thermoforming process can be integrally connected to the unaltered structure (e.g., yarn or fiber) that can provide a three-dimensional structure and / or other properties for a particular point on an article of wear.

[0122] Example thermoplastic elastomer

[0123] In various aspects, the polymeric composition used for the coating of the first yarns described herein includes one or more thermoplastic elastomers. In one aspect, an "elastomer" is defined as a material having an elongation at break greater than 400% as determined using ASTM D-412-98 at 25°C. In another aspect, the elastomer forms a plaque, where the plaque has a breaking strength of 10 to 35 kilogram force (kgf), or about 10 to about 25 kgf, or about 10 to about 20 kgf, or about 15 to about 35 kgf, or about 20 to about 30 kgf. In another aspect, the tensile breaking strength or ultimate strength is greater than 70 kilogram force per square centimeter (kgf / cm 2 ), or greater than 80 kgf / cm 2In another aspect, the elastomeric trim panel has an elongation at break of 450% to 800%, or 500% to 800%, or 500% to 750%, or 600% to 750%, or 450% to 700%. In yet another aspect, the elastomeric trim panel has a load at 100% strain of 3 to 8 kilogram force per millimeter, or about 3 to about 7 kilogram force per millimeter, about 3.5 to about 6.5 kilogram force per millimeter, or about 4 to about 5 kilogram force per millimeter. In one aspect, the elastomeric trim panel has a stiffness of 850 kilogram-millimeters to 2200 kilogram-millimeters, or about 850 kilogram-millimeters to about 2000 kilogram-millimeters, or about 900 kilogram-millimeters to about 1750 kilogram-millimeters, or about 1000 kilogram-millimeters to about 1500 kilogram-millimeters, or about 1500 kilogram-millimeters to about 2000 kilogram-millimeters. In one aspect, the elastomeric trim panel has a stiffer of about 35 to about 155, or about 50 to about 150, or about 50 to about 100, or about 50 to about 75, or about 60 to about 155, or about 80 to about 150. In yet another aspect, the elastomeric trim panel has a tear strength of about 35 to about 80, or about 35 to about 75, or about 40 to about 60, or about 45 to about 50.

[0124] In aspects, exemplary thermoplastic elastomers include homopolymers and copolymers. The term “polymer” refers to a polymeric molecule having one or more monomer species, and includes homopolymers and copolymers. The term “copolymer” refers to a polymer having two or more monomer species, and includes terpolymers (i.e., copolymers having three monomer species). In certain aspects, the thermoplastic elastomer is a random copolymer. In one aspect, the thermoplastic elastomer is a block copolymer. For example, the thermoplastic elastomer can be a block copolymer having repeating blocks (segments) of polymeric units of the same chemical structure (relatively hard (hard segments)) and repeating blocks of polymeric segments (relatively soft (soft segments)). In aspects, in block copolymers, including block copolymers having repeating hard segments and soft segments, physical crosslinks can be present within or between blocks, or both within and between blocks. Specific examples of hard segments include isocyanate segments and polyamide segments. Specific examples of soft segments include polyether segments and polyester segments. As used herein, a polymeric segment can be a specific type of polymeric segment, such as, for example, an isocyanate segment, a polyamide segment, a polyether segment, a polyester segment, etc. It is understood that the chemical structure of a segment is derived from the chemical structure described. For example, an isocyanate segment is a polymeric unit that includes an isocyanate functional group. When referring to a block of polymeric segments of a particular chemical structure, the block can include up to 10 mol% of segments of other chemical structures. For example, as used herein, a polyether segment is understood to include up to 10 mol% of non-polyether segments.

[0125] In one aspect, the first polymeric composition includes a polymer component consisting of all polymers present in the polymeric composition; optionally, wherein, and the polymer component includes two or more polymers, wherein the two or more polymers differ from one another in the chemical structure of the individual segments of each of the two or more polymers, or in the molecular weight of each of the two or more polymers, or in both.

[0126] In various aspects, the thermoplastic elastomer can include one or more of a thermoplastic copolyester elastomer, a thermoplastic polyether block amide elastomer, a thermoplastic polyurethane elastomer, a polyolefin-based copolymer elastomer, a thermoplastic styrene copolymer elastomer, a thermoplastic ionomer elastomer, or any combination thereof. In one aspect, the first polymeric composition includes a thermoplastic elastomer styrene copolymer. In further aspects, the thermoplastic elastomer styrene copolymer can be a styrene butadiene styrene (SBS) block copolymer, a styrene ethylene / butylene styrene (SEBS) resin, a styrene acrylonitrile (SAN) resin, or any combination thereof. In one aspect, the polymeric composition includes a thermoplastic elastomer polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof. In some aspects, the thermoplastic elastomer polyester polyurethane can be an aromatic polyester, an aliphatic composition, or a combination thereof. It should be appreciated that other thermoplastic polymeric materials not specifically described below can also be contemplated for use in the coated fibers and / or uncoated fibers as described herein. In one aspect, the polymeric composition includes a thermoplastic elastomer having a melting temperature greater than about 110 °C and less than about 170 °C. In another aspect, the polymeric composition including the thermoplastic elastomer has a melting temperature of about 110 °C to about 170 °C, about 115 °C to about 160 °C, about 120 °C to about 150 °C, about 125 °C to about 140 °C, about 110 °C to about 150 °C, or about 110 °C to about 125 °C.

[0127] In various aspects, the thermoplastic elastomer has a glass transition temperature (Tg) of less than 50 °C when determined according to ASTM D3418-97 as described below. In some aspects, the thermoplastic elastomer has a glass transition temperature (Tg) of about -60 °C to about 50 °C, about -25 °C to about 40 °C, about -20 °C to about 30 °C, about -20 °C to about 20 °C, or about -10 °C to about 10 °C when determined according to ASTM D3418-97 as described below. In one aspect, the glass transition temperature of the thermoplastic elastomer is selected such that an article including the coated yarns disclosed herein, wherein the coated yarns include a coating material including the thermoplastic elastomer, the thermoplastic material is above its glass transition temperature when incorporated in an article of footwear during normal wear (i.e., more rubbery and less brittle).

[0128] In one aspect, the thermoplastic elastomer comprises: (a) a plurality of first segments; (b) a plurality of second segments; and, optionally, (c) a plurality of third segments. In various aspects, the thermoplastic elastomer is a block copolymer. In some aspects, the thermoplastic elastomer is a multi-block copolymer. In further aspects, the thermoplastic elastomer is a random copolymer. In still further aspects, the thermoplastic elastomer is a condensation copolymer.

[0129] In further aspects, the thermoplastic elastomer has a weight average molecular weight of about 50,000 Daltons to about 1,000,000 Daltons, about 50,000 Daltons to about 500,000 Daltons, about 75,000 Daltons to about 300,000 Daltons, about 100,000 Daltons to about 200,000 Daltons.

[0130] In further aspects, the thermoplastic elastomer has a ratio of the first segments to the second segments of about 1 : 1 to about 1 :2, based on the weight of each of the first segments and the second segments; or a ratio of the first segments to the second segments of about 1 : 1 to about 1 : 1.5, based on the weight of each of the first segments and the second segments.

[0131] In further aspects, the thermoplastic elastomer has a ratio of the first segments to the third segments of about 1 : 1 to about 1 :5, based on the weight of each of the first segments and the third segments; a ratio of the first segments to the third segments of about 1 : 1 to about 1 :3, based on the weight of each of the first segments and the third segments; a ratio of the first segments to the third segments of about 1 : 1 to about 1 :2, based on the weight of each of the first segments and the third segments; or a ratio of the first segments to the third segments of about 1 : 1 to about 1 :3, based on the weight of each of the first segments and the third segments.

[0132] In further aspects, the thermoplastic elastomer has first segments derived from a first component having a number average molecular weight of about 250 Daltons to about 6,000 Daltons, about 400 Daltons to about 6,000 Daltons, about 350 Daltons to about 5,000 Daltons, or about 500 Daltons to about 3,000 Daltons.

[0133] In some aspects, the thermoplastic elastomer comprises phase-separated domains. For example, the plurality of first segments can phase separate into domains that predominantly include the first segments. Further, the plurality of second segments derived from segments having different chemical structures can phase separate into domains that predominantly include the second segments. In some aspects, the first segments can comprise hard segments and the second segments can comprise soft segments. In other aspects, the thermoplastic elastomer can comprise phase-separated domains comprising a plurality of first copolyester units.

[0134] In an aspect, the polymer composition has a glass transition temperature of about 20 °C to about -60 °C prior to thermoforming. In an aspect, the polymer composition has a Taber abrasion of about 10 milligrams to about 40 milligrams prior to thermoforming as determined by ASTM D3389. In an aspect, the polymer composition has a durometer hardness (Shore A) of about 60 to about 90 as determined by ASTM D2240 prior to thermoforming. In an aspect, the polymer composition has a specific gravity of about 0.80 g / cm3to about 1.30 g / cm3as determined by ASTM D792 prior to thermoforming. In an aspect, the polymer composition has a melt flow index of about 2 grams / 10 minutes to about 50 grams / 10 minutes at 160 °C when using a test weight of 2.16 kilograms prior to thermoforming. In an aspect, the polymer composition has a melt flow rate of greater than about 2 grams / 10 minutes at 190 °C or 200 °C when using a test weight of 10 kilograms prior to thermoforming. In an aspect, the polymer composition has a modulus of about 1 megapascal to about 500 megapascal prior to thermoforming. 3 3 In an aspect, the polymer composition has a glass transition temperature of about 20 °C to about -60 °C prior to thermoforming. In an aspect, the polymer composition has a Taber abrasion of about 10 milligrams to about 40 milligrams prior to thermoforming as determined by ASTM D3389. In an aspect, the polymer composition has a durometer hardness (Shore A) of about 60 to about 90 as determined by ASTM D2240 prior to thermoforming. In an aspect, the polymer composition has a specific gravity of about 0.80 g / cm3to about 1.30 g / cm3as determined by ASTM D792 prior to thermoforming. In an aspect, the polymer composition has a melt flow index of about 2 grams / 10 minutes to about 50 grams / 10 minutes at 160 °C when using a test weight of 2.16 kilograms prior to thermoforming. In an aspect, the polymer composition has a melt flow rate of greater than about 2 grams / 10 minutes at 190 °C or 200 °C when using a test weight of 10 kilograms prior to thermoforming. In an aspect, the polymer composition has a modulus of about 1 megapascal to about 500 megapascal prior to thermoforming.

[0135] Example thermoplastic polyurethane elastomer

[0136] In certain aspects, the coated thermoplastic elastomer as used for the first yarn in some aspects herein is a thermoplastic polyurethane (TPU) elastomer. The thermoplastic polyurethane elastomer can be a thermoplastic block polyurethane copolymer. The thermoplastic polyurethane copolymer can be a copolymer comprising hard segments and soft segments, including blocks of hard segments and blocks of soft segments. The hard segments can include or consist of isocyanate segments. In the same or alternative aspects, the soft segments can include or consist of polyether segments, or polyester segments, or a combination of polyether segments and polyester segments. In an aspect, the thermoplastic material or polymer component of the thermoplastic material can include or consist essentially of elastomeric thermoplastic polyurethane hard segments and soft segments, such as an elastomeric thermoplastic polyurethane having repeating blocks of hard segments and repeating blocks of soft segments.

[0137] In aspects, one or more of the thermoplastic polyurethane elastomers can be produced by polymerizing one or more isocyanates with one or more polyols to produce a copolymer chain having urethane linkages (— N(CO)O—) as illustrated in Formula 1 below, where the isocyanates each preferably include two or more isocyanate (-NCO) groups per molecule, such as 2, 3, or 4 isocyanate groups per molecule (although monofunctional isocyanates can optionally be included, for example as chain termination units).

[0138] In certain aspects, the coated thermoplastic elastomer as used for the first yarn in some aspects herein is a thermoplastic polyurethane (TPU) elastomer. The thermoplastic polyurethane elastomer can be a thermoplastic block polyurethane copolymer. The thermoplastic polyurethane copolymer can be a copolymer comprising hard segments and soft segments, including blocks of hard segments and blocks of soft segments. The hard segments can include or consist of isocyanate segments. In the same or alternative aspects, the soft segments can include or consist of polyether segments, or polyester segments, or a combination of polyether segments and polyester segments. In an aspect, the thermoplastic material or polymer component of the thermoplastic material can include or consist essentially of elastomeric thermoplastic polyurethane hard segments and soft segments, such as an elastomeric thermoplastic polyurethane having repeating blocks of hard segments and repeating blocks of soft segments.

[0137] In aspects, one or more of the thermoplastic polyurethane elastomers can be produced by polymerizing one or more isocyanates with one or more polyols to produce a copolymer chain having urethane linkages (— N(CO)O—) as illustrated in Formula 1 below, where the isocyanates each preferably include two or more isocyanate (-NCO) groups per molecule, such as 2, 3, or 4 isocyanate groups per molecule (although monofunctional isocyanates can optionally be included, for example as chain termination units).

[0138] In certain aspects, the coated thermoplastic elastomer as used for the first yarn in some aspects herein is a thermoplastic polyurethane (TPU) elastomer. The thermoplastic polyurethane elastomer can be a thermoplastic block polyurethane copolymer. The thermoplastic polyurethane copolymer can be a copolymer comprising hard segments and soft segments, including blocks of hard segments and blocks of soft segments. The hard segments can include or consist of isocyanate segments. In the same or alternative aspects, the soft segments can include or consist of polyether segments, or polyester segments, or a combination of polyether segments and polyester segments. In an aspect, the thermoplastic material or polymer component of the thermoplastic material can include or consist essentially of elastomeric thermoplastic polyurethane hard segments and soft segments, such as an elastomeric thermoplastic polyurethane having repeating blocks of hard segments and repeating blocks of soft segments.

[0137] In aspects, one or more of the thermoplastic polyurethane elastomers can be produced by polymerizing one or more isocyanates with one or more polyols to produce a copolymer chain having urethane linkages (— N(CO)O—) as illustrated in Formula 1 below, where the isocyanates each preferably include two or more isocyanate (-NCO) groups per molecule, such as 2, 3, or 4 isocyanate groups per molecule (although monofunctional isocyanates can optionally be included, for example as chain termination units).

[0138] In certain aspects, the coated thermoplastic elastomer as used for the first yarn in some aspects herein is a thermoplastic polyurethane (TPU) elastomer. The thermoplastic polyurethane elastomer can be a thermoplastic block polyurethane copolymer. The thermoplastic polyurethane copolymer can be a copolymer comprising hard segments and soft segments, including blocks of hard segments and blocks of soft segments. The hard segments can include or consist of isocyanate segments. In the same or alternative aspects, the soft segments can include or consist of polyether segments, or polyester segments, or a combination of polyether segments and polyester segments. In an aspect, the thermoplastic material or polymer component of the thermoplastic material can include or consist essentially of elastomeric thermoplastic polyurethane hard segments and soft segments, such as an elastomeric thermoplastic polyurethane having repeating blocks of hard segments and repeating blocks of soft segments.

[0139] In these aspects, each R1and R2is independently an aliphatic segment or an aromatic segment. Optionally, each R2may be a hydrophilic segment.

[0140] Unless otherwise indicated, any functional group or compound described herein can be substituted or unsubstituted. A "substituted" group or compound, such as an alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxy, ester, ether, or carboxylate, refers to an alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxy, ester, ether, or carboxylate group having at least one hydrogen radical replaced by a non-hydrogen radical (i.e., a substituent). Examples of non-hydrogen groups (or substituents) include, but are not limited to, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, ether, aryl, heteroaryl, heterocycloalkyl, hydroxyl, oxo (or oxo), alkoxy, ester, thioester, acyl, carboxyl, cyano, nitro, amino, amido, sulfur, and halogen. When a substituted alkyl includes more than one non-hydrogen radical, the substituents can be bound to the same carbon or to two or more different carbon atoms.

[0141] Additionally, the isocyanate can also be chain-extended with one or more chain extenders to bridge two or more isocyanates. This can result in a polyurethane copolymer chain as shown in Formula 2 below, where R3includes the chain extender. Like each R1and R3, each R3is independently an aliphatic segment or an aromatic segment.

[0142]

[0143] Based on the particular isocyanate used, each segment R1or first segment in Formula 1 and Formula 2 can independently include a linear or branched C 3-30 segment, and can be aliphatic, aromatic, or a combination including aliphatic and aromatic portions. The term "aliphatic" refers to a saturated or unsaturated organic molecule that does not include a cyclic, conjugated ring system with delocalized pi electrons. In contrast, the term "aromatic" refers to a cyclic, conjugated ring system with delocalized pi electrons that exhibits greater stability than a hypothetical ring system with localized pi electrons.

[0144] Based on the total weight of the reactant monomers, each segment R1can be present in an amount of 5 to 85 weight percent, 5 to 70 weight percent, or 10 to 50 weight percent.

[0145] In the aliphatic aspect (from aliphatic isocyanates), each segment R1can include a linear aliphatic group, a branched aliphatic group, an alicyclic group, or a combination thereof. For example, each segment R1can include a linear or branched C 3-20 alkylene segment (e.g., C 4-15 alkylene or C 6-10 alkylene), one or more C3-8 Cycloalkyl segments (e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, or cyclooctyl) and combinations thereof.

[0146] Examples of suitable aliphatic diisocyanates for preparing polyurethane copolymer chains include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), butyl diisocyanate (BDI), dicyclohexylmethane diisocyanate (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), diisocyanate methylcyclohexane, diisocyanate methyltricyclodecane, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4'-dicyclohexylmethane diisocyanate (H12MDI), diisocyanate dodecane, lysine diisocyanate, and combinations thereof.

[0147] In the aromatic aspect (from aromatic isocyanates), each segment R1 may include one or more aromatic groups, such as phenyl, naphthyl, tetrahydronaphthyl, phenanthryl, biphenylene, indanyl, indenyl, anthracene, and fluorenyl. Unless otherwise specified, the aromatic group may be an unsubstituted aromatic group or a substituted aromatic group, and may also include heteroaromatic groups. “Heteroaromatic” refers to a monocyclic or polycyclic (e.g., fused bicyclic and fused tricyclic) aromatic ring system in which one to four ring atoms are selected from oxygen, nitrogen, or sulfur, and the remaining ring atoms are carbon, and wherein the ring system is connected to the rest of the molecule by any ring atom. Examples of suitable heteroaromatic groups include pyridyl, pyrazinyl, pyrimidinyl, pyrroleyl, pyrazolyl, imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isoxazolyl, thiadiazolyl, oxadiazolyl, furanyl, quinolinyl, isoquinolinyl, benzoxazolyl, benzimidazolyl, and benzothiazolyl.

[0148] Examples of suitable aromatic diisocyanates for preparing polyurethane copolymer chains include toluene diisocyanate (TDI), TDI adducts with trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylphenyl dimethyl diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), 1,5-naphthalene diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3′-dimethyldiphenyl-4,4′-diisocyanate (DDDI), 4,4′-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some respects, the copolymer chains are substantially free of aromatic groups.

[0149] In certain aspects, the polyurethane copolymer chains are prepared from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. For example, the coated fibers of the present disclosure, as described herein, can include one or more polyurethane copolymer chains prepared from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. 12 aliphatic compounds, and combinations thereof.

[0150] In certain aspects, crosslinked polyurethane chains (e.g., partially crosslinked polyurethane copolymers that retain thermoplastic properties) or crosslinkable polyurethane chains can be used in accordance with the present disclosure. Crosslinked or crosslinkable polyurethane copolymer chains can be prepared using a polyfunctional isocyanate. Examples of suitable triisocyanates for preparing the polyurethane copolymer chains include adducts of TDI, HDI, and IPDI with trimethylolpropane (TMP), uretdiones (i.e., dimeric isocyanates), polymeric MDI, and combinations thereof.

[0151] The segment R3 in Formula 2 can include a linear or branched C2-C 10 segment, and can be, for example, aliphatic, aromatic, or polyether, based on the particular chain extender polyol used. Examples of suitable chain extender polyols for preparing the polyurethane copolymer chains include ethylene glycol, lower oligomers of ethylene glycol (e.g., diethylene glycol, triethylene glycol, and tetraethylene glycol), 1,2-propanediol, 1,3-propanediol, lower oligomers of propylene glycol (e.g., dipropylene glycol, tripropylene glycol, and tetrapropylene glycol), 1,4-butanediol, 2,3-butanediol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 1,4-cyclohexanedimethanol, 2-ethyl-1,6-hexanediol, 1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol, dihydroxyalkylated aromatic compounds (e.g., bis(2-hydroxyethyl) ether of hydroquinone and resorcinol, xylene-a,a-diol, bis(2-hydroxyethyl) ether of xylene-a,a-diol, and combinations thereof.

[0152] The segment R2 in Formulas 1 and 2 can include a polyether group, a polyester group, a polycarbonate group, an aliphatic group, or an aromatic group. Each segment R2 can be present in an amount of 5 wt% to 85 wt%, 5 wt% to 70 wt%, or 10 wt% to 50 wt%, based on the total weight of the reactant monomers.

[0153] Optionally, in some examples, the thermoplastic polyurethane elastomer is a thermoplastic polyurethane having a relatively high degree of hydrophilicity. For example, the thermoplastic polyurethane can be a thermoplastic polyether polyurethane, wherein the segment R2in Formula 1 and Formula 2 comprises a polyether group, a polyester group, a polycarbonate group, an aliphatic group, or an aromatic group, wherein the aliphatic group or aromatic group is substituted with one or more pendant groups having a relatively large degree of hydrophilicity (i.e., a relatively “hydrophilic” group). The relatively “hydrophilic” group can be selected from the group consisting of a hydroxyl group, a polyether, a polyester, a polylactone (e.g., polyvinylpyrrolidone (PVP)), an amino group, a carboxylate, a sulfonate, a phosphate, an ammonium (e.g., tertiary and quaternary ammonium), a zwitterion (e.g., a betaine such as poly(carboxybetaine (pCB) and an ammonium phosphonate such as phosphatidylcholine), and combinations thereof. In such examples, this relatively hydrophilic group or segment of R2may form part of the polyurethane backbone, or can be grafted as a pendant group to the polyurethane backbone. In some examples, the pendant hydrophilic group or segment can be bonded to the aliphatic group or aromatic group through a linker. Each segment R2may be present in an amount of 5 to 85 weight percent, 5 to 70 weight percent, or 10 to 50 weight percent, based on the total weight of the reactant monomers.

[0154] In some examples, at least one R2segment of the thermoplastic polyurethane elastomer comprises a polyether segment (i.e., a segment having one or more ether groups). Suitable polyethers include, but are not limited to, polyethylene oxide (PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF), polytetramethylene oxide (PTmO), and combinations thereof. The term “alkyl” as used herein refers to straight-chain saturated hydrocarbon groups and branched-chain saturated hydrocarbon groups comprising 1 to 30 carbon atoms, for example, 1 to 20 carbon atoms or 1 to 10 carbon atoms. The term “C n ” refers to an alkyl group having “n” number of carbon atoms. For example, C4alkyl refers to an alkyl group having 4 carbon atoms. C 1-7 alkyl refers to an alkyl group having a number of carbon atoms encompassing the entire range (i.e., 1 to 7 carbon atoms) as well as all subgroups (e.g., 1-6, 2-7, 1-5, 3-6, 1, 2, 3, 4, 5, 6, and 7 carbon atoms). Non-limiting examples of alkyl groups include methyl, ethyl, n-propyl, i-propyl, n-butyl, sec-butyl (2-methylpropyl), t-butyl (1,1-dimethylethyl), 3,3-dimethylpentyl, and 2-ethylhexyl. Unless otherwise indicated, an alkyl group can be an unsubstituted alkyl group or a substituted alkyl group.

[0155] In some examples of the thermoplastic polyurethane elastomer, at least one R2 segment comprises a polyester segment. The polyester segment can be derived from the polyesterification of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methyl pentanediol-1,5- diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, and combinations thereof) and one or more dicarboxylic acids (e.g., adipic acid, succinic acid, sebacic acid, suberic acid, methyl adipic acid, glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid, and citraconic acid, and combinations thereof). The polyester can also be derived from polycarbonate prepolymers such as poly(hexamethylene carbonate) diol, poly(propylene carbonate) diol, poly(tetramethylene carbonate) diol, and poly(nona methylene carbonate) diol. Suitable polyesters can include, for example, polyethylene adipate (PEA), poly(l,4-butylene adipate), poly(butylene adipate), poly(hexamethylene adipate), polycaprolactone, polyhexamethylene carbonate, poly(propylene carbonate), poly(tetramethylene carbonate), poly(nona methylene carbonate), and combinations thereof.

[0156] In various aspects of the thermoplastic polyurethane elastomer, at least one R2 segment comprises a polycarbonate segment. The polycarbonate segment can be derived from the reaction of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 3-methyl-1,5-pentanediol, diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, and combinations thereof) and ethylene carbonate.

[0157] In various examples of the thermoplastic polyurethane elastomer, at least one R2 segment can include an aliphatic group substituted with one or more groups having a relatively greater degree of hydrophilicity (i.e., a relatively “hydrophilic” group). The one or more relatively hydrophilic groups can be selected from the group consisting of hydroxyl, polyether, polyester, polylactone (e.g., polyvinylpyrrolidone), amino, carboxylate, sulfonate, phosphate, ammonium (e.g., tertiary and quaternary ammonium), zwitterionic (e.g., betaines such as poly(carboxybetaine (pCB) and ammonium phosphonate groups such as phosphatidylcholine), and combinations thereof. In some examples, the aliphatic group is linear and can include, for example, a C1-C20 alkylene chain or a C1-C20 alkenylene chain (e.g., methylene, ethylene, propylene, butylene, pentylene, hexylene, heptylene, octylene, nonylene, decylene, undecylene, dodecylene, tridecylene, ethenylene, propenylene, butenylene, pentenylene, hexenylene, heptenylene, octenylene, nonenylene, decenylene, undecenylene, dodecenylene, tridecenylene). The term “alkylene” refers to a divalent hydrocarbon group. The term refers to an alkylene group having “n” number of carbon atoms. For example, a C1-C20 alkylene group refers to an alkylene group having 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 carbon atoms. In some examples, the aliphatic group is branched. In some examples, the aliphatic group is cyclic. In some examples, the aliphatic group is a combination of linear, branched, and / or cyclic. 1-6 Alkylene refers to an alkylene group having, for example, 1, 2, 3, 4, 5, or 6 carbon atoms. The term “alkenylene” refers to a divalent hydrocarbon group having at least one double bond.

[0158] In some cases, at least one R2 segment includes an aromatic group substituted with one or more relatively hydrophilic groups. The one or more hydrophilic groups can be selected from the group consisting of hydroxyl, polyether, polyester, polylactone (e.g., polyvinylpyrrolidone), amino, carboxylate, sulfonate, phosphate, ammonium (e.g., tertiary and quaternary ammonium), zwitterionic (e.g., betaines such as poly(carboxybetaine (pCB) and ammonium phosphonate groups such as phosphatidylcholine), and combinations thereof. Suitable aromatic groups include, but are not limited to, phenyl, naphthyl, tetrahydronaphthyl, phenanthryl, biphenylenyl, indanyl, indenyl, anthryl, fluorenyl pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isoxazolyl, thiadiazolyl, oxadiazolyl, furanyl, quinolinyl, isoquinolinyl, benzoxazolyl, benzimidazolyl, and benzothiazolyl, and combinations thereof.

[0159] In various aspects, the aliphatic and aromatic groups can be substituted with one or more relatively hydrophilic pendant groups and / or charged pendant groups. In some aspects, the pendant hydrophilic groups include one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) hydroxyl groups. In various aspects, the pendant hydrophilic groups include one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) amino groups. In some cases, the pendant hydrophilic groups include one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) carboxylic acid groups. For example, the aliphatic groups can include one or more polyacrylic acid groups. In some cases, the pendant hydrophilic groups include one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) sulfonic acid groups. In some cases, the pendant hydrophilic groups include one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more) phosphonic acid groups. In some examples, the pendant hydrophilic groups include one or more ammonium groups (e.g., tertiary and / or quaternary ammonium). In other examples, the pendant hydrophilic groups include one or more zwitterionic groups (e.g., betaines such as poly(carboxybetaine (pCB) and ammonium phosphonate groups such as phosphatidylcholine groups).

[0160] In some aspects, the R2segment can include a charged group that is capable of binding to a counterion to ionically crosslink the thermoplastic elastomer and form an ionomer. In these aspects, for example, R2is an aliphatic or aromatic group having a pendant amino, carboxylate, sulfonate, phosphate, ammonium, or zwitterionic group, or a combination thereof.

[0161] In various cases where the pendant hydrophilic groups are present, the pendant “hydrophilic” groups are at least one polyether group, such as two polyether groups. In other cases, the pendant hydrophilic groups are at least one polyester. In various cases, the pendant hydrophilic groups are polylactone groups (e.g., polyvinylpyrrolidone). Each carbon atom of the pendant hydrophilic groups can be optionally substituted with, for example, C1-C6alkyl. 1-6 In some of these aspects, the aliphatic and aromatic groups can be graft polymer groups, where the pendant groups are homopolymer groups (e.g., polyether groups, polyester groups, polyvinylpyrrolidone groups).

[0162] In some aspects, the pendant hydrophilic groups are polyether groups (e.g., polyethylene oxide groups, polyethylene glycol groups), polyvinylpyrrolidone groups, polyacrylic acid groups, or a combination thereof.

[0163] As described herein, the thermoplastic polyurethane elastomers can be physically crosslinked, for example, through non-polar or polar interactions between urethane or carbamate groups on the polymer (hard segments). In these aspects, component R1 in Formula 1, as well as components R1 and R3 in Formula 2, form portions of the polymer that are generally referred to as “hard segments,” and component R2 forms a portion of the polymer that is generally referred to as a “soft segment.” In these aspects, the soft segment can be covalently bonded to the hard segment. In some examples, the thermoplastic polyurethane elastomer having physically crosslinked hard segments and soft segments can be a hydrophilic thermoplastic polyurethane elastomer (i.e., a thermoplastic polyurethane elastomer comprising hydrophilic groups as disclosed herein).

[0164] In one aspect, prior to thermoforming, the thermoplastic polyurethane elastomer is an aromatic polyester thermoplastic elastomer polyurethane or an aliphatic polyester thermoplastic elastomer polyurethane having the following properties: (1) a glass transition temperature glass transition temperature of about 20 °C to about -60 °C; (2) a Taber abrasion of about 10 milligrams to about 40 milligrams as determined by ASTM D3389; (3) a durometer hardness (Shore A) of about 60 to about 90 as determined by ASTM D2240; (4) a specific gravity of about 0.80 g / cm3to about 1.30 g / cm3as determined by ASTM D792; (5) a melt flow index of about 2 grams / 10 minutes to about 50 grams / 10 minutes at 160 °C using a test weight of 2.16 kilograms; (6) a melt flow rate of greater than about 2 grams / 10 minutes at 190 °C or 200 °C when using a test weight of 10 kilograms; and (7) a modulus of about 1 megapascal to about 500 megapascal. 3 3

[0165] Commercially available thermoplastic polyurethane elastomers having greater hydrophilicity suitable for use in the present application include, but are not limited to, those under the trade designation “TECOPHILIC,” such as TG-500, TG-2000, SP-80A-150, SP-93A-100, SP-60D60 (Lubrizol Corporation, Countryside, IL), “ESTANE” (e.g., 58238, T470A; Lubrizol, Countryside, IL), and “ELASTOLLAN” (e.g., 9339, 1370A; BASF).

[0166] In various aspects, the thermoplastic polyurethane elastomer can be partially covalently crosslinked, as previously described herein.

[0167] Example thermoplastic styrenic copolymer elastomer

[0168] ​​In certain aspects, the thermoplastic elastomer is a thermoplastic elastomeric styrene copolymer. Examples of these copolymers include, but are not limited to, styrene butadiene styrene (SBS) block copolymers, styrene ethylene / butylene styrene (SEBS) resins, polyacetal resins (POM), styrene acrylonitrile resins (SAN), or blends, alloys, or composites thereof. Exemplary commercially available thermoplastic elastomeric styrene copolymers include MONOPRENE IN5074, SP066070, and SP16975 (Teknor Apex, Pawtucket, RI) which are styrene ethylene / butylene styrene (SEBS) resins. In some aspects, the blends, alloys, and composites should be melt compatible or can be compatible with additives, oils, or grafted chemical moieties in order to achieve miscibility.

[0169] In one aspect, the thermoplastic elastomeric styrene copolymer includes at least one block as shown in Formula 3 below:

[0170]

[0171] In another aspect, the thermoplastic elastomeric styrene copolymer can be an SBS block copolymer including a first polystyrene block (block m of Formula 4), a polybutadiene block (block o of Formula 4), and a second polystyrene block (block p of Formula 4), wherein the SBS block copolymer has the general structure shown in Formula 4 below:

[0172]

[0173] In another aspect, the thermoplastic elastomeric styrene copolymer can be an SEBS block copolymer including a first polystyrene block (block x of Formula 5), a polyolefin block (block y of Formula 5), wherein the polyolefin block includes alternating polyethylene blocks (block v of Formula 5) and polybutylene blocks (block w of Formula 4), and a second polystyrene block (block z of Formula 5), as seen in Formula 5 below:

[0174]

[0175] In one aspect, the SEBS polymer has a density of about 0.88 grams per cubic centimeter to about 0.92 grams per cubic centimeter. In further aspects, the SEBS polymer can be up to 15% to 25% lower than the crosslinked rubber, crosslinked polyurethane, and thermoplastic polyurethane materials. In further aspects, the lower density coating composition provides weight savings and cost savings per part while achieving similar performance for the same volume of material used.

[0176] Reference to "a" compound means one or more molecules of the compound, and is not limited to a single molecule of the compound. Further, the one or more molecules can be the same or not the same, so long as they belong to the class of the compound. Thus, for example, "polyamide" is interpreted to include one or more polymeric molecules of polyamide, where the polymeric molecules can be the same or not the same (e.g., different molecular weights and / or isomers).

[0177] The terms "at least one" element and one or more of the elements are used interchangeably, and have the same meaning as including a single element and a plurality of elements, and can also be indicated at the end of the elements by the suffix "(s)". For example, "at least one polyamide", "one or more polyamides", and "a plurality of polyamides" can be used interchangeably and have the same meaning.

[0178] Unless otherwise indicated, temperatures referred to herein are measured at standard atmospheric pressure (i.e., 1 ATM).

[0179] Property analysis and characterization procedures

[0180] Evaluation of the various properties and characteristics described herein is conducted by various test procedures as described below.

[0181] Sample coefficient of friction The static or dynamic coefficient of friction (COF) of a textile or panel sample can be determined using test method ASTM D1894. In this method, the sample is cut to size and mounted on a sled, and a 100 gram weight plate is placed on the sled. During the test, the weighted sled is pulled across the test surface of the material being tested. For example, static and dynamic wet and dry COF can be determined by pulling the sled across a concrete surface to determine the COF of the sample and the concrete. The coefficient of friction of the sample relative to the surface is captured by recording the normal force (100 grams plus the weight of the sled) and measuring the applied force required to pull the sled across the test surface. The coefficient of friction (COF) is then calculated from the ratio of the two forces. Dry COF is determined by testing a dry sample against a dry test surface, and wet COF is determined by testing a sample wetted with water by immersing the sample in room temperature water for 10 minutes against a test surface that is wetted with room temperature water.

[0182] Textile-ball coefficient of friction testThe static and dynamic coefficient of friction (COF) of samples prepared using the component sampling procedure or the textile sampling procedure described below relative to samples from a panel of "MERLIN" soccer balls (Nike, Inc., Beaverton, OR, USA) can be determined using a modified version of the test method ASTM D1894 as described for sample friction coefficients. In this method, the sample is cut to size and mounted on an acrylic substrate, and the ball material is cut to size and mounted on a sled. Once the ball material has been mounted on the sled, the sled has a 3.9 inch x 1 inch contact footprint, and a weight of approximately 0.402 kilograms. During the test, the sample and the ball material are positioned such that the outward-facing surface of the ball material contacts the surface of the sample, which is intended to form the outward-facing surface of an article of footwear, and the sled is pulled across the sample. Dry samples and dry ball material are used to determine the static dry COF or the dynamic dry COF. To determine the static or dynamic wet COF, both the sample and the ball material are soaked in room temperature water for 10 minutes immediately prior to the test. Each measurement is repeated at least 3 times, and the run results are averaged.

[0183] Melting and glass transition temperature test. The melting temperature and / or glass transition temperature of samples prepared according to the material sampling procedure described below are determined according to ASTM D3418-97 using a commercially available differential scanning calorimeter ("DSC"). Briefly, 10 to 60 milligrams of sample are placed in an aluminum DSC pan and then sealed with a crimping press. The DSC is configured to scan from -100 °C to 225 °C at a heating rate of 20 °C / minute, hold at 225 °C for 2 minutes, and then cool at a rate of -20 °C / minute to 25 °C. The DSC curve resulting from this scan is then analyzed using standard techniques to determine the glass transition temperature and the melting temperature. The enthalpy of fusion is calculated by integrating the melting endotherm and normalizing by the mass of the sample. The enthalpy of crystallization upon cooling is calculated by integrating the cooling exotherm and normalizing by the mass of the sample.

[0184] Distortion temperature test.The Vicat softening temperature of samples prepared according to the Material Sampling Procedure or Component Sampling Procedure described below is determined according to the test method detailed in the ASTM Standard Test Method for Vicat Softening Temperature of Plastics, Tm D1525-09, preferably using Load A and Rate A. Briefly, the Vicat softening temperature is the temperature at which a flat-ended needle penetrates a sample to a depth of 1 millimeter under a specified load. The temperature reflects the softening point expected when the material is used in elevated temperature applications. This softening point is taken as the temperature at which the sample is penetrated to a depth of 1 millimeter by a flat-ended needle having a 1 square millimeter2circular or square cross section. For the Vicat A test, a load of 10 Newtons (N) is used, while for the Vicat B test, the load is 50 Newtons. The test involves placing the test sample in the test apparatus so that the penetrating needle is at least 1 millimeter from the edge on its surface. The sample is loaded according to the requirements of the Vicat A or Vicat B test. The sample is then lowered into an oil bath at 23 °C. The oil bath is raised at a rate of 50 °C or 120 °C per hour until the needle penetrates 1 millimeter. The thickness of the test sample must be in the range between 3 millimeters and 6.5 millimeters, and the width and length are at least 10 millimeters. Up to three layers can be stacked to achieve the minimum thickness.

[0185] Melt flow index test The melt flow index of samples prepared according to the Material Sampling Procedure described below is determined according to the test method detailed in the Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer, ASTM D1238-13, using Procedure A described therein. Briefly, the melt flow index measures the rate of extrusion of a thermoplastic through an orifice under prescribed temperature and load. In the test method, approximately 7 grams of material is loaded into the barrel of a melt flow apparatus, which has been heated to the material's prescribed temperature. The material's prescribed weight is applied to the plunger and forces the molten material through the die. The timed extrudate is collected and weighed. The melt flow index value is calculated in g / 10 min for a given applied load and applied temperature. The melt flow index can be determined at 160 °C using a weight of 2.16 kg, or at 200 °C using a weight of 10 kg, as described in ASTM D1238-13.

[0186] Melt polymer viscosity test. The test is performed using a 2 millimeter plaque or film prepared according to the plaque or film sampling procedure described below. A 50 millimeter sample disc is cut from the plaque or film using a circular die. The test sample is mounted on a 50 millimeter diameter aluminum parallel plate on an ARES-G2 (displacement controlled) rheometer. The top plate is lowered so that the test sample is in contact with both plate surfaces under a defined normal force load and the stage is heated to 210°C. The sample is equilibrated until molten for a defined dwell time (minutes) and an oscillatory shear frequency sweep is applied at low strain amplitude to collect rate dependent data. The ratio of applied shear stress required to produce oscillatory motion at a given shear frequency yields a measured viscosity value. Viscosity data can be collected from 0.1 reciprocal seconds to 1000 reciprocal seconds as a function of shear rate.

[0187] Panel modulus test . The modulus of a sample prepared according to the yarn sampling procedure described below is determined according to the test method for Tensile Properties of Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomers - Tension detailed in ASTM D412-98 Standard Test Methods, with the following modifications. The sample size is ASTM D412-98 Die C and the sample thickness used is 2.0 millimeters ± 0.5 millimeters. The type of grips used is pneumatic grips with metal serrated gripping faces. The gripping distance used is 75 millimeters. The loading rate used is 500 millimeters / minute. Modulus (initial) is calculated by taking the slope of stress (MPa) versus strain in the initial linear region. This test can also be used to determine other tensile properties such as break strength, break strain, load at 100% strain, stiffness, sturdiness, tear strength, etc.

[0188] Yarn denier and thickness test . To determine denier, a yarn sample is prepared according to the yarn sampling procedure described below. A known length of the yarn sample is measured and its corresponding weight is measured. This is converted to grams per 9000 meters of yarn. To determine the thickness of a coated yarn, the yarn is first cut with a razor and observed under a microscope, where the coating thickness relative to the core yarn diameter is measured in proportion.

[0189] Yarn modulus, tenacity, and elongation testYarn modulus of samples prepared according to the Yarn Sampling Procedure described above was determined and was tested according to the test method detailed in EN ISO 2062 (Textiles - Package yarn) - Determination of the breaking force and elongation at break of single yarn using constant rate of extension (CRE) testing machine. The following modifications to the test method were used. Five test specimens were prepared with a sample length of 600 millimeters. The equipment used was an Instron Universal Testing System. The Instron pneumatic cord and thread chuck or similar pneumatic chuck was installed with a chuck distance of 250 millimeters. When the Instron pneumatic cord and thread chuck was used, the chuck distance was set to 145 ± 1 millimeters and the gauge length distance was set to 250 ± 2 millimeters. The pre-load was set to 5 grams and the loading rate used was 250 millimeters / minute. Modulus (initial) was calculated by taking the slope of stress (MPa) versus strain in the initial linear region. The maximum tensile force value was recorded. Tenacity and elongation of the yarn samples were determined according to the test method detailed in EN ISO 2062 with a pre-load set to 5 grams. The elongation was recorded at the maximum tensile force value applied before break. In some aspects, tenacity was calculated as the ratio of the load required to break the sample to the linear density of the sample.

[0190] Specific gravity test. Specific gravity (SG) was determined according to the test method detailed in ASTM D792 using volumetric displacement. For example, the SG of samples taken using the plaque sampling procedure or component sampling procedure was measured using a digital balance or a Densicom tester (Qualitest, Plantation, FL, USA). Each sample was weighed (g) and then submerged in a distilled water bath (22 °C ± 2 °C). To avoid errors, for example, by wiping the sample with isopropyl alcohol before submerging the sample in water, or using a brush to remove air bubbles on the surface of the sample after submerging the sample in water. The weight of the sample in distilled water was recorded. The specific gravity was calculated using the following formula:

[0191]

[0192] Durometer hardness test The hardness of a material can be determined according to the test method detailed in ASTM D-2240 Durometer Hardness using the Shore A scale.

[0193] Yarn shrinkage testThe self-standing shrinkage of a yarn can be determined by the following method. A yarn sample is prepared according to the Yarn Sampling Procedure described below, and cut into a length of about 30 millimeters with minimal tension at about room temperature (e.g., 20°C). The cut sample is placed in an oven at 50°C or 70°C for 90 seconds. The sample is removed from the oven and measured. Using the pre-oven and post-oven measurements of the sample, the percent shrinkage is calculated by dividing the post-oven measurement by the pre-oven measurement and multiplying by 100.

[0194] Stoll abrasion test Wear resistance, including wear resistance simulating wear of footwear uppers, can be determined using the Stoll Wear Test using samples prepared according to the Component Sampling Procedure, the Panel or Film Sampling Procedure, or the Textile Sampling Procedure described below. The minimum number of samples for the Stoll Wear Test is 3. The samples used herein are hand cut or die cut into a circle having a diameter of 112 millimeters. The Stoll Wear Test is more fully described in ASTM D3886 and can be conducted on an Atlas Universal Wear Tester. In the Stoll Wear Test, the abrasive media is moved over a stationary mounted test sample, and the visual appearance of the sample is monitored. The Stoll Wear Test is conducted under pressure to simulate wear under normal use.

[0195] DIN abrasion test Samples are prepared according to the Component Sampling Procedure, the Panel or Film Sampling Procedure, or the Textile Sampling Procedure described below. Abrasion loss is tested on a cylindrical sample having a diameter of 16 ± 0.2 millimeters and a minimum thickness of 6 millimeters using an ASTM standard hole drill. Abrasion loss is determined using Method B of ASTM D 5963-97a on a Gotech GT-7012-D Abrasion Tester machine. The test is conducted at 22°C with an abrasion path of 40 meters. The standard rubber #1 used in the test has a density of 1.336 grams per cubic centimeter (g / cm 3 ). The smaller the amount of abrasion loss, the better the wear resistance.

[0196] Water permeability testWater Permeability. The water permeability of a sample prepared using the Component Sampling Procedure, the Panel or Film Sampling Procedure, or the Textile Sampling Procedure described below is determined as follows. The sample to be tested is mounted on a support pedestal at a 45 degree angle to the horizontal. The support pedestal includes a 152 millimeter diameter sample holder inner ring. The sample is allowed to equilibrate in a laboratory environment for at least 2 hours prior to testing. The test sample is cut into a 220 millimeter diameter circle. Thicker or stiffer materials, such as leather or stiff synthetic leather, will have 3 notches in the outer edge of the sample. The sample can be cut by hand or die cut. The test sample of softer material is cut to the same size and the length direction is marked on the test sample. The backing paper is prepared from a white or off-white paper towel, coffee filter, or similar thin absorbent paper. The backing paper is also cut into a 220 millimeter diameter circle. One piece of backing paper is prepared for each test sample and the backing paper is not reused. The backing paper and sample are placed in a sample holder which is in turn placed in a spray test apparatus. The sample length direction should be parallel to the water flow direction. The funnel between the spray nozzle and the test sample is adjusted to a height of 6 inches (152.4 millimeters). The spray nozzle must be over the center of the test sample. 250 ± 2 milliliters of distilled water is added to the funnel and the water is sprayed onto the test sample. Within 10 seconds of the end of the spraying, the top surface is evaluated for water repellency. After evaluating the top surface, the sample holder is removed from the support pedestal and the backing paper is evaluated to determine if water has penetrated through the sample. The water permeability is reported after the visual evaluation and the sample is rated as "Pass" or "Fail" according to the degree of wetting. The sample is considered to pass the test if no adhesion or wetting of the top surface is observed, if slight random adhesion or wetting of the top surface is observed, or if wetting of the top surface at the point of spray is observed. Further wetting beyond the point of spray and / or including the back surface indicates that the sample has failed the water permeability test.

[0197] Textile-ball impact test Textile Sampling Procedure. A test sample of a textile is prepared according to the Component Sampling Procedure or the Textile Sampling Procedure described below. A 10 inch by 8 inch test sample of the textile is mounted on the outer surface of a metal cylinder having a 10 inch circumference. The test sample and cylinder are mounted on a robot swing arm which swings at a rate of 50 miles per hour and impacts the equator of a stationary ball. The ball used is a regulation size Nike "MERLIN" soccer ball inflated to 0.80 bar. A high speed video camera is used to record the ball position immediately following the impact. The spatial position and rotation of the ball between multiple frames of the images recorded by the high speed video camera are then used to calculate the velocity and rotational velocity of the ball immediately following the impact. Each measurement is repeated at least 3 times and the run results are averaged.

[0198] Upper-ball impact testThe entire male size 10.5 football shoe or the upper of the male size 10.5 football shoe is mounted on the robot's swing arm and positioned so that the ball impacts the shoe on the medial side of the front quarter, on or near the laces (when the shoe includes a lacing structure), and so that the upper impacts the equator of the ball as the robot's swing arm swings at a rate of 50 miles per hour. The ball used is a regulation size Nike "MERLIN" football inflated to 0.80 bar. A high speed video camera is used to record the ball's position immediately following impact. The spatial position and rotation of the ball between multiple frames of the image recorded by the high speed video camera is then used to calculate the velocity and rotational velocity of the ball immediately following impact using software. Each measurement is repeated at least 3 times and the results are averaged.

[0199] Sampling Procedure

[0200] Using the test described above, various properties of the materials and articles formed therefrom disclosed herein can be characterized using samples prepared using the following sampling procedure:

[0201] Material sampling procedure The material sampling procedure can be used to obtain a pure sample of a polymeric composition or polymer, or in some cases, a sample of the materials that form the polymeric composition or polymer. The materials are provided in a media form, such as a sheet, a pellet, a powder, a pellet, etc. If the source of the polymeric material or polymer cannot be obtained in pure form, a sample can be cut from a component or element containing the polymeric material or polymer, such as a composite element or sole structure, thereby isolating a sample of the material.

[0202] Panel or film sampling procedure.A sample of the polymer composition or polymer is prepared. A portion of the polymer or polymer composition is then molded into a plaque or film of a size suitable for the test apparatus. For example, when using a Ross Flexometer, a plaque or film sample is sized to fit inside the Ross Flexometer used by hot forming the polymer composition or polymer in a mold to a size of about 15 centimeters (cm) by 2.5 centimeters (cm) and a thickness of about 1 millimeter (mm) to about 4 mm. For a plaque sample of a polymer, the sample can be prepared by melting the polymer, loading the molten polymer into a mold, re-solidifying the polymer into the shape of the mold, and removing the solidified molded sample from the mold. Alternatively, a sample of the polymer can be melted and then extruded into a film, which is cut to size. For a sample of a polymer composition, the sample can be prepared by blending the components of the polymer composition together, melting the thermoplastic components of the polymer composition, loading the molten polymer composition into a mold, re-solidifying the polymer composition into the shape of the mold, and removing the solidified molded sample from the mold. Alternatively, a sample of the polymer material can be prepared by mixing and melting the components of the polymer composition, and then the molten polymer composition can be extruded into a film, which is cut to size. For a film sample of a polymer or polymer composition, the film is extruded as a web or sheet of fibers or a sheet having a substantially constant film thickness (within ±10% of the average film thickness) for the film, and cooled to solidify the resulting web or sheet. A sample having a surface area of 4 square centimeters is then cut from the resulting web or sheet. Alternatively, if the source of the film material cannot be obtained in pure form, the film can be cut from a backing of a footwear component or from a support backing of a co-extruded sheet or web, thereby isolating the film. In either case, a sample having a surface area of 4 square centimeters is then cut from the resulting isolated film.

[0203] Component sampling procedure The procedure can be used to obtain a sample of a material, including a sample of a polymer composition or textile, or a portion of a textile, such as a thermoformed web, from a component of an article of footwear, an article of footwear, a component of an article of apparel, an article of apparel, a component of an article of sporting equipment, or an article of sporting equipment. The sample of the material is cut from the article or component using a blade, including the material in a non-wet state (e.g., at 25°C and 20% relative humidity). If the material is bonded to one or more additional materials, the procedure can include separating the additional material(s) from the material to be tested. For example, to test a material on a ground-facing surface of a sole structure, the opposite surface can be skinned, abraded, scraped, or otherwise cleaned to remove any adhesive, yarn, fiber, foam, etc. that is fixed to the material to be tested. The resulting sample includes the material and can include any additional materials bonded to the material.

[0204] A sample is taken at a location along the article or component that provides a substantially constant material thickness (within ±10% of the average material thickness) of the material present on the article or component, e.g., for an article of footwear, in the forefoot region, midfoot region, or heel region of the ground-facing surface. For many of the test protocols described above, a sample having a surface area of 4 square centimeters (cm2) is used. The sample is cut to the size and shape appropriate for the test apparatus (e.g., a dog bone shaped sample). In cases where the material is not present in any section having a 4 square centimeter surface area and / or the material thickness is not substantially constant for sections having a 4 square centimeter surface area, sample sizes having smaller cross-sectional surface areas can be obtained, and the measurement of the specific area adjusted accordingly.

[0205] Yarn sampling procedure The yarn to be tested is stored at room temperature (20°C to 24°C) for 24 hours prior to testing. The first 3 meters of material are discarded. The sample yarn is cut to a length of approximately 30 millimeters with minimal tension at about room temperature (e.g., 20°C).

[0206] Textile sampling procedure The textile to be tested is stored at room temperature (20°C to 24°C) for 24 hours prior to testing. The textile sample is cut to the size as specified by the test method to be used, with minimal tension at about room temperature (e.g., 20°C).

[0207] Example aspects

[0208] The following clauses represent example aspects of the concepts contemplated herein. Any one of the following clauses can be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that expressly depend from a prior clause) can be combined as long as it remains within the scope of the aspects contemplated herein. The following clauses are illustrative in nature and are not limiting.

[0209] Clause 1. A knitted component having a first surface and an opposite second surface, the first surface of the knitted component comprising: a first region having a first coefficient of friction, the first region comprising a first yarn having a core and a coating, the coating at least partially surrounding the core; and a second region having a second coefficient of friction different from the first coefficient of friction, the second region comprising a second yarn, wherein the first region and the second region form an alternating pattern such that the first region occupies 40% to 80% of the total surface area of the first surface.

[0210] Clause 2. The knitted component of Clause 1, wherein the coating comprises a thermoplastic elastomer.

[0211] Clause 3. The knitted component of any of clauses 1-2, wherein a first region of the first regions comprises a thermoformed network of interlaced yarns including the core and the coating, wherein the coating consolidates the thermoformed network of interlaced yarns by surrounding at least a portion of the core and occupying at least a portion of spaces between the yarns in the thermoformed network of interlaced yarns.

[0212] Clause 4. The knitted component of any of clauses 1-3, wherein the first coefficient of friction is greater than the second coefficient of friction.

[0213] Clause 5. The knitted component of any of clauses 1-4, wherein the first coefficient of friction and the second coefficient of friction are dynamic coefficients of friction.

[0214] Clause 6. The knitted component of any of clauses 1-5, wherein the second yarn does not include the coating.

[0215] Clause 7. The knitted component of any of clauses 1-6, wherein the alternating pattern is a concentric pattern.

[0216] Clause 8. The knitted component of any of clauses 1-7, wherein a first region of the first regions and a second region of the second regions are continuous in the alternating pattern, wherein a boundary between the first region and the second region is curvilinear.

[0217] Clause 9. The knitted component of any of clauses 1-8, wherein a first region of the first regions and a second region of the second regions are continuous in the alternating pattern, wherein a boundary between the first region and the second region is linear.

[0218] Clause 10. The knitted component of any of clauses 1-9, wherein a first region of the first regions and a second region of the second regions are continuous in the alternating pattern, wherein a first raised portion of the first surface continuously extends across the first region and the second region in a first direction.

[0219] Clause 11. A knitted article of a footwear upper having an outward-facing surface portion and an opposite inward-facing surface portion, the outward-facing surface comprising: a first region having a first coefficient of friction, the first region comprising a first yarn; and a second region having a second coefficient of friction different from the first coefficient of friction, the second region comprising a second yarn, wherein the first region and the second region form a first alternating pattern in a first zone of the outward-facing portion such that the first region occupies 40-80% of a total surface area of the outward-facing surface portion in the first zone.

[0220] Clause 12. The knitted article of footwear uppers of Clause 11, wherein the first regions and the second regions form a second alternating pattern in a second zone of the outward-facing portion, such that the first regions comprise 40% to 80% of a total surface area of the outward-facing surface portion in the second zone.

[0221] Clause 13. The knitted article of footwear uppers of Clause 12, wherein the first zone is on a medial portion of the knitted article of footwear uppers and the second zone is on a lateral portion of the knitted article of footwear uppers.

[0222] Clause 14. The knitted article of footwear uppers of any one of Clauses 11 to 13, wherein the first alternating pattern is a concentric pattern.

[0223] Clause 15. The knitted article of footwear uppers of any one of Clauses 11 to 13, wherein the first alternating pattern comprises at least one of a curvilinear border between first regions in the first regions and second regions in the second regions or a linear border between the first regions in the first regions and the second regions in the second regions.

[0224] Clause 16. The knitted article of footwear uppers of any one of Clauses 12 to 15, wherein first regions in the first regions comprise a thermoformed network of interlaced yarns each having a core, such that a thermoplastic elastomer consolidates the interlaced yarns by surrounding at least a portion of the core and occupying at least a portion of a space between the yarns in the thermoformed network of interlaced yarns.

[0225] Clause 17. The knitted article of footwear uppers of any one of Clauses 11 to 16, wherein the first zone extends across at least a portion of a toe region of the knitted article of footwear uppers.

[0226] Clause 18. The knitted article of footwear uppers of any one of Clauses 11 to 16, wherein the first zone extends across at least a portion of a toe region of the knitted article of footwear uppers and at least one of a medial side and a lateral side of the knitted article of footwear uppers.

[0227] Clause 19. A method of manufacturing a knitted component having a first surface and an opposite second surface, the method comprising: knitting a first yarn and a second yarn into the knitted component; and thermoforming the first surface of the knitted component, wherein the first surface of the knitted component comprises: a first region having a first coefficient of friction, wherein the first region comprises a thermoformed network of interlaced yarns each having a core such that a thermoplastic elastomer consolidates the interlaced yarns by surrounding at least a portion of each core and occupying at least a portion of a space between the yarns in the thermoformed network of interlaced yarns; and a second region having a second coefficient of friction different from the first coefficient of friction, the second region comprising the second yarn, wherein the first region and the second region form an alternating pattern such that the first region occupies 40% to 80% of a total surface area of the first surface.

[0228] Clause 20. The method of clause 19, wherein thermoforming the first surface further comprises molding the first surface with one or more raised portions of the first surface, the one or more raised portions extending across a plurality of the first regions and a plurality of the second regions.

[0229] Aspects of the disclosure have been described as illustrative and not limiting. Alternative aspects will become apparent to those skilled in the art without departing from the scope of the disclosure. Alternative means of implementing the above described improvements will become apparent to those skilled in the art.

[0230] It should be understood that certain features and subcombinations are of utility and can be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all of the steps listed in each figure is required to be performed in the specific order described.

[0231] While specific elements and steps are discussed in connection with each other, it should be understood that any element and / or step provided herein should be considered to be combinable with any other element and / or step, whether explicitly provided or not, while still being within the scope provided herein. Since many possible aspects of the disclosure can be made without departing from the scope thereof, it is understood that all matter contained herein or shown in the accompanying drawings shall be interpreted as illustrative and not limiting.

Claims

1. A knitted component having a first surface and an opposite second surface, the first surface of the knitted component comprising: a plurality of first regions having a first coefficient of friction, the plurality of first regions comprising a first yarn having a core and a coating, the coating at least partially surrounding the core; and a plurality of second regions having a second coefficient of friction different from the first coefficient of friction, the plurality of second regions comprising a second yarn, wherein the plurality of first regions and the plurality of second regions form an alternating pattern such that the plurality of first regions occupy 40% to 80% of a total surface area of the first surface, and wherein the second surface of the knitted component comprises a plurality of third regions opposite the plurality of first regions and the plurality of second regions on the first surface, the plurality of third regions comprising a third yarn having an elastomeric fiber or an elastomeric polyurethane material.

2. The knitted component of claim 1, wherein the coating comprises a thermoplastic elastomer.

3. The knitted component of claim 1, wherein a first region of the plurality of first regions comprises a thermoformed network of interlaced yarns including the core and the coating, wherein the coating consolidates the thermoformed network of interlaced yarns by surrounding at least a portion of the core and occupying at least a portion of a space between yarns in the thermoformed network of interlaced yarns.

4. The knitted component of claim 1, wherein the first coefficient of friction is greater than the second coefficient of friction.

5. The knitted component of claim 1, wherein the first coefficient of friction and the second coefficient of friction are dynamic coefficients of friction.

6. The knitted component of claim 1, wherein at least a portion of the second yarn does not include the coating.

7. The knitted component of claim 1, wherein the alternating pattern is a concentric pattern.

8. The knitted component of claim 1, wherein a first region of the plurality of first regions and a second region of the plurality of second regions are continuous in the alternating pattern, wherein a boundary between the first region and the second region is curvilinear.

9. The knitted component of claim 1, wherein a first region of the plurality of first regions and a second region of the plurality of second regions are continuous in the alternating pattern, wherein a boundary between the first region and the second region is linear.

10. The knitted component of claim 1, wherein a first region of the plurality of first regions and a second region of the plurality of second regions are continuous in the alternating pattern, wherein a first raised portion of the first surface continuously extends across the first region and the second region.

11. A knitted article of a footwear upper of footwear, the knitted article of the footwear upper having an outward-facing surface portion and an opposite inward-facing surface portion, the outward-facing surface comprising: a plurality of first regions having a first coefficient of friction, the plurality of first regions comprising a first yarn; and a plurality of second regions having a second coefficient of friction different from the first coefficient of friction, the plurality of second regions comprising a second yarn, wherein the plurality of first regions and the plurality of second regions form a first alternating pattern in a first zone of the outward-facing surface portion, such that the plurality of first regions occupy 40% to 80% of a total surface area of the outward-facing surface portion in the first zone, and wherein the inward-facing surface includes a plurality of third regions opposite the plurality of first regions and the plurality of second regions on the outward-facing surface, the plurality of third regions including third yarns having an elastic fiber or an elastic polyurethane material.

12. The knitted article of footwear uppers of claim 11, wherein the plurality of first regions and the plurality of second regions form a second alternating pattern in a second zone of the outward-facing surface portion, such that the plurality of first regions occupy 40% to 80% of a total surface area of the outward-facing surface portion in the second zone.

13. The knitted article of footwear uppers of claim 12, wherein the first zone is on a medial portion of the knitted article of footwear uppers and the second zone is on a lateral portion of the knitted article of footwear uppers.

14. The knitted article of footwear uppers of claim 13, wherein the first alternating pattern is a concentric pattern.

15. The knitted article of footwear uppers of claim 13, wherein, the first alternating pattern includes at least one of a curvilinear boundary between a first region of the plurality of first regions and a second region of the plurality of second regions or a linear boundary between the first region of the plurality of first regions and the second region of the plurality of second regions.

16. The knitted article of footwear uppers of claim 11, wherein a first region of the plurality of first regions includes a thermoformed network of interlaced yarns each having a core, such that a thermoplastic elastomer consolidates the interlaced yarns by surrounding at least a portion of the core and occupying at least a portion of a space between the yarns in the thermoformed network of interlaced yarns.

17. The knitted article of footwear uppers of claim 11, wherein the first zone extends across at least a portion of a toe region of the knitted article of footwear uppers.

18. The knitted article of footwear uppers of claim 11, wherein the first zone extends across at least a portion of a toe region of the knitted article of footwear uppers and at least one of a medial side and a lateral side of the knitted article of footwear uppers.

19. A method of manufacturing a knitted component having a first surface and an opposite second surface, the method comprising: knitting a first yarn and a second yarn into the knitted component; and thermoforming the first surface of the knitted component, wherein the first surface of the knitted component includes: a plurality of first regions having a first coefficient of friction, the plurality of first regions including a thermoformed network of interlaced yarns each having a core, such that a thermoplastic elastomer consolidates the interlaced yarns by surrounding at least a portion of each core and occupying at least a portion of a space between the yarns in the thermoformed network of interlaced yarns, and a plurality of second regions having a second coefficient of friction different from the first coefficient of friction, the plurality of second regions including the second yarn, wherein the plurality of first regions and the plurality of second regions form an alternating pattern such that the plurality of first regions comprise 40% to 80% of the total surface area of the first surface, and wherein the second surface of the knitted component comprises a plurality of third regions opposite the plurality of first regions and the plurality of second regions on the first surface, the plurality of third regions comprising third yarns having an elastic fiber or an elastic polyurethane material.

20. The method of claim 19, wherein thermoforming the first surface further comprises molding the first surface with one or more raised portions of the first surface, the one or more raised portions extending across the plurality of first regions and the plurality of second regions.

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