Knit textile and upper and method of making the same

Abstract

This application relates to a knitted textile and a shoe upper, and a method of manufacturing the same. A wearable article having one or more textiles comprising a low-processing-temperature polymer composition and a high-processing-temperature polymer composition is disclosed; as well as a method of manufacturing the wearable article. The low-processing-temperature polymer composition and the high-processing-temperature polymer composition may be selectively incorporated into the textile to provide one or more structural properties and / or other advantageous properties to the article. The textile may be thermoformed to impart such structural properties and / or other advantageous properties to the wearable article. This abstract is intended as a search tool for searching in a particular art and is not intended to limit this disclosure.

Description

[0001] This application is a divisional application of the application filed on November 9, 2017, with application number 202110802431.X, entitled "Knitted textiles and shoe uppers and methods of manufacturing the same".

[0002] The application filed on November 9, 2017, with application number 202110802431.X and entitled "Knitted textiles and shoe uppers and methods of manufacturing thereof", is a divisional application of the application filed on November 9, 2017, with application number 201711100304.5 and entitled "Knitted textiles and shoe uppers and methods of manufacturing thereof".

[0003] Cross-reference of related applications

[0004] This application claims the benefit of each of U.S. Provisional Applications filed on November 9, 2016, namely, 62 / 419,824; 62 / 419,832; 62 / 419,841; and 62 / 419,851, each of which is incorporated herein by reference in its entirety. Technical Field

[0005] This disclosure relates to articles of manufacture, such as clothing, footwear, and sporting goods. More specifically, this disclosure relates to articles comprising one or more materials, said materials comprising a low-processing-temperature polymer composition and a high-processing-temperature polymer composition. This disclosure also relates to methods of manufacturing articles using materials comprising both low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. Background of the Invention

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

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

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

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

[0010] The first yarn and the second yarn at least partially form a plurality of interconnected rows on the outer surface of the knitted textile, the outer surface including at least a first region, a second region and a third region, the second region being located between the first region and the third region, the first region including the second yarn with increased concentration compared to the second region, and the third region including the first yarn with increased concentration compared to the second region.

[0011] In some embodiments, the knitted textile is a component of footwear, clothing, or sporting goods.

[0012] In some embodiments, the knitted textile is an upper for footwear articles; and the third region includes a region configured as a ground-facing outsole region, a region configured as a periphery of the sole region, a region configured as a heel region, a region configured as a pullover region, and combinations thereof.

[0013] In some embodiments, the knitted textile is an upper for footwear articles; and the second region includes a region configured as a periphery of the sole, a region configured as a heel region, a region configured as a pullover region, a region configured as a medial midfoot region, a region configured as a lateral midfoot region, and combinations thereof.

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

[0015] In some implementations, the first region essentially does not contain the first yarn.

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

[0017] In some embodiments, the one or more first thermoplastic polymers of the first yarn comprise one or more thermoplastic polymers selected from the group consisting of polyesters, polyethers, polyamides, polyurethanes and polyolefins.

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

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

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

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

[0022] A complete knitted textile is provided, comprising a first yarn and a second yarn, the first yarn comprising a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers; the second yarn comprising a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high-processing-temperature polymer composition exhibits a melting temperature T higher than that of the low-processing-temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs The first yarn and the second yarn at least partially form a plurality of interconnected rows on the outer surface of the complete knitted textile, the outer surface including at least a first region, a second region and a third region, the second region being located between the first region and the third region, the first region including the second yarn with increased concentration compared to the second region, and the third region including the first yarn with increased concentration compared to the second region;

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

[0024] While at least a portion of the complete knitted textile is on the molded outer surface, the temperature of the complete knitted textile is increased to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. mAnd below at least one of the following of the high-processing-temperature polymer composition: 1) the creep relaxation temperature T cr ;2) The heat distortion temperature T hd ; or 3) the Vicat softening temperature T vs ;as well as

[0025] After increasing the temperature of the complete knitted textile, while at least a portion of the complete knitted textile remains on the molded outer surface, the temperature of the complete knitted textile is reduced to below the melting temperature T of the low-processing-temperature polymer composition. m The temperature is such that knitted products are formed.

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

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

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

[0029] In some embodiments, the protective sleeve further includes a raised surface of the protective sleeve that contacts at least a portion of the outer surface of the knitted textile.

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

[0031] Another aspect of this disclosure provides a knitted article comprising:

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

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

[0034] At least a portion of the second yarn is present in at least a first loop and a second loop, wherein at least a portion of the first loop of the second yarn and at least a portion of the second loop of the second yarn are connected by at least a portion of the first reflow material, and the knitted article has an outer surface comprising at least a first region, a second region and a third region, the second region being located between the first region and the third region, the first region comprising the second yarn with an increased concentration compared to the second region, and the third region comprising the first reflow material with an increased concentration compared to the second region.

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

[0036] In some embodiments, the knitted fabric is a component of footwear, and at least a portion of the third region is the outsole area facing the ground. Attached Figure Description

[0037] Other aspects of this disclosure will become readily apparent upon review of the detailed description described below in conjunction with the accompanying drawings.

[0038] Figure 1A These are top and side perspective views of footwear articles according to various aspects of the present invention, which mainly illustrate the positions of three different textile zones.

[0039] Figure 1B According to various aspects of the present invention Figure 1A Perspective views of the bottom and sides of footwear products.

[0040] Figure 1C According to various aspects of the present invention Figure 1A The top and side perspective views of the alternative aspects of footwear products mainly illustrate the location of three different textile zones.

[0041] Figure 2A This is a side view of a garment article according to various aspects of the present invention, which mainly illustrates the elbow patch.

[0042] Figure 2B According to various aspects of the present invention Figure 2A A close-up view of the elbow patch of the garment, which mainly illustrates three different textile areas.

[0043] Figure 3 It is a schematic plan view of a textile having three types of textile zones according to various aspects of the present invention.

[0044] Figures 4A to 4E Depicting aspects of the present invention Figure 3 Exemplary cross-sections of various types of textile zones.

[0045] Figures 5A to 5J The description of various aspects according to the present invention may exist in Figures 4A to 4E Exemplary knitted structures in segments of an exemplary cross-section depicted in the figure.

[0046] Figure 6 It is a schematic representation of two interconnected rows of coils having different types of yarns and depicting interlaced interfaces according to various aspects of the invention.

[0047] Figure 7A This is a schematic representation of three interconnected coil rows according to various aspects of the invention, wherein the middle coil row is formed of yarns different from those of the outer coil rows.

[0048] Figure 7B According to various aspects of the invention, after exposure to the thermoforming process... Figure 7A A schematic representation of interconnected coil rows, showing that the middle coil row transforms into a molten yarn component after thermoforming, but the two outer coil rows do not transform.

[0049] Figure 8 According to various aspects of the present invention Figure 7B A schematic representation of the cross-section of the molten yarn component, showing a portion of the yarn from one of the outer coil rows encapsulated within the molten yarn component.

[0050] Figure 9A The diagram in FIG7 is a schematic representation of a cross section of a portion of the interconnected rows according to various aspects of the invention, showing a coil in the middle coil row and a coil in the upper coil row.

[0051] Figure 9B According to various aspects of the invention, the interconnected rows in FIG7 have been exposed after the thermoforming process. Figure 9A A schematic representation of the cross-section, showing how the yarn loops in the middle row deform but still maintain the general yarn structure.

[0052] Figure 10A This is a schematic representation of three interconnected rows of yarn of one type according to various aspects of the invention, wherein the anchoring yarn is in a float structure and a tuck structure.

[0053] Figure 10B According to various aspects of the present invention Figure 10A A schematic representation of interconnecting rows, and showing that after thermoforming, one type of yarn forming the interconnecting rows has been transformed into a molten yarn component, wherein the anchoring yarn still appears as yarn.

[0054] Figure 10C According to various aspects of the present invention Figure 10B A schematic representation of the cross-section of the molten yarn component, showing the anchoring yarn encapsulated within the molten yarn component.

[0055] Figure 11A According to various aspects of the present invention Figure 3 A schematic representation of a portion of the textile fabric's textile area, showing areas with different types of fibers.

[0056] Figure 11B According to various aspects of the invention, after exposure to the thermoforming process... Figure 11A The diagram is a schematic representation of a portion of the material, and shows that one type of fiber has been transformed into a non-fiber material, in which fibers of another material are embedded within the non-fiber material.

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

[0058] Figure 12 This is a schematic side view of a footwear article comprising textile material according to various aspects of the invention, showing a chassis, heel support frame, and insole for incorporation into said footwear article.

[0059] Figure 13 According to various aspects of the present invention Figure 12 The cross-section of the footwear product has a base, heel support frame and insole positioned inside the footwear product.

[0060] Figure 14 This is a schematic side view of a footwear article comprising textile material according to various aspects of the invention, showing the addition of ground-engaging anti-slip studs to the ground-facing outsole area of ​​the footwear article.

[0061] Figure 15The figures are top and side perspective views according to various aspects of the invention, showing an upper for footwear articles placed on a shoe last.

[0062] Figure 16 It is from the shoe last of the present invention. Figure 15 The top and side perspective views of the shoe upper show that the upper at least surrounds the bottom portion of the last.

[0063] Figure 17 It is from various aspects of the present invention Figure 16 The cross-section of the upper on the shoe last shows the contact between the shoe last and the inner surface of the upper.

[0064] Figure 18 It is from various aspects of the present invention Figure 16 The top and side perspective views of the shoe last show the protective sleeve surrounding the shoe upper.

[0065] Figure 19 It is from various aspects of the present invention Figure 18 A cross-section of the shoe upper covered with a protective sleeve, showing the outer surface of the shoe upper in contact with the protective sleeve.

[0066] Figure 20A It is from various aspects of the present invention Figure 16 A side view of the shoe upper on the shoe last, showing a vacuum bag containing the shoe upper.

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

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

[0069] Figure 22 This is a flowchart illustrating an exemplary process for manufacturing shoe uppers according to various aspects of the present invention.

[0070] Figure 23 This is a flowchart of another exemplary process for manufacturing shoe uppers according to various aspects of the present invention.

[0071] Figure 24 This is a flowchart illustrating an exemplary process for manufacturing knitted uppers for footwear articles according to various aspects of the present invention.

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

[0073] Figure 26 This is a flowchart illustrating an exemplary process for manufacturing an upper for footwear articles according to various aspects of the present invention.

[0074] Figure 27 This is a flowchart illustrating an exemplary process for manufacturing outsoles of footwear articles according to various aspects of the present invention. Detailed Implementation Plan

[0075] This disclosure relates to textiles or combinations of textiles and other materials (e.g., shaped components, films, second textiles, yarns, or fibers), wherein one or more of the textiles or other materials comprise a low-processing-temperature composition, and one or more of the textiles or other materials comprise a high-processing-temperature composition. In some aspects, a single textile comprises both a low-processing-temperature composition and a high-processing-temperature composition. This disclosure also relates to methods of thermoforming textiles alone or in combination with one or more other materials on a molding surface to reshape the textiles, attaching the one or more other materials to the textiles using a reflow polymeric material, or performing both operations. The thermoforming process involves placing at least a portion of the textile on the molding surface and, while the textile remains in contact with the molding surface, increasing the temperature of the entire textile to a first temperature, and then decreasing the temperature of the entire textile to a second temperature. The first temperature is a temperature above the melting point of the low-processing-temperature composition but below at least one of the following of the high-processing-temperature polymeric composition: 1) creep relaxation temperature T. cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vsTherefore, using the disclosed process, the portion of a textile and / or one or more materials containing the low-processing-temperature composition is melted, reflowed, and then re-cured into a new shape or configuration, while the portion forming the high-processing-temperature composition retains its original shape or configuration. Forming first fibers and / or yarns from the low-processing-temperature composition and using these fibers and / or yarns to construct textiles such as woven textiles, knitted textiles, non-woven textiles, braided textiles, etc., is a particularly effective and efficient way to incorporate the low-processing-temperature composition into these thermoforming processes. For example, the use of the disclosed textiles and process makes it possible to produce thermoformed articles containing integrally formed regions using only a single textile and only a single thermoforming process, the articles having properties ranging from conventional textiles to solid molding polymers. It has been found that producing yarns and / or fibers that function well in the disclosed process, while also producing a final article with the desired properties, requires the use of a low-processing-temperature composition having a balance of several properties disclosed herein. Examples of polymers that can provide this balance of properties in low-processing-temperature compositions are also disclosed. In specific instances, low-processing-temperature compositions for producing yarns suitable for use on commercial weaving or knitting equipment are also disclosed.

[0076] Therefore, in various aspects, this disclosure is intended to overcome the shortcomings of various aspects of the prior art. In particular, one aspect of this disclosure is to provide a knitted fabric that can be used as a component of footwear articles, garment articles, or sporting goods comprising a low-temperature treated polymer composition and a high-temperature treated polymer composition. In some aspects, the knitted fabric is a component of footwear articles such as shoe uppers. The knitted fabric can be manufactured using a disclosed process comprising weaving a first row of loops consisting of a first yarn and a second yarn, the first yarn comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, and the second yarn comprising a high-temperature treated polymer composition comprising one or more second thermoplastic polymers.

[0077] The disclosed knitted fabric can be used to manufacture knitted articles comprising a first reflow material, which is a product obtained by melting and re-solidifying a first yarn. The first reflow material comprises a low-temperature treated polymer composition comprising one or more first thermoplastic polymers. A second yarn comprises a high-temperature treated polymer composition comprising one or more second thermoplastic polymers. A process for manufacturing the knitted articles is also disclosed herein. The knitted articles can be footwear, clothing, or sporting goods.

[0078] In all respects, this disclosure relates to the composition of knitted articles: a first yarn comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, and a second yarn comprising a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits a creep relaxation temperature T cr The melting temperature T of the polymer composition is higher than that of the cryogenic treatment. m The first part of the knitted product is composed of at least a first yarn and a second yarn forming a plurality of interconnected loops.

[0079] In one aspect, this disclosure relates to the composition of knitted articles: a first yarn comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, and a second yarn comprising a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits a heat distortion temperature T0. hd The melting temperature T of the polymer composition is higher than that of the cryogenic treatment. m The first part of the knitted product is composed of at least a first yarn and a second yarn forming a plurality of interconnected loops.

[0080] In one aspect, this disclosure relates to the composition of knitted articles: a first yarn comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, and a second yarn comprising a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits a Vicat softening temperature T0. vs The melting temperature T of the polymer composition is higher than that of the cryogenic treatment. m The first part of the knitted product is composed of at least a first yarn and a second yarn forming a plurality of interconnected loops.

[0081] In one aspect, this disclosure relates to the composition of knitted articles: a first yarn comprising a cryogenically treated polymer composition, wherein the cryogenically treated polymer composition comprises one or more first thermoplastic polymers, the cryogenically treated polymer composition exhibiting a melting temperature T m The temperature is 135°C or lower; the second yarn comprises a high-temperature treated polymer composition, which comprises one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits: 1) a creep relaxation temperature T cr ;2) Heat distortion temperature T hd 3) Vicat softening temperature T vs In this process, at least one temperature is higher than the melting temperature T of the low-temperature treated polymer composition. m The first part of the knitted product is composed of at least a first yarn and a second yarn forming a plurality of interconnected loops.

[0082] In one aspect, this disclosure relates to a process for manufacturing the composition of an article: providing a knitted article according to any one of aspects 1-117; combining the knitted article with one or more other components to form a footwear article, a garment article, or a sporting goods article.

[0083] In one aspect, this disclosure relates to a process for manufacturing knitted articles, the process comprising: knitting a first row of loops composed of a first yarn and a second yarn, the first yarn comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, the second yarn comprising a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits: 1) a creep relaxation temperature T cr ;2) Heat distortion temperature T hd 3) Vicat softening temperature T vs In this process, at least one temperature is higher than the melting temperature T of the low-temperature treated polymer composition. m The second row of loops is woven from a first yarn and a second yarn, wherein at least a portion of the first row and a portion of the second row form a plurality of interconnected loops.

[0084] In one aspect, this disclosure relates to a process for manufacturing knitted articles, the process comprising: knitting a first row comprising a first yarn and a second yarn, wherein the first yarn comprises a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, and the second yarn comprises a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits: 1) a creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs In this process, at least one temperature is higher than the melting temperature T of the low-temperature treated polymer composition. m The anchor yarn is woven into a loop of one or more first yarns in a first row of loops, wherein the anchor yarn comprises an anchor yarn composition comprising one or more polymers, the anchor yarn composition exhibiting an elongation lower than that of a low-temperature treated polymer composition, the first row of loops being on the outer surface of the knitted article, the outer surface comprising at least a first zone, a second zone, and a third zone, wherein the second zone is located between the first zone and the third zone, and the first yarns in the third zone are denser than those in the second zone.

[0085] In one aspect, this disclosure relates to the composition of a knitted article: a first reflow material, wherein the first reflow material is a product of melting and re-solidifying a first yarn, the first reflow material comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers; and a second yarn comprising a high-temperature treated polymer composition, wherein the high-temperature treated polymer composition comprises one or more second thermoplastic polymers; wherein the high-temperature treated polymer composition exhibits a creep relaxation temperature T cr The melting temperature T of the polymer composition is higher than that of the cryogenic treatment. m At least a portion of the second yarn is located at least in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are connected to a portion of the first return material.

[0086] In one aspect, this disclosure relates to the composition of knitted articles: a first reflow material, wherein the first reflow material is a product of melting and re-solidifying a first yarn, the first reflow material comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers; and a second yarn, the second yarn comprising a high-temperature treated polymer composition, wherein the high-temperature treated polymer composition comprises one or more second thermoplastic polymers; wherein the high-temperature treated polymer composition exhibits a heat distortion temperature T0. hd The melting temperature T of the polymer composition is higher than that of the cryogenic treatment. m At least a portion of the second yarn is located at least in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are connected to a portion of the first return material.

[0087] In one aspect, this disclosure relates to the composition of knitted articles: a first reflow material, wherein the first reflow material is a product of melting and re-solidifying a first yarn, the first reflow material comprising a low-temperature treated polymer composition comprising one or more first thermoplastic polymers; and a second yarn, the second yarn comprising a high-temperature treated polymer composition, wherein the high-temperature treated polymer composition comprises one or more second thermoplastic polymers; wherein the high-temperature treated polymer composition exhibits a Vicat softening temperature T0. vs The melting temperature T of the polymer composition is higher than that of the cryogenic treatment. m At least a portion of the second yarn is located at least in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are connected to a portion of the first return material.

[0088] In one aspect, this disclosure relates to the composition of knitted articles: a first reflow material, wherein the first reflow material is a product of melting and re-solidifying a first yarn, the first reflow material comprising a cryogenic polymer composition, and the cryogenic polymer composition comprising one or more first thermoplastic polymers; the cryogenic polymer composition exhibiting a melting temperature T m The temperature is 135°C or lower; and a second yarn comprising a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits: 1) a creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs In this process, at least one temperature is higher than the melting temperature T of the low-temperature treated polymer composition. m At least a portion of the second yarn is located at least in the first row and the second row of the coil, and at least a portion of the first row of the second yarn coil and at least a portion of the second row of the second yarn coil are connected to a portion of the first return material.

[0089] In every respect, this disclosure relates to the process of manufacturing the composition of an article: providing a disclosed knitted article; and then combining the knitted article with one or more other materials to form a footwear article, an apparel article, or a sporting goods article.

[0090] In all respects, this disclosure relates to a process for manufacturing knitted articles, the process comprising: receiving a complete knitted fabric comprising a first yarn and a second yarn, wherein the first yarn comprises a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, wherein the second yarn comprises a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits: 1) a creep relaxation temperature T cr ;2) Heat distortion temperature T hd 3) Vicat softening temperature T vs In this process, at least one temperature is higher than the melting temperature T of the low-temperature treated polymer composition. m In the first portion of the knitted fabric, at least one of the first yarn and the second yarn can form a plurality of interconnected loops; at least a portion of the knitted fabric is placed on the forming surface; while at least a portion of the knitted fabric is placed on the forming surface, the temperature of the entire knitted fabric is raised above the melting temperature T of the low-temperature treated polymer composition. m Below the high-temperature treated polymer composition: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature Tvs At any temperature; after the entire knitted fabric has been heated, while at least a portion of the knitted fabric remains on the forming surface, the temperature of the entire knitted fabric is lowered below the melting temperature T of the low-temperature treatment polymer composition. m This process creates a knitted product.

[0091] In one aspect, this disclosure relates to a process for manufacturing knitted articles, the process comprising: receiving a complete knitted fabric comprising a first yarn and a second yarn, wherein the first yarn comprises a low-temperature treated polymer composition comprising one or more first thermoplastic polymers, wherein the second yarn comprises a high-temperature treated polymer composition comprising one or more second thermoplastic polymers, wherein the high-temperature treated polymer composition exhibits: 1) a creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs In this process, at least one temperature is higher than the melting temperature T of the low-temperature treated polymer composition. m The first portion of the knitted fabric comprises a first row of loops, each loop comprising a first yarn and a second yarn; an anchoring yarn is woven into one or more loops of the first yarn in the first row of loops, wherein the anchoring yarn comprises an anchoring yarn composition comprising one or more polymers, the anchoring yarn composition exhibiting an elongation lower than that of the low-temperature treated polymer composition, the first row of loops being on the outer surface of the knitted fabric, the outer surface comprising at least a first region, a second region, and a third region, wherein the second region is located between the first and third regions, and the first row of yarns in the third region is denser than that in the second region; at least a portion of the knitted fabric is placed on a forming surface; while at least a portion of the knitted fabric is placed on the forming surface, the temperature of the entire knitted fabric is increased, the increased temperature being higher than the melting temperature T of the low-temperature treated polymer composition. m Below the high-temperature treated polymer composition: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs At any temperature; after the entire knitted fabric has been heated, while at least a portion of the knitted fabric remains on the forming surface, the temperature of the entire knitted fabric is lowered below the melting temperature T of the low-temperature treatment polymer composition. m This process creates a knitted product.

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

[0093] Exemplary footwear articles are athletic shoes or sporting footwear, including (but not limited to) running shoes, basketball shoes, football boots, baseball shoes, soccer shoes, tennis shoes, rugby shoes, cross-training shoes, walking shoes, hiking boots, golf shoes, rubber-soled athletic shoes, etc. Alternatively, footwear articles can be non-athletic footwear, including (but not limited to) dress shoes, slippers, casual shoes, sandals, and boots, including work boots. Shoes may or may not cover the wearer's entire foot. For example, shoes may be sandals or other articles that expose most of the wearing foot. Therefore, those skilled in the art will understand that the materials and processes disclosed herein are applicable to a wide variety of footwear types or styles other than the specific types or styles discussed in the following materials and depicted in the accompanying drawings.

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

[0095] The disclosed articles may comprise molded parts, films, fibers, yarns, or combinations thereof comprising low-processing-temperature polymer compositions (described below) and high-processing-temperature polymer compositions (also described below). The disclosed articles comprise at least two polymer compositions that balance several material properties as described herein. Furthermore, the compositions and processes used to form these articles will be selected based on a number of factors, including the type of article to be manufactured and its typical application.

[0096] In various respects, the disclosed molded parts, films, textiles, and articles comprise two different polymer compositions, one of which can melt or deform during thermoforming performed within a first temperature range (referred to herein as a low-processing-temperature polymer composition), while the other polymer composition maintains its shape within the first temperature range (referred to herein as a high-processing-temperature polymer composition). It will be understood that the reference to "polymer composition" is intended to refer to a composition comprising at least one polymer. Optionally, additional components such as pigments, dyes, fillers, processing aids, etc., may be present in the polymer composition. The low-processing-temperature composition comprises one or more first thermoplastic polymers. The high-processing-temperature composition comprises one or more second polymers. In some instances, the high-processing-temperature polymer composition is a thermoplastic composition and comprises one or more second thermoplastic polymers. The polymer compositions disclosed herein can be used to form molded parts, films, and / or fibers. The molded parts and / or films can then be incorporated into articles as described herein. The fibers can then be used to form yarns and textiles as described herein, and these yarns and textiles can also be incorporated into articles as described herein. On the other hand, the disclosed textiles and articles include a first film, fiber or yarn comprising a low-processing-temperature polymer composition and a second film, fiber or yarn comprising a high-processing-temperature polymer composition.

[0097] As mentioned above, the articles described herein may comprise materials such as molded parts, films, fibers, yarns, and / or textiles, wherein said articles are formed at least in part from low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. In some instances, said materials are formed at least in part from low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. As used herein, “low-processing-temperature polymer composition” and “high-processing-temperature polymer composition” refer to the relative creep relaxation temperature (T0) of each of these compositions. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) and / or melting temperature (T m The relative terminology of creep relaxation temperature (T) for low-processing polymer compositions.cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) and melting temperature (T) m This is understood to be below the decomposition temperature of the polymer composition at the high processing temperature. These parameters are described in further detail below. It should be understood that other properties and parameters may differ between the low-processing-temperature polymer composition and the high-processing-temperature polymer composition, as discussed in detail below. In various respects, the low-processing-temperature polymer composition and / or the high-processing-temperature polymer composition, or both, may be present in the molded parts, films, textiles, yarns, or fibers.

[0098] In all respects, when the low-processing-temperature polymer composition and the high-processing-temperature polymer composition are thermoplastic compositions, the melting temperature (T) of the low-processing-temperature polymer composition is... m The polymer composition has at least one of the following properties below the high processing temperature: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m In other words, for example, low-processing-temperature polymer compositions exhibit lower creep relaxation temperatures (T0) than high-processing-temperature polymer compositions. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) or melting temperature (T) m The melting temperature (T) of one or more of the following: m The melting temperature (T) m The melting temperature of the polymer composition is lower than the high processing temperature (T). m ).

[0099] On the other hand, the melting temperature (T) of low-processing-temperature polymer compositions m The creep relaxation temperature (T) of polymer compositions below the high processing temperature cr On the other hand, the melting temperature (T) of the low-processing-temperature polymer composition. m The Vicat softening temperature (T) of polymer compositions below the high processing temperature vs On the other hand, the melting temperature (T) of the low-processing-temperature polymer composition. m The heat distortion temperature (T) of polymer compositions below the high processing temperature hd On the other hand, the melting temperature (T) of the low-processing-temperature polymer composition. m The melting temperature of the polymer composition is lower than the high processing temperature (T). m ).

[0100] In all aspects, the melting temperature (T) of the high-processing-temperature polymer composition m The polymer composition has at least one of the following properties that are greater than the low processing temperature: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m In other words, for example, polymer compositions processed at high temperatures exhibit a higher creep relaxation temperature (T0) than polymer compositions processed at low temperatures. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) or melting temperature (T) m The melting temperature (T) of one or more of the following: m The melting temperature (T) m Melting temperature of polymer compositions below low processing temperature (T) m ).

[0101] On the other hand, the melting temperature (T) of high-processing-temperature polymer compositions m The creep relaxation temperature of the polymer composition is greater than the low-processing temperature (T). cr On the other hand, the melting temperature (T) of high-processing-temperature polymer compositions. m The Vicat softening temperature (T) of the polymer composition is greater than that of the low-processing-temperature polymer composition. vs On the other hand, the melting temperature (T) of high-processing-temperature polymer compositions. m The heat distortion temperature (T) of the polymer composition at a lower processing temperature is greater than that at a lower processing temperature. hd On the other hand, the melting temperature (T) of high-processing-temperature polymer compositions. m The melting temperature of the polymer composition is greater than that of the low-processing temperature polymer composition (T). m ).

[0102] In various respects, low-processing-temperature polymer compositions and high-processing-temperature polymer compositions can be selectively incorporated into textiles or articles to impart one or more structural properties and / or other advantageous properties to said textiles or articles. In various respects, the textile can be thermoformed to impart such structural properties and / or other advantageous properties. Thermoforming can be performed at temperatures below at least one of the following properties of the high-processing-temperature polymer composition: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) mCreep relaxation of polymer compositions can be achieved at temperatures below the high-processing temperature (T). cr The thermoforming can be performed within a temperature range below the Vicat softening temperature (T0) of the polymer composition at high processing temperatures. vs The thermoforming is performed within a temperature range below the high processing temperature of the polymer composition (T). hd The thermoforming can be performed within a temperature range below the high processing temperature of the polymer composition (T). m The thermoforming is performed within the temperature range of ).

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

[0104] In all respects, the disclosed fibers can be used to prepare yarns. Yarns can be formed using short fibers or long fibers. The yarns of this disclosure comprise at least one of low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. Examples of this disclosure include both low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. For example, a yarn may comprise one or more of the disclosed fibers, said fibers comprising a low-processing-temperature polymer composition, a mixture of two or more low-processing-temperature polymer compositions, a high-processing-temperature polymer composition, a mixture of a high-processing-temperature polymer composition or more low-processing-temperature polymer compositions, or a mixture of one or more low-processing-temperature polymer compositions and one or more high-processing-temperature polymer compositions. Substantially all or most of the fibers of the yarn may be formed from a low-processing-temperature polymer composition. Alternatively, substantially all or most of the fibers of the yarn may be formed from a high-processing-temperature polymer composition. A yarn may comprise fibers formed from a low-processing-temperature polymer composition or fibers formed from a high-processing-temperature polymer composition, or both types of fibers. A yarn may comprise fibers formed from a low-processing-temperature polymer composition, wherein the yarn is coated with a high-processing-temperature polymer composition. Alternatively, the yarn may comprise fibers formed from a high-processing-temperature polymer composition, wherein the yarn is coated with a low-processing-temperature polymer composition.

[0105] In various aspects, the aforementioned fibers or yarns can be used to prepare textiles. Textiles may include one or more of the disclosed fibers or yarns. In various aspects, textiles may be woven textiles comprising one or more of the disclosed yarns. In another aspect, textiles may be knitted textiles comprising one or more of the disclosed yarns. In yet another aspect, textiles may be nonwoven textiles comprising one or more of the disclosed fibers.

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

[0107] In various aspects, low-processing-temperature polymer compositions or high-processing-temperature polymer compositions can be used to manufacture membranes. In some aspects, the membrane may comprise one or more low-processing-temperature polymer compositions. Alternatively, in some aspects, the membrane may comprise one or more high-processing-temperature polymer compositions. In other aspects, the membrane may comprise one or more low-processing-temperature polymer compositions and one or more high-processing-temperature polymer compositions. In various aspects, the membrane may be a multilayer membrane comprising one or more of the disclosed membranes, for example, a bilayer membrane comprising a first layer containing a low-processing-temperature polymer composition and a second layer containing a high-processing-temperature polymer composition. The multilayer membrane may be formed by co-extrusion or lamination.

[0108] In the conventional manufacturing process of articles comprising wearable garments, the transition zone from a first functional zone to a second functional zone can be achieved through a change in the material that imparts said functionality. This transition zone, from a first material having a first functional description to a second material having a different functional description, can introduce constraints into the final article. For example, in the case of shoes, the transition zone from the sole to the upper appears near the shoe's bite line. This transition zone can be referred to as a hard-soft transition zone because the sole generally has a relatively rigid response to foot movement, and the upper has a relatively generally non-rigid response to foot movement. Other such hard-soft transition zones can exist in other locations on the shoe, depending on the design and construction methods used. At this transition zone, the wearer of the shoe may experience discomfort because the portion of the foot allowed on one side of the transition zone moves in a different way than the portion of the foot on the other side (e.g., more freely). This abrupt change in the allowable degrees of freedom of movement of the wearer's foot (e.g., the hard-soft transition zone) can affect the perceived performance and feel of the shoe. To limit the effects of the hard-soft transition zone, manufacturers may insert multiple layers of material or otherwise mechanically manipulate the transition zone to mask the change. Each of these changes may introduce complexity, additional processing steps, and / or materials, which could further impact the shoe's efficiency, cost, and weight.

[0109] Therefore, the aspects contemplated herein allow for integrally molded article portions having transition zones from a first functional area to a second functional area, said transition zone being constructed into and during the formation of said zone. For example, manipulation of materials and techniques, such as needlework, can be implemented to allow a gradient from the first functional area to the second functional area. Returning to the hard-soft transition zone of a shoe, it is contemplated that the first functional area of ​​the shoe (e.g., the sole area) is formed (e.g., knitted) using a first type of material (e.g., a low-processing-temperature polymer composition described below), and the second functional area of ​​the shoe (e.g., the upper portion) is formed (e.g., knitted) using a different material (e.g., a high-processing-temperature polymer composition described below). Alternatively or additionally, the sole area of ​​the shoe is knitted using a first type of needlework, and the upper portion of the shoe is knitted using a second type of needlework. Furthermore, in this example, the transition zone from the first functional area (e.g., the sole area) to the second functional area (e.g., the upper area) may include one or more transition regions in which knitting techniques (e.g., stitch selection, layer manipulation) and / or materials are blended in a defined manner to integrally form a more natural transition from the first to the second functional area during the manufacture of said areas. This integral transition between functional areas can, in exemplary respects, positively influence the wearer's perceived performance and / or feel of the shoe.

[0110] In one aspect, a textile is provided, comprising a first plurality of fibers comprising a low-processing-temperature polymer composition. The textile further comprises a second plurality of fibers comprising a high-processing-temperature polymer composition. The first plurality of fibers and the second plurality of fibers can be deposited to form separate regions of the textile. For example, the first plurality of fibers can form a first surface of the textile, and the second plurality of fibers can form a second surface of the textile opposite to the first surface. Alternatively or additionally, the first plurality of fibers can form a central portion of the first surface of the textile, and the second plurality of fibers can form a transverse portion of the first surface of the textile. The first plurality of fibers and the second plurality of fibers can be laid in a first region, a second region, and a third region, the second region being positioned between the first region and the third region, wherein the first region comprises a second plurality of fibers with an increased concentration compared to the second region, and wherein the third region comprises a first plurality of fibers with an increased concentration compared to the second region. In a particular example, the textile is a nonwoven textile. In some examples, the textile is a component of an article of the present disclosure, such as an apparel article, footwear article, or sporting equipment article. In a particular example, the textile is a component of the upper of a footwear article. Textile components may include at least 75% of the weight of the upper used in footwear products.

[0111] In one aspect, a textile is provided, the textile comprising a first yarn comprising a low-processing-temperature polymer composition. The textile further comprises a second yarn comprising a high-processing-temperature polymer composition. The first and second yarns can be used to form separate regions of the textile. The first and second yarns can be contained in a first region, a second region, and a third region, the second region being positioned between the first and third regions, wherein the first region comprises a second yarn with an increased concentration compared to the second region, and wherein the third region comprises a first yarn with an increased concentration compared to the second region. In some instances, the textile is a component of an article of the present disclosure, such as an apparel article, footwear article, or sporting equipment article. In a particular instance, the textile is a component of an upper for a footwear article. The textile component may comprise at least 75% by weight of the upper for a footwear article.

[0112] In one aspect, a woven textile is provided, comprising a first yarn comprising a low-processing-temperature polymer composition. The woven textile further comprises a second yarn comprising a high-processing-temperature polymer composition. The first and second yarns can be used to form separate regions of the woven textile. For example, the first yarn can form substantially all or a portion of the warp yarns of the weave of the woven textile, and the second yarn can form substantially all or a portion of the weft yarns of the weave of the woven textile, or vice versa. The first and second yarns can form a first region, a second region, and a third region, the second region being located between the first and third regions, wherein the first region comprises a second yarn with an increased concentration compared to the second region, and wherein the third region comprises a first yarn with an increased concentration compared to the second region. In some instances, the woven textile is a component of an article of the present disclosure, such as an apparel article, footwear article, or sporting equipment article. In a particular instance, the woven textile is a component of the upper of a footwear article. The woven textile component may comprise at least 75% by weight of the upper of the footwear article.

[0113] In one aspect, a knitted textile is provided, the knitted textile comprising a first yarn comprising a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The knitted textile further comprises a second yarn comprising a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The first and second yarns at least partially form a plurality of interconnected rows in at least one knitted layer of the knitted textile, the at least one knitted layer having at least a first region, a second region, and a third region, the second region being positioned between the first and third regions, wherein the first region comprises a second yarn with an increased concentration compared to the second region, and wherein the third region comprises a first yarn with an increased concentration compared to the second region. In some instances, the knitted textile is a component of an article of the present disclosure, such as an apparel article, footwear article, or sporting goods article. In a particular instance, the knitted textile is a component of an upper for a footwear article. The knitted textile component may comprise at least 75% by weight of the upper for the footwear article.

[0114] The knitted textile can be formed by a knitting process, such as horizontal knitting or circular knitting. In some aspects, the knitted textile can have a substantially seamless configuration. In other aspects, the knitted textile can be a knitted article formed from a single-piece knitted structure. As utilized herein, a knitted article is defined as being formed from a “single-piece knitted structure” when it is formed as a single element by a knitting process. That is, the knitting process substantially forms the various features and structures of the knitted article without requiring a large number of additional manufacturing steps or processes. Although parts of the knitted article may be joined together after the knitting process (e.g., the edges of the knitted article are joined together, such as at seams), the knitted article remains formed from a single-piece knitted structure because it is formed as a single knitted element. In various aspects, the knitted article may further include other elements that can be added after the knitting process (e.g., tongues, labels, laces, heel supports, logos, trademarks, signs).

[0115] Knitted textiles can incorporate various types of stitches and yarns, as well as combinations of stitches and yarns. Regarding stitches, a knitted textile can have one type of stitch in one area and another type of stitch in another area. Depending on the type and combination of stitches used, the areas of the knitted textile can have, for example, a plain weave, a mesh knit, or a rib knit. Different types of stitches can affect the physical properties of the knitted textile, including aesthetics, stretch, thickness, breathability, and abrasion resistance. That is, different types of stitches can impart different properties to different areas of the knitted textile. Regarding yarns, a knitted textile can have one type of yarn in one area and another type of yarn in another area; for example, one area of ​​the knitted textile may contain a yarn comprising a low-temperature processing polymer composition, and another area may contain a yarn comprising a high-temperature processing polymer composition. Depending on various design criteria, knitted textiles can incorporate yarns with different fineness, materials (e.g., cotton, elastic fibers, polyester, synthetic fibers, wool, and nylon), and twist. Different types of yarn can affect the physical properties of knitted textiles, including aesthetics, stretch, thickness, breathability, and abrasion resistance. In other words, different types of yarn can impart different properties to different areas of the knitted textile. By combining various types of stitches and yarns, and combinations of stitches and yarns, each area of ​​the knitted fabric can possess specific properties, which, when used in footwear, apparel, or sporting goods, can enhance the comfort, durability, and performance of the knitted textile as needed.

[0116] The knitted textiles can be prepared through a variety of suitable processes. For example, the knitted textiles can be manufactured using a horizontal knitting process. While horizontal knitting provides a suitable process for forming knitted textiles, other knitting processes can also be used, such as wide-tube circular knitting, narrow-tube circular knitting jacquard, single-sided circular knitting jacquard, double-sided circular knitting jacquard, warp-knitted fabrics, warp-knitted raschel, and double-needle combed raschel. In various aspects, the knitted textiles can undergo post-processing steps, such as removing portions of the knitted textiles, adding components to the knitted textiles, or creating a wool texture. In other aspects, the knitted textiles can include various knitted structures and / or comprise different knitted sublayers.

[0117] In some respects, the entire knitted fabric can be seamless. Seamless knitted fabrics can be provided, for example, through circular knitting. Circular knitting allows for the provision of three-dimensional preformed fabrics without the need for seams at designated locations. Therefore, unwanted seams in knitted fabrics can be avoided, and three-dimensional preformed knitted fabrics can have the particularly good fit of a seamless structure and the additional benefits mentioned above.

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

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

[0120] In various respects, the textile comprises a second plurality of fibers containing a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first plurality of fibers. m (1) Creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m ).

[0121] On the other hand, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer compositions in the first plurality of fibers. m Large creep relaxation temperature (T) cr ).

[0122] On the other hand, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer compositions among the plurality of fibers. m Large heat distortion temperature (T) hd ).

[0123] On the other hand, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer compositions in the first plurality of fibers. m Large Vicat softening temperature (T) vs ).

[0124] On the other hand, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer compositions in the first plurality of fibers. m Large melting temperature (T) m ).

[0125] On the other hand, the textile includes a first yarn comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The textile may be a knitted textile. The textile may be a woven textile. The textile may be a textile article. The textile article may be an upper portion for footwear.

[0126] In various respects, the textile comprises a second yarn containing a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m (1) Creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m ).

[0127] On the other hand, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large creep relaxation temperature (T) cr ).

[0128] On the other hand, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the yarn. m Large heat distortion temperature (T) hd ).

[0129] On the other hand, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large Vicat softening temperature (T) vs ).

[0130] On the other hand, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large melting temperature (T) m ).

[0131] In some aspects, a textile article is provided comprising a molten fiber component that has been thermoformed from a first state as a first plurality of fibers to a second state as a molten fiber component (i.e., a component formed of a plurality of fibers, wherein at least a portion of the plurality of fibers has been at least partially melted and re-cured into a new form different from their fiber morphology). The first plurality of fibers comprises a low-processing-temperature polymer composition. It will be understood that the molten fiber component may comprise, for example, partially melted first plurality of fibers, substantially fully melted first plurality of fibers, and mixtures thereof. The textile article may also comprise a second plurality of fibers comprising a high-processing-temperature polymer composition. Optionally, the molten fiber component and the second plurality of fibers at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region contains a higher concentration of the second plurality of fibers compared to the second region, and the third region contains a higher concentration of the molten fiber component compared to the second region. In some instances, this structure may form the outer surface of the article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

[0132] In one aspect, the textile article includes a first plurality of fibers, the first plurality of fibers comprising a low-processing-temperature polymer composition, the low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The textile article may be a component of clothing articles. The textile article may be a non-woven textile article. The textile article may be a component of sporting goods articles. The textile article may be a component of footwear articles. The textile article may be an upper portion of footwear articles.

[0133] In various respects, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m (1) Creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) mThe first plurality of fibers change from a first state as a first plurality of fibers to a second state as molten fiber components.

[0134] On the other hand, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Large creep relaxation temperature (T) cr The first plurality of fibers change from a first state as a first plurality of fibers to a second state as molten fiber components.

[0135] On the other hand, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Large heat distortion temperature (T) hd The first plurality of fibers change from a first state as a first plurality of fibers to a second state as molten fiber components.

[0136] On the other hand, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Large Vicat softening temperature (T) vs The first plurality of fibers change from a first state as a first plurality of fibers to a second state as molten fiber components.

[0137] On the other hand, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Large melting temperature (T) m The first plurality of fibers change from a first state as a first plurality of fibers to a second state as molten fiber components.

[0138] In some aspects, a textile article is provided comprising a molten yarn component that has been thermoformed from a first state as a first yarn to a second state as a molten yarn component (i.e., a component formed from yarn that has been at least partially melted and re-solidified into a new form different from its yarn form). The first yarn comprises a low-processing-temperature polymer composition. It will be understood that the molten yarn component may include, for example, a partially melted first yarn, a substantially fully melted first yarn, and mixtures thereof. The knitted article may also comprise a second yarn comprising a high-processing-temperature polymer composition. Optionally, the molten yarn component and the second yarn at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region contains a higher concentration of the second yarn compared to the second region, and the third region contains a higher concentration of the molten yarn component compared to the second region. In some instances, this structure may form the outer surface of the article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

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

[0140] In various respects, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first yarn. m (1) Creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0141] On the other hand, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large creep relaxation temperature (T) crThe first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0142] On the other hand, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large heat distortion temperature (T) hd The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0143] On the other hand, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large Vicat softening temperature (T) vs The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0144] On the other hand, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition in the first yarn. m Large melting temperature (T) m The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0145] In some aspects, the textile article is a knitted article comprising a plurality of interconnected rows. Each of the plurality of interconnected rows comprises a first yarn and a second yarn. The first yarn comprises a low-processing-temperature polymer composition. The second yarn comprises a high-processing-temperature polymer composition. The knitted article further comprises at least one knitted layer comprising at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. Each of the plurality of interconnected rows extends through the first zone, the second zone, and the third zone, wherein the third zone has a higher concentration of the first yarn compared to the second zone. In some instances, this structure may form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface. Additionally, the knitted article comprises an anchoring yarn extending through at least a portion of the third zone. The anchoring yarn comprises a high-processing-temperature polymer composition, for example, fibers formed from a high-processing-temperature polymer composition. The anchoring yarn exhibits a lower elongation than the first yarn.

[0146] In addition to textiles and articles comprising textiles, this disclosure also relates to articles comprising molten film components that are thermoformed from a first state as a film to a second state as a molten film (i.e., a film comprising a low-processing-temperature polymeric material, wherein at least a portion of the low-processing-temperature polymeric material of the film has been melted and re-cured on a substrate into a new morphology different from its film morphology). The articles may also comprise a high-processing-temperature composition. Optionally, the molten film component and the high-processing-temperature composition at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region contains a higher concentration of the high-processing-temperature composition compared to the second region, and the third region contains a higher concentration of the molten film component compared to the second region. In some instances, this structure may form the outer surface of the article, wherein the first, second, and third regions each form a portion of the outer surface.

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

[0148] In various respects, the article comprises a second element (e.g., a molding component, film, textile, fiber, yarn) containing a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (Tm) higher than that of a low-processing-temperature polymer composition of a molten film component. m (1) Creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The molten film component transitions from a first state as a film to a second state as a molten film component.

[0149] On the other hand, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a higher melting temperature (Tm) than the low-processing-temperature polymer composition of the molten film component. m Large creep relaxation temperature (T) cr The molten film component transitions from a first state as a film to a second state as a molten film component.

[0150] On the other hand, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a higher melting temperature (Tm) than the low-processing-temperature polymer composition of the molten film component. m Large heat distortion temperature (T) hd The molten film component transitions from a first state as a film to a second state as a molten film component.

[0151] On the other hand, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a higher melting temperature (Tm) than the low-processing-temperature polymer composition of the molten film component. m Large Vicat softening temperature (T) vs The molten film component transitions from a first state as a film to a second state as a molten film component.

[0152] On the other hand, the textile article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Large melting temperature (T) m The first plurality of fibers change from a first state as a first plurality of fibers to a second state as molten fiber components.

[0153] This disclosure also relates to an article comprising a first polymeric component including a molten zone, said molten zone being thermoformed from a first state as a molded component to a second state as a molten molded component (i.e., the molded component comprises a low-processing-temperature polymeric material, wherein at least a portion of said low-processing-temperature polymeric material has been melted and re-cured into a new form different from its original molded component form). The first component may also include a region formed by a high processing temperature. Alternatively or additionally, the article may also include a second component comprising a high-processing-temperature polymer composition.

[0154] In one aspect, an article includes a first molded component comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The article may be a component of clothing articles. The article may be a component of sporting goods articles. The article may be a component of footwear articles. The article may be an upper portion of footwear articles. The article may be a sole element of footwear articles.

[0155] In various respects, the article comprises a second element (e.g., a molding part, film, textile, fiber, yarn) containing a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first molding part.m (1) Creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The first forming component changes from a first state as a forming component to a second state as a molten forming component.

[0156] On the other hand, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first molded part. m Large creep relaxation temperature (T) cr The first forming component changes from a first state as a first forming component to a second state as a molten forming component.

[0157] On the other hand, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first forming element. m Large heat distortion temperature (T) hd The first forming element changes from a first state as a forming element to a second state as a molten forming part.

[0158] On the other hand, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first forming element. m Large Vicat softening temperature (T) vs The first forming element changes from a first state as a first forming element to a second state as a molten forming part.

[0159] On the other hand, the textile article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) higher than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Large melting temperature (T) m The first plurality of fibers change from a first state as a first forming component to a second state as a molten forming component.

[0160] In one aspect, a knitted upper for footwear articles is provided, the knitted upper comprising a first yarn comprising a low-processing-temperature polymer composition. The knitted upper for footwear articles further comprises a second yarn comprising a high-processing-temperature polymer composition. The first and second yarns at least partially form a plurality of interconnected rows in at least one knitted layer of the knitted upper for footwear articles, the at least one knitted layer having at least a first region, a second region, and a third region, the second region being positioned between the first and third regions, wherein the first region comprises a second yarn with an increased concentration compared to the second region, and wherein the third region comprises a first yarn with an increased concentration compared to the second region. In some instances, this structure can form the outer surface of an article, wherein the first, second, and third regions each form a portion of the outer surface.

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

[0162] In some respects, footwear articles are footwear articles, which include (but are not limited to) articles such as shoes. Footwear articles generally comprise an upper and a sole structure. The upper provides coverage for the foot, comfortably accommodating the foot and positioning it securely relative to the sole structure. Additionally, the upper generally provides protection for the foot. The sole structure can provide various forms of support, cushioning, and shock absorption. The sole structure is attached to the lower portion of the upper and generally positioned between the foot and the ground. Besides mitigating ground reaction forces (i.e., providing cushioning) during walking, running, and other walking activities, the sole structure can, for example, influence foot movement (e.g., by resisting pronation), impart stability, and provide grip. Thus, the upper and sole structures work together to provide a comfortable structure suitable for a wide variety of sports activities.

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

[0164] The upper may also incorporate a lacing system to adjust the fit of the shoe and allow the foot to enter and exit through holes in the upper. The lacing system is often incorporated into the upper to selectively change the size of the ankle opening and allow the wearer to modify certain dimensions of the upper (particularly the girth) to accommodate feet of different sizes. Additionally, the upper may include a tongue that extends below the lacing system to improve shoe comfort (e.g., adjusting the pressure applied to the foot via the lacing), and the upper may also include a heel support to limit or control heel movement. Furthermore, the upper may include a tongue that extends below the lacing system to improve shoe fit and comfort, and the upper may incorporate a heel support.

[0165] In some aspects, the sole structure may include one or more components or layers that may individually or collectively provide several properties to the footwear article, such as support, rigidity, flexibility, stability, cushioning, comfort, reduced weight, or other properties. In some aspects, the sole structure may include layers referred to as the insole, midsole, and outsole. However, in some aspects, one or more of these components may be omitted. In some aspects, the sole may optionally include a sole plate. In some aspects, the sole structure includes an outsole component comprising an external primary surface that exposes and contacts the ground, and an internal primary surface. In another aspect, the sole structure may further include a midsole component that can be attached to the upper along its entire length. When present, the midsole forms an intermediate layer of the sole structure and serves a variety of purposes, including controlling foot movement and damping impact.

[0166] The midsole, which can be attached to the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes, including controlling foot movement and damping impact. Many midsole configurations are primarily formed of an elastic polymer foam material extending across the entire length and width of the shoe, such as polyurethane (PU) or ethylene vinyl acetate (EVA). The midsole may also incorporate plates, adjusters, fluid-filled chambers, and / or, for example, other elements that further dampen forces, influence foot movement, and / or provide stability.

[0167] The outsole forms the element of the shoe that contacts the ground and is typically made of a durable, abrasion-resistant material that includes textures or other features to improve grip. The outsole may be made of a durable, abrasion-resistant material (e.g., rubber) that includes textures to improve grip. Optionally, the outsole may further include anti-slip studs.

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

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

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

[0171] As discussed above, certain aspects relate to one or more textiles comprising fibers and / or yarns including low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. In some aspects, such textiles can form at least a portion of sporting goods articles or clothing articles. In some aspects, the disclosed textiles can form at least a portion of a component of footwear articles. For example, the disclosed textiles can form at least a portion of the upper of shoes such as athletic shoes.

[0172] Now, let's look at the diagram, specifically, the steering... Figure 1A and Figure 1B Footwear article 100 is described as an exemplary wearable article. Figure 1A and Figure 1B Describe 100 types of footwear. Although... Figure 1A and Figure 1B Footwear articles 100 are depicted, but it should be understood that this disclosure also anticipates other clothing articles. Figure 1A and Figure 1B Footwear 100 generally includes a ground-facing outsole area 110, a collar area 112, a lateral midfoot area 114a and a medial midfoot area 114b, a toe box area 116, and a heel area 118. Additionally, footwear 100 may include multiple eyelets 120, an upper area 122, a tongue area 124, and a throat area 126. For example... Figure 1A and Figure 1B As shown, footwear 100 is intended for use on the right foot; however, it should be understood that the following discussion can also be applied to a mirror image of footwear 100 intended for use on the left foot.

[0173] exist Figure 1A and Figure 1B The footwear article 100 depicted may include at least one textile 102, which at least partially forms part of the footwear article 100. The textile 102 of the footwear article 100 may include at least three separate textile zones, such as zones 104, 106, and 108, that identify specific functional areas of the footwear article 100. In some aspects, these specific functional areas are at least partially related to the targeted incorporation of specific textile media in varying amounts, techniques, and combinations into these textile zones (in... Figure 1A and Figure 1B This is described in relation to regions 104, 106, and 108. It should be understood that while textile 102 contains three specific functional regions, more than three functional regions are also expected.

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

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

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

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

[0178] Alternatively or additionally, the three textile zones 104, 106 and 108 may be located at least partially within the midfoot zone, for example, within the lateral midfoot zone 114a and / or the medial midfoot zone 114b.

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

[0180] In some aspects, such as being able to Figure 1A As seen, textile zone 106 extends toward eyelet 120 away from textile zone 104. In these respects, the combination of textile media comprising a low-processing-temperature polymer composition and textile media comprising a high-processing-temperature polymer composition allows for the transfer of forces transmitted from eyelet 120 or other lacing mechanisms to this combination of textile media present in the outer midfoot zone 114a and / or the inner midfoot zone 114b. In some respects, for successful transfer of forces transmitted from eyelet 120, textile zone 104 and / or the low-processing-temperature polymer composition present in textile zone 104 may terminate in zone 128, which, when textile 102 is a knitted textile formed on a commercial knitting machine, is at least about 0.5 cm, about 1.0 cm, or about 2.0 cm away from eyelet 120, and / or at least about 3 stitches, at least about 4 stitches, or at least about 5 stitches below eyelet 120. In these respects, the flexibility and suppleness of the high-processing-temperature polymer composition present in region 108 adjacent to eyelet 120 can facilitate the transfer of forces transmitted from eyelet 120 to textile region 106 and / or to the low-processing-temperature polymer composition present in outer midfoot region 114a and / or inner midfoot region 114b.

[0181] In Figure 1A and Figure 1B In the aspects depicted, textile region 106 is positioned within pullover region 116 and heel region 118. In these aspects, the combination of low-processing-temperature polymer compositions and high-processing-temperature polymer compositions can provide structure and / or support due to the rigidity provided by the thermoforming material. Furthermore, the thermoforming material can provide abrasion resistance in pullover region 116 and / or heel region 118. Alternatively, textile region 104 can be formed in at least a portion of pullover region 116 and / or heel region 118 to achieve increased rigidity or increased abrasion resistance because textile region 104 contains a larger amount of low-processing-temperature polymer composition or an alternative positioning of the low-processing-temperature polymer composition (e.g., an outer knitted surface) than textile region 106.

[0182] Figure 1CAlternative aspects of footwear article 100a are described. In these aspects, footwear article 100a may generally include at least three types of textile areas: textile area 104a, textile area 106a, and textile area 108a. In some aspects, textile areas 104a, 106a, and 108a may have the same characteristics as those described above. Figure 1A The properties and parameters of the textile zones 104, 106 and 108 of the footwear product 100 discussed are the same.

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

[0184] In some respects, in addition to providing structure, rigidity, strength and / or support to one or more areas of a wearable article, thermoformed materials can provide waterproof or water-resistant surfaces.

[0185] Figure 2A and Figure 2B Shirt 200 is depicted as an exemplary garment. Figure 2A and Figure 2B The shirt 200 depicted includes at least one textile 202 that at least partially forms part of the shirt 200. (As shown in...) Figure 2B As can be seen from the text, textile 202 may comprise three separate textile zones 204, 206a-d, and 208 that can identify specific functional areas of 200. In some respects, these specific functional areas are at least partially associated with the targeted incorporation of specific textile media in varying amounts and combinations into these textile zones 204, 206a-d, and 208.

[0186] In some respects, textile region 204 may include reinforcing areas, such as an outward-facing membrane or patch 210, which may, for example, provide abrasion resistance to elbow region 212 of shirt 200. In these respects, the targeted integral incorporation of a low-processing-temperature polymer composition into textile region 204 may at least partially form patch 210 during the thermoforming of textile 202 by melting or deforming the low-processing-temperature polymer composition and subsequently cooling and solidifying the molten material to form patch 210.

[0187] In various aspects, textile zone 208 can exhibit flexibility and / or suppleness similar to conventional shirt materials. In these aspects, textile zone 208 may contain or only contain a high-processing-temperature polymer composition. Furthermore, in some aspects, textile zone 206 may at least partially provide a transition zone within textile 202 from the rigid or semi-rigid patch 210 present in textile zone 204 to the flexible portion present in textile zone 208. In these aspects, textile zones 206a-d may contain a combination of a low-processing-temperature polymer composition present in textile zone 204 and a high-processing-temperature polymer composition present in textile zone 208. Although in Figure 2A and Figure 2B Not shown, but textile zones 206b-d also provide transition zones to, for example, flexible materials present in textile zone 208.

[0188] In some respects, as referenced above Figure 1A and Figure 1B Similar to textile zone 106 of textile 102, this combination of a low-processing-temperature polymer composition from textile zone 204 and a high-processing-temperature polymer composition from textile zone 208 can provide a seamless or integrated transition zone for the flexible, flexible portions present in textile zone 208 from patch 210 to shirt 200.

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

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

[0191] Similar to Figure 1A and Figure 1B Textiles 102 and Figure 2A and Figure 2B Textiles 202, Figure 3 The textile 300 comprises three types of textile zones. For example, the textile 300 includes: textile zone 302, which may contain fibers and / or yarns comprising a low-processing-temperature polymer composition; textile zones 306a and 306b, which may contain a high-processing-temperature polymer composition; and textile zones 304a and 304b, which may contain a combination of fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition. Figure 3 In the textile 300, textile areas 304a and 304b can be located on either side of textile area 302, while textile areas 306a and 306b can be located on opposite sides of textile areas 304 and 304b, respectively.

[0192] In some respects, fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile zone 302 can impart structural or functional properties to textile 300, which can be used to form wearable articles, when exposed to a thermoforming process. For example, textile zone 302 may represent at least a portion forming the ground-facing outsole 112. Figure 1A and Figure 1B The textile 102 has a textile zone 104. In various aspects, fibers and / or yarns, including those containing high-processing-temperature polymer compositions present in 306a and 306b, can be directed onto the textile 300 (e.g., in...). Figure 1A and Figure 1BThe textile zone 108 of the footwear article 100 depicted herein is endowed with flexibility or suppleness. Furthermore, in various aspects, textile zones 304a and 304b may comprise a combination of fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile zone 302 and fibers and / or yarns comprising a high-processing-temperature polymer composition present in textile zones 306a and 306b. Moreover, as discussed above, in certain aspects, this combination of fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition in textile zones 304a and 304b can provide a transition for integration between the rigid thermoforming material in textile zone 302 and the flexible, supple high-processing-temperature polymer composition in textile zones 306a and 306b.

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

[0194] It should be understood that although this document may only further describe the sub-regions of textile region 304a, these descriptions apply to the sub-regions existing in textile region 304b. Furthermore, it should be understood that if textile regions 304a and / or 306a are further discussed in some descriptions, then these descriptions also apply to textile regions 304b and 306b, respectively.

[0195] In some respects, based on the relative positioning of fibers and / or yarns comprising low-processing-temperature polymer compositions and fibers and / or yarns comprising high-processing-temperature polymer compositions in textile zones 302, 304a, and 306a, textile 300 may have different concentrations of low-processing-temperature polymer compositions and / or high-processing-temperature polymer compositions in these textile zones 302, 304a, and 306a.

[0196] As used herein, the term "concentration" refers to a cluster or aggregation in a given volume. Therefore, the term concentration encompasses the measurement of a specified volume (e.g., cm³). 3The amount of material in the fabric (e.g., weight in grams). For example, in knitted textiles, a first portion of a single knitted layer of the textile may have a higher concentration of first yarn compared to a second portion of the textile by having more stitches (e.g., knit stitches, tuck stitches, and / or float stitches) than a second portion of the same size. In another example, in nonwoven textiles, if a first portion of the textile is formed with more first fibers (e.g., weight in grams) than a second portion of the same size, then the first portion may have a higher concentration of first fibers.

[0197] In various aspects, textile zone 302 may contain fibers and / or yarns comprising a low-processing-temperature polymer composition at a higher concentration compared to textile zones 304a and / or 306a. For example, in these aspects, textile zone 302 may have at least 5% more by weight of fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile zones 304a and / or 306a. In another aspect, textile zone 302 may have at least 10% more by weight of fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile zones 304a and / or 306a. In one aspect, textile zone 302 may have at least 25% more by weight of fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile zones 304a and / or 306a.

[0198] In the same or alternative aspects, textile zone 304a may contain fibers and / or yarns comprising a low-processing-temperature polymer composition at a higher concentration compared to textile zone 306a. For example, in these aspects, textile zone 304a may have at least 5% more by weight of fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile zone 306a. In another aspect, textile zone 304a may have at least 10% more by weight of fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile zone 306a. In yet another aspect, textile zone 304a may have at least 25% more by weight of fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile zone 306a.

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

[0200] In some aspects, textile zone 304a may contain fibers and / or yarns comprising a high-temperature processing temperature polymer composition at an increased concentration compared to textile zone 302. For example, in these aspects, textile zone 304a may have at least 5% more by weight of fibers and / or yarns comprising a high-temperature processing temperature polymer composition compared to textile zone 302. In another aspect, textile zone 304a may have at least 10% more by weight of fibers and / or yarns comprising a high-temperature processing temperature polymer composition compared to textile zone 302. In one aspect, textile zone 304a may have at least 25% more by weight of fibers and / or yarns comprising a high-temperature processing temperature polymer composition compared to textile zone 302.

[0201] Figures 4A to 4D Exemplary cross-sections of textile regions 302, 304a, and 306a of textile 300 are schematically depicted. Generally, Figure 4A An exemplary cross-section from textile zone 306a is depicted, and in some respects further illustrates how this portion of textile zone 306a contains fibers and / or yarns comprising high-processing-temperature polymer compositions but not fibers and / or yarns comprising low-processing-temperature polymer compositions present in textile zone 302. Figure 4B An exemplary cross-section from textile zone 302 is depicted, and in various respects it is also illustrated how this portion of textile zone 302 includes fibers and / or yarns comprising low-processing-temperature polymer compositions but not fibers and / or yarns comprising high-processing-temperature polymer compositions present in textile zone 306a. Figure 4C and Figure 4D Two exemplary cross-sections from textile zone 304a are depicted, and it is further illustrated how fibers and / or yarns comprising low-processing-temperature polymer compositions and fibers and / or yarns comprising high-processing-temperature polymer compositions are present in these exemplary portions of textile zone 304a.

[0202] Now, we will describe it from the perspective of textile 300 as a knitted textile. Figures 4A to 4D The cross-section is depicted in the diagram. The various processes used to form knitted textiles and the types of yarn that can be used are discussed in detail below. It is anticipated that a variety of knitting techniques can be implemented to achieve the described results. For example, in some aspects, purl stitches can be used instead of "knit stitches" to achieve comparable results with different aesthetics and / or textures. For simplicity, "knit stitches" will be discussed here, but functional equivalents are expected to be substituted. Similarly, "tuck stitches" can be discussed in certain aspects, but alternative stitching techniques are also expected to be implemented to achieve comparable results. Although relatively simple knitting structures are depicted and discussed, numerous warp-knitted and weft-knitted structures can be formed through, for example, horizontal knitting, wide-tube circular knitting, narrow-tube circular knitting jacquard, single-jersey circular knitting jacquard, double-jersey circular knitting jacquard, double-needle comb Raschel, warp-knitted jacquard, and warp-knitted fabrics.

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

[0204] Figures 5A to 5J The description may exist in Figures 4A to 4D Exemplary potential knitted structures in various segments of the cross-section depicted in the figure. Figure 5A Depicts the undercut (or sometimes referred to as plain stitch) structure 502 formed by the posterior needle bed 504. It should be understood that, according to conventional needle step diagrams, rows of small circles associated with the posterior needle bed 504 represent needles (e.g., needle 505) of the posterior needle bed 504. Furthermore, for the anterior needle bed, for example, in… Figure 5B The same applies to the anterior needle bed 508 depicted in the diagram; that is, the rows of small circles associated with the anterior needle bed 508 represent needles (e.g., needle 507) in the anterior needle bed 508.

[0205] Figure 5B Depict the needle structure 506 formed by the front needle bed 508. Figure 5C Depicts a floating thread structure and a tucked thread structure 510, which has a tucked thread structure formed by a front needle bed 512 and a rear needle bed 514. Figure 5D Another floating thread structure and tucked structure 516 is depicted, which has a tucked structure formed by the front needle bed 518 and the rear needle bed 520. Figure 5E Describe the structure of the floating line organization 522. Figure 5F Depict the stitch and tufting structure 524, which has a stitch 524a formed by a back needle bed 528 and a tufting structure 524b formed by a front needle bed 526. Figure 5G Depict the needle and floating thread structure 530, wherein the needle is formed on the anterior needle bed 532. Figure 5HDepict the needle and floating thread structure 534, wherein the needle is formed on the back needle bed 536. Figure 5I Depict a tuck and floating knitting structure 538, wherein the tuck structure is formed through the front needle bed 540. Figure 5J Depict a tucked and floating knitted structure 542, wherein the tucked structure is formed by the back needle bed 544.

[0206] Now let's return to the cross-sections 4A-4D of textile 300. Generally, the cross-sections depicted in 4A-4D are similarly structured due to the main structure of knitted textiles. For example, in various aspects, there are tubular knitted structures that comprise knitted structures primarily formed by the back needle bed (e.g., in...). Figure 5A The knitted structure 502 depicted in the image and the knitted structure mainly formed on the front needle bed (e.g., in...) Figure 5B The knitted structure 506 is depicted in the image. Furthermore, in these respects, this tubular knitted structure is connected via one or more tuck and float structures, wherein the tuck is formed by the back needle bed and the front needle bed (e.g., respectively in…). Figure 5C and Figure 5D The loop and float structures depicted in Figures 510 and 516.

[0207] The tubular knitted structure of this connection is schematically depicted by three horizontal rows highlighted in the cross-sections drawn in 4A-4D. For example, Figure 4A Describing a polymer composition containing a high processing temperature Figure 3 The cross section 402 of textile zone 306a.

[0208] Figure 4A The cross-section 402 schematically depicts the top segment 404, the middle segment 406, and the bottom segment 408. The top segment 404 and the bottom segment 408 represent the knitted structures used to form the tubular knitted structures, while the middle segment 406 represents the tuck and float knitted structures used to connect the tubular knitted structures together. Therefore, in some aspects, the top segment 404 may contain, respectively, the knitted structures formed by the tuck and float knitted structures. Figure 5A and Figure 5F One or more of the knitted structures 502 and 524 depicted in the diagram. Bottom segment 408 may be included. Figure 5B The knitted structure 506 is depicted in the image. The intermediate segment 406 may contain elements respectively in... Figure 5C and Figure 5D One or more of the knitted structures 510 and 516 depicted in the text.

[0209] Figure 4B A cross-section 410 is depicted of a textile region 302 comprising a yarn including a low-processing-temperature polymer composition. Cross-section 410 includes a top section 412, a middle section 414, and a bottom section 416, which may include the components described above. Figure 4AThe same knitted structure is identified in the top segment 404, middle segment 406 and bottom segment 408 of the cross section 402.

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

[0211] In some respects, in areas of textile 300 containing a large amount of yarn comprising a low-processing-temperature polymer composition (e.g., textile zone 302), anchoring yarns 413 may be provided in textile 300 to help constrain the flow of the molten low-processing-temperature polymer composition and / or provide a degree of flexibility to the thermoforming material. Figure 4B In the cross-section 410 depicted, the anchoring yarn 413 is shown as being present in the intermediate segment 414 between the top segment 412 and the bottom segment 416. In these respects, this positioning of the anchoring yarn 413 can result in the anchoring yarn 413 being embedded or encapsulated by a polymer composition at a low processing temperature after the textile 300 has been thermoformed.

[0212] Although Figure 4B The anchor yarn 413 is depicted as a straight line, but it should be understood that this is a schematic representation of the anchor yarn 413 and is not intended to specify any particular type of knitted structure. For example, the anchor yarn 413 can exist in textile 300 as many different types of knitted structures, such as in... Figure 5E and Figure 5GOne or more of the structures depicted in -J. In some respects, the choice of stitch length for anchor yarn 413 can depend on the desired resistance to the elongation of the material through which anchor yarn 413 extends. For example, an anchor yarn stitch length with five stitches floating between tucks or knits will provide greater resistance to the stretching of the material through which anchor yarn 413 extends compared to an anchor yarn stitch length with only two or three stitches floating between tucks or knits. In this example, the different resistance to elongation between the floating lengths is due to non-linear portions (e.g., stitch loops) that elongate more easily than linear segments, resulting in different amounts of resistance to elongation.

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

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

[0215] Figure 4C The cross section 418 includes the sections mentioned above. Figure 4A and Figure 4B The same type of general tubular knitted structure is discussed for cross sections 402 and 410. Therefore, cross section 418 includes a top segment 426, a middle segment 428, and a bottom segment 430. The top segment 426, middle segment 428, and bottom segment 430 may each include the sections mentioned above. Figure 4A The same knitted structure is discussed for the top segment 404, middle segment 406 and bottom segment 408 of the cross section 402.

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

[0217] Section 424b includes a tubular knitted structure made of yarn comprising a high-processing-temperature polymeric composition; however, the knitted structure formed by the front and back needle beds (using yarn comprising a high-processing-temperature polymeric composition) is joined via a float structure and a tuck structure (or equivalent effective stitches) from yarn comprising a low-processing-temperature polymeric composition. This section 424b describes how, once the textile 300 has undergone thermoforming, the low-processing-temperature polymeric composition can physically join two outer knitted layers together via a veneer or film of thermoforming material during melting and solidification. In these respects, a garment having this type of tubular knitted structure, already thermoformed and joined via an integral thermoforming material, will primarily consist of typical knitted yarn layers joined together via a thermoforming film on opposite outer surfaces of the textile. This structure can be used to provide the garment with waterproof / water-resistant or other weatherproofing properties while still maintaining the typical appearance and feel of a knitted garment.

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

[0219] Figure 4D The top region 440, middle region 442, and bottom region 444 of the cross section 432 can each contain the references mentioned above. Figure 4A The same knitted structure is discussed for the top segment 404, middle segment 406 and bottom segment 408 of the cross section 402, so as to provide the same type of general tubular structure.

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

[0221] Part 438c includes a tubular structure using yarns comprising a low-processing-temperature polymer composition, which are connected via a float structure and a tuck structure from yarns comprising a high-processing-temperature polymer composition. In these respects, after thermoforming, this part 438c can encapsulate the yarns comprising the high-processing-temperature polymer composition within a liner of molten and cooled thermoformed material. In some respects, such a structure can provide a degree of flexibility to an otherwise rigid thermoformed material.

[0222] For example, Figure 4E Describing and Figure 4D The cross-section 432 is the same as the cross-section 446, except that an anchoring yarn 448 has been added to at least a portion of the region containing the yarn comprising the low-processing-temperature polymer composition. In some respects, the anchoring yarn 448 may have the characteristics described above. Figure 4B The anchoring yarn 413 and any or all properties discussed. For example, the anchoring yarn can be incorporated into the use of... Figure 5E and Figure 5G -J describes one or more of the knitted structures in textiles.

[0223] It is possible Figure 4E As seen in the diagram, the anchoring yarn 448 extends from portion 450 of cross-section 446 corresponding to textile region 302, and extends into portions 452a and 452b of sub-regions 305a and 305b corresponding to textile region 304a. Furthermore, in these respects, Figure 4E The description includes yarns containing low-temperature polymer compositions, which also exist (e.g., as having the presence of...). Figure 5A and Figure 5BThe anchor yarn 448 is at least the same portion as the anchor yarn 448 in one or more yarns of the knitted structure of the textile. Therefore, in some aspects, the anchor yarn 448 may extend as a float structure along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low-temperature polymer composition. Furthermore, in some aspects, the anchor yarn 448 may extend as a float structure along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low-temperature polymer composition, and the yarn comprising the low-temperature polymer composition may also be used to form at least a portion of a tucked structure and / or a knitted section. In these aspects, when using the yarn comprising the low-temperature polymer composition and the anchor yarn 448 to at least partially form a tucked structure or knitted section, the anchor yarn 448 may extend along at least two, at least three, at least four, or at least five adjacent loops of the yarn comprising the low-temperature polymer composition. In the same or alternative respects, the anchor yarn 448 may be joined at loops that are spaced apart by a number of stitches within 50% or 25% of the gauge of the knitting machine used to form at least a portion of the textile 300, for example, in a tucked or knitted pattern.

[0224] As discussed above, in one or more aspects, the anchoring yarn 448 may extend from textile zone 302 toward textile zone 306a into textile zone 304a. In these aspects, the anchoring yarn 448 may extend from textile zone 302 toward textile zone 306a into textile zone 304a as far as the yarn comprising the low-processing-temperature polymer composition extends toward textile zone 306a into textile zone 304a, because there is little need to constrain flow and / or provide flexibility to the thermoforming material during thermoforming, since the yarn comprising the high-processing-temperature polymer composition from region 306a is also present in textile zone 304a.

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

[0226] As discussed above, in some respects, when textile 300 is a knitted textile, it will... Figures 4A to 4E The cross-section of the textile depicted is shown as having a top section, a bottom section, and a middle section, wherein the top and bottom sections can form a tubular knitted structure with a top knitted layer and a bottom knitted layer (and wherein the tuck stitches or other connecting stitches present in the middle section can also form a portion of a tubular or general knitted structure). In these respects, each of the top and bottom outer knitted layers can contain multiple interconnected rows.

[0227] In addition, Figure 3 In textile 300, sub-regions 305a-d within region 304a have at least one interlaced interface, such as interlaced interface 306. The interlaced interface, such as interlaced interface 306, provides an interlaced or non-linear transition between the sub-regions of textile 300 along the width w of the textile. In these respects, when textile 300 is thermoformed, these interlaced interfaces provide a finer integrated transition between the rigid region formed by the low-processing-temperature polymer composition in textile region 302 and the flexible region formed by the yarn comprising a high-processing-temperature polymer composition in textile region 306a. In various respects, this fine integrated transition, at least partially provided by the interlaced interfaces, can increase the durability or tear strength of the thermoformed textile 300, in contrast to similar textiles with a linear, abrupt transition between a single rigid and flexible material.

[0228] In the case where textile 300 is a knitted textile, the interlacing interface 306 can depict how different rows of yarns on the top or bottom outer knitted layer can have different amounts of loops (or general stitch selection) comprising yarns of low-processing-temperature polymeric compositions and / or yarns comprising high-processing-temperature polymeric compositions. Because textiles can have multiple layers (e.g., top, middle, and bottom), interlacing interfaces can be found in any combination of layers and are not limited to the exposed or depicted surfaces. Alternatively, as provided herein and as contemplated, a transition zone from a first primary material (e.g., fibers and / or yarns comprising high-processing-temperature polymeric compositions) to a second primary material (e.g., fibers and / or yarns comprising low-processing-temperature polymeric compositions) forms in the textile; this transition zone may appear only at the middle layer or at a combination of the middle layer and one or more outer layers. It should be understood that for the following discussion of knitted layers, it is assumed that when… Figure 3 When textile 300 is a knitted textile, the view of textile 300 depicts the top layer. Furthermore, the same description applies to the bottom knitted layer.

[0229] Figure 6 An exemplary portion 600 of the top layer of textile 300 is schematically depicted, showing a portion of the interlaced interface 306. Figure 6As can be seen, portion 600, the first row 602 of the coil, is interconnected to the second row 604 of the coil. It should be understood that, although in Figure 6 Only two interconnected rows are depicted, but more than two rows may be interconnected in the top knitted layer of textile 300. As used herein, “interconnected” when referring to an interconnected row means how at least a portion of the coil in the first coil row is attached to at least a portion of the coil in the second coil row. Figure 6 An exemplary aspect of interconnected rows is depicted, wherein individual loops from a second row 604 interlock with individual loops from a first row 602. As used herein, "interlock" refers to how a loop from one row can wrap around, for example, a loop in a knitting stitch, and also to, for example, how a loop can pass another segment of yarn through the loop (or through the loop and around the yarn forming the loop) during an overlocking process to form a second loop.

[0230] In part 600 of textile 300, the first row 602 and the second row 604 contain two types of yarn: a first yarn 606 which may include a high-temperature processing polymer composition and a second yarn 608 which may include a low-temperature processing polymer composition. Although only two rows are depicted in part 600, it should be understood that the top knit layer of textile 300 may contain any number of rows. In all respects, each of the rows present in the top knit layer of textile 300 may contain two or more types of yarn, such as... Figure 6 Described in the text.

[0231] exist Figure 6 As can be seen, each row, for example, the first row 602 and the second row 604, can extend from the textile area 302 to the textile area 306a (in some respects, each of the rows can extend from the textile area 306a to the textile area 306b). In some aspects, in Figure 6 As can be seen, the second yarn 608 in the first row 602 and the second row 604 can extend from the textile area 302 into the textile 304a. In the same or alternative respects, the first yarn 606 can extend from the textile area 304a into the textile area 306a. It should be understood that although the schematic portion 600 of the textile 300 depicts each loop as having only a single yarn, more than one yarn can be present at one or more loops (e.g., another yarn can be combined with...). Figure 6 (The portion of the 600 coils forms a coiled structure), such as Figures 4A to 4E The cross-section depicted therein.

[0232] As discussed above, the outer knitted layer 600 of textile 300 represents at least a portion of the interlacing interface 306. In some respects, the interlacing interface 306 (and any other interlacing interface) can be formed by multiple rows of the same type of yarn extending different distances from one region (or sub-region) into the next region or sub-region. For example, in Figure 6 As can be seen, in the first row 602, the second yarn 608 extends further from the textile area 302 towards the textile area 306a into the textile area 304a compared to the second yarn 608 extending from the textile area 302 towards the textile area 306a into the textile area 304a. In these respects, the different distances the second yarn 608 extends into the textile area 304a result in different amounts of loops of the second yarn 608 in each of the first row 602 and the second row 604a, which can change the yarn density in a given region / sub-region. Therefore, in these respects, within the textile area 304a, loops of the second yarn 608 in the first row 602 can interlock with loops of the second yarn 608 in the first row 602 at the first ridge 608, while at the second ridge 610, the second yarn 608 in the first row 602 can interlock with loops of the first yarn 604 in the first row 602. In terms of similarity or substitution, within textile zone 304a, the first yarn 604 in the first row 602 may interlock with the first yarn 604 in the second row 604 at the third rib 612.

[0233] In one or more aspects, the interlacing interface, for example, interlacing interface 306, can result in adjacent rows of multiple rows in textile 300 having different numbers of loops of yarn comprising a low-processing-temperature polymer composition and yarn comprising a high-processing-temperature polymer composition. For example, in Figure 6 In the upper knitted layer portion 600 of the textile 300 depicted, it can be seen that in at least a portion of the textile zone 304a, the first row 602 has a different number of loops of the first yarn 606 and / or the second yarn 608 than the second row 604. Furthermore, in the same or alternative aspects, within at least a portion of the textile zone 304a, adjacent ribs may have one or more loops of different yarns. For example, as... Figure 6 As described in the upper knitted layer portion 600 of the textile 300, the raised pattern 610 includes loops of both the first yarn 606 and the second yarn 608, while the raised pattern 612 includes loops of the first yarn 606.

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

[0235] Figure 7A A schematic depiction of the process prior to thermoforming. Figure 3 The textile 300 comprises a portion 700 of the upper knitted layer of the textile region 304a. This portion 700 includes a first row 702 and a second row 704 having a first yarn 708 comprising a high-processing-temperature polymer composition. The portion also includes a third row 706 of a second yarn 710 comprising a low-processing-temperature polymer composition. In this respect, the third row 706 of loops of the second yarn 710 may be interconnected (e.g., interlocked) to the first row 702 and the second row 707 having the first yarn 708.

[0236] Figure 7B Part 700 is depicted after exposure to the thermoforming process. (Comparison) Figure 7A and Figure 7B As can be seen, a second yarn 710 comprising a low-processing-temperature polymer composition is thermoformed from yarn material into a molten yarn component 712. In some aspects, the heating step of the thermoforming process causes at least partially the low-processing-temperature polymer composition in the second yarn 710 to melt and flow, and subsequently solidifies into the molten yarn component 712 by completing the thermoforming process.

[0237] In all aspects, Figure 7A and Figure 7B As can be seen, the thermoforming process has also changed. Figure 3 At least a portion of the knitted structure of the upper knitted layer of the textile 300. For example, it has been transformed in Figure 7A The rows 702, 704, and 706 depicted in the diagram cause at least part of the portion 700 to no longer contain interconnected rows of coils comprising yarns of low-processing-temperature polymer compositions and yarns comprising high-processing-temperature polymer compositions, as the yarn 710 in the second row 706 is transformed into molten yarn components 712. Figure 7B As can be seen, although the thermoforming process can eliminate Figure 3 The interconnected loops in the upper knitted layer portion 700 of the textile 300 can be connected by molten yarn components 712 to the remaining rows 702 and 704. In these respects, Figure 3This portion 700 of the upper knitted layer of the textile 300 allows the positions of rows 702 and 704 to be fixed relative to each other, in contrast to when rows 702 and 704 are interconnected via rows 706 prior to thermoforming. Furthermore, in these respects, the top portion 714 of the loops of the first row 702 can still be freely interconnected with other rows of yarn, thereby allowing adjustment of the level of rigidity and / or three-dimensional forming provided by the textile zone 304a.

[0238] Figure 8 Depicting along in Figure 7B Section line 8 as described in the text Figure 3 The cross-section of the upper knitted layer of the textile 300 is 700. Figure 8 As can be seen, at least a portion of the first yarn 708 can be encapsulated within the molten yarn component 712. Depending on the conditions used during the thermoforming process, the molten yarn component 712 can solidify into a film structure that surrounds at least a portion of the loops of the first row 702 and the second row 704 of the first yarn 708 comprising a high-processing-temperature polymer composition.

[0239] In Figure 7B and Figure 8 As can be seen from the aspects depicted, the first yarn 708, comprising a high-processing-temperature polymer composition, does not melt or deform after exposure to the thermoforming process. Furthermore, in some aspects, the first yarn 708 may contain a dye 716 (depicted as speckles within the first yarn 708) that does not leach out after exposure to the thermoforming process. For example, in Figure 7B and Figure 8 As can be seen, no dye 716 is visibly leached from the first yarn 708 into the adjacent area (e.g., adjacent area 718) of the molten yarn component 712. In some aspects, at least about 80% by weight, at least about 90% by weight, at least about 95% by weight, or at least 99% by weight of dye 716 remains within or in the first yarn 708. Figure 3 The upper knitted layer of the textile 300 is within the thermoformed portion 700. In the same or alternative respects, after thermoforming, no dye is visibly leached into the [textile / fabricated / contained / etc.]. Figure 3 The upper knitted layer portion 700 of the textile 300 is incorporated into any additional material associated with the final wearable garment therein.

[0240] Figure 9A and Figure 9B Describing one aspect, among which Figure 3 The upper knitted layer portion 700 of the textile 300 is exposed to the thermoforming process, but this only results in deformation of the low-processing-temperature polymer composition in the second yarn 710, without eliminating... Figure 7AAt least a portion of the interconnected rows 702, 704, and 706. As used herein, “deformation” in the context of a thermoforming process for knitted textiles refers to altering the structure of the yarn so that the yarn does not melt and flow in a manner that substantially eliminates the knitted structure of the textile (e.g., by eliminating one or more interconnected loops or interlocking rows).

[0241] Figure 9A Depicting along section line 9A-B before the thermoforming process Figure 3 The cross-section of the upper knitted layer portion 700 of the textile 300, and Figure 9B Depicting the same cross-section after the thermoforming process. Figure 9B As can be seen, after exposure to the thermoforming process, the second yarn 710 in the third row 706 has a modified yarn structure 710a, while the structure of the first yarn 708 remains unchanged. In this respect, the second yarn 710 in the third row 706 remains interlocked with the first row 702 and the second row 704, and maintains... Figure 3 The textile 300 has an upper knitted layer portion 700 of an overall knitted structure.

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

[0243] Figures 10A to 10C Depicting before and after thermoforming Figure 3 The textile 300 has a knitted layer portion 1000 in the upper knitted layer of the textile area 302. Figure 10A The yarn comprising a low-processing-temperature polymer composition is depicted in three rows, 1010, 1012, and 1014. Figure 10A The anchoring yarn 1016 is further depicted as extending as a float structure 1016a and a loop structure 1016b.

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

[0245] As discussed above, in some respects, the textiles described herein may include knitted textiles, for example, in Figures 4A to 10C The image depicts a portion of a knitted textile. A knitted upper for footwear is an exemplary knitted textile. In these respects, at least a portion, and in some respects, the substantially integral portion of the knitted upper of the footwear can be formed of a knitted textile. The knitted textile may additionally or alternatively form another element of the footwear, such as a midsole or a ground-facing outsole. The knitted textile may have a first side forming an inner surface of the upper (e.g., perforations facing the footwear) and a second side forming an outer surface of the upper. The upper containing the knitted textile may substantially surround the perforations so as to substantially enclose the foot when the footwear is in use. The first and second sides of the knitted textile may exhibit different properties (e.g., the first side may provide abrasion resistance and comfort, while the second side may be relatively rigid and provide water resistance).

[0246] In various respects, knitted textiles can be formed as a single, integral element during a knitting process (e.g., a weft knitting process (e.g., using a horizontal knitting machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process). That is, the knitting process can substantially form the knitted structure of the textile without requiring significant post-knitting processes or steps. Alternatively, two or more parts of the knitted textile can be formed separately and subsequently attached. In some embodiments, the knitted textile can be shaped after the knitting process to form and maintain the desired shape of the upper (e.g., by using a foot-shaped last). The shaping process may involve attaching the knitted textile to another object (e.g., a label) at the seam by sewing, by using adhesives, or by another suitable attachment process, and / or attaching one part of a knitted component to another part of a knitted component.

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

[0248] Knitted textiles can also provide desirable aesthetic properties by incorporating yarns with different colors or other visual properties arranged in specific patterns. The yarns and / or knitting structure of a knitted textile can be varied in different locations, allowing the knitted component to have two or more parts with different properties (e.g., the portion forming the throat area of ​​a shoe upper can be relatively elastic, while another portion can be relatively inelastic). In some aspects, knitted textiles can incorporate one or more materials with properties that change in response to stimuli (e.g., temperature, moisture, electric current, magnetic field, or light).

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

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

[0251] Figures 11A to 11C Depicting it Figure 3 The textile 300 is a non-woven textile and is subject to a thermoforming process. Figure 11A yes Figure 3 A schematic depiction of part 1100 of the textile area 304a of the textile 300. Figure 11A As can be seen, the portion comprises a first group 1110 of first fibers 1116 comprising a high-processing-temperature polymer composition, a second group 1112 of first fibers 1116, and a third group 1114 of second fibers 1118 comprising a low-processing-temperature polymer composition. It should be understood that portion 1100 of the textile 300 is illustrative, and the placement and spacing of the first fibers 1116 and the second fibers 1118 may vary in the textile.

[0252] Although Figures 11A to 11C Not depicted in the text, but in the aspect where textile 300 is a nonwoven textile, one or more interfaces between different portions of different fibers may also include one or more interlaced interfaces, for example, interlaced interface 306. In these aspects, interlaced interface 306 may depict how the transition between regions or subregions having different concentrations of fibers comprising a low-processing-temperature polymer composition and / or different concentrations of fibers comprising a high-processing-temperature polymer composition does not follow... Figure 3 The width w of the textile 300 appears in a linear manner.

[0253] Now return to Figures 11A to 11C as well as Figure 11C Specifically, in which the thermoforming process causes the low-processing-temperature polymer composition in the second fiber 1118 to melt and flow, the second fiber 1118 has been transformed into a non-fibrous material 1120, while the first fiber 1116 has not been transformed and thus retains its fibrous form. In these respects, the non-fibrous material 1120 can bond the first group 1110 of the first fiber 1116 to the second group 1112 of the first fiber 1116. Figure 11C A cross-section along section line 11C is shown, which in some respects illustrates how at least a portion of the first fiber 1116 can be encapsulated within the non-fibrous material 1120. In various respects, it is contemplated that at least a portion of the first fiber 1116 can be at least partially embedded within the non-fibrous material 1120, such that the first fiber 1116 is not completely encapsulated by the non-fibrous material 1120.

[0254] Although not depicted in the figure, in some respects, after exposure to the thermoforming process, the second fiber 1118 may not melt and flow, but instead may deform and change shape. Figure 9A and Figure 9B This describes this deformation of the fiber or yarn. (Related to the previous text...) Figure 9A and Figure 9B As with the deformation of fibers or yarns, in some respects, a second fiber can be deformed and molded onto another first or second fiber (or the same fiber) and mechanically coupled or physically bonded to said fiber.

[0255] Methods for manufacturing

[0256] Some conventional thermoforming processes involve selectively thermoforming only a portion of the article, for example, by shielding parts of the article that are not desired to be exposed to the thermoforming process, or by using a tool that contacts or covers only a portion of the article. However, such conventional methods result in time- and energy-intensive manufacturing processes because multiple steps are required before and after the thermoforming process to shield and expose certain parts of the article, or multiple sets of tools are required. Other conventional thermoforming processes involve thermoforming article components before assembly into an article. This conventional process is also time- and resource-intensive because multiple steps and machines are required to individually form article components before assembling the article. Furthermore, articles formed from several individual components produce multiple seams where the individual components join, thus providing weaknesses in the article, making it feel less natural to the wearer, and / or causing actual discomfort or injury to the wearer.

[0257] The manufacturing method disclosed herein solves one or more of the aforementioned problems. The manufacturing method disclosed herein utilizes one or more of the molding components, films, textiles, yarns, and fibers disclosed herein, wherein said one or more molding components, films, textiles, yarns, and fibers comprise at least one low-processing-temperature polymer composition as disclosed herein. The manufacturing method disclosed herein also utilizes one or more of the molding components, films, textiles, yarns, and fibers disclosed herein, wherein said one or more molding components, films, textiles, yarns, and fibers comprise at least one high-processing-temperature polymer composition as disclosed herein. The disclosed manufacturing method includes a thermoforming step, wherein the low-processing-temperature polymer composition is softened or melted without melting or softening the high-processing-temperature polymer composition. Thermoforming is performed at a temperature range below at least one of the following properties of the high-processing-temperature polymer composition: (1) creep relaxation temperature (Tcr); (2) Vicat softening temperature (Tvs); (3) heat distortion temperature (Thd); or (4) melting temperature (Tm). Thermoforming can be performed in a temperature range below the creep relaxation temperature (Tcr) of the high-processing-temperature polymer composition. Thermoforming can be performed in a temperature range below the Vicat softening temperature (Tvs) of the high-processing-temperature polymer composition. Thermoforming can be performed in a temperature range below the heat distortion temperature (Thd) of the high-processing-temperature polymer composition. Thermoforming can be performed in a temperature range below the melting temperature (Tm) of the high-processing-temperature polymer composition.

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

[0259] Because such structural features are constructed into the article in several respects depending on their location within the low-processing-temperature polymer composition and the high-processing-temperature polymer composition, these structural features immediately become integrated with each other after thermoforming, thus allowing for a more natural feel for the wearer or user. For example, a knitting program for electronic knitting equipment can be used to determine the location of the structural features. However, as noted, the manufacturing methods (and the advantages associated with these processes) are not limited to the use of the textiles disclosed herein. For example, a process for forming structural features in the disclosed article may utilize a film comprising a low-processing-temperature polymer composition and a textile comprising a high-processing-temperature polymer composition, said process also contemplated as a process for programming structural features into the disclosed article. Alternatively, a process for effectively programming structural features into the disclosed article may utilize a molded part comprising a low-processing-temperature polymer composition and a textile comprising a high-processing-temperature polymer composition.

[0260] Furthermore, this selective incorporation of low-processing-temperature polymer compositions and high-processing-temperature polymer compositions into the article provides a streamlined manufacturing method. For example, in some aspects, the entire article can be formed by arranging components and exposing said arranged components to a thermoforming process, where components containing low-processing-temperature polymer compositions melt, flow, and re-solidify into more rigid structural features, while components containing high-processing-temperature polymer compositions do not deform during the thermoforming process. In such aspects, this allows the entire article to be exposed to the thermoforming process without the need to shield or protect areas that the manufacturer does not wish to melt, flow, and re-solidify, resulting in a more time- and energy-efficient manufacturing method. Additionally, in some cases, using the article described herein in the manufacturing method also allows for the provision of several different structures or other advantageous features in said article without the need to assemble individual components into the final article, as such features can be constructed into the article at the textile layer using both low-processing-temperature and high-processing-temperature polymer compositions.

[0261] In various respects, the thermoforming process occurs at a temperature under which the yarn or fiber has been dyed (e.g., at a temperature under which yarns or fibers comprising a high-processing-temperature polymer composition were previously dyed), such that during the thermoforming process, such dyes do not filter out from the yarn or fiber and enter the surrounding low-processing-temperature polymer composition. Therefore, in order to form the various textiles and articles described herein, the melting temperature of the low-processing-temperature polymer composition in the first yarn or fiber is lower than the temperature used to dye the second yarn or fiber (e.g., a second yarn or fiber comprising a high-processing-temperature polymer composition).

[0262] In addition, the fact that the composition has this range of melting temperatures (i.e., below the melting temperature of the second yarn or fiber under which the high-processing-temperature polymer composition was dyed) presents another problem, because so many of the tested low-processing-temperature polymer compositions evaluated do not produce yarns suitable for use in commercial knitting equipment, where significant shrinkage occurs when exposed to temperatures under which commercial knitting equipment typically operates.

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

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

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

[0266] On another front, a method is provided for manufacturing an upper for a garment. The method includes weaving a first row, comprising interlacing a first yarn with a second yarn. The first yarn comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing-temperature polymer composition exhibits at least one of the following: (1) a creep relaxation temperature (Tcr); (2) a Vicat softening temperature (Tvs); (3) a heat distortion temperature (Thd); or (4) a melting temperature (Tm) greater than the melting temperature (Tm) of the low-processing-temperature polymer composition. In some aspects, at least a portion of the first yarn is a warp; and at least a portion of the second yarn is a weft. Alternatively, at least a portion of the first yarn is a weft; and at least a portion of the second yarn is a warp.

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

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

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

[0270] The methods, procedures, and operations described herein are not to be construed as requiring them to be performed in a specific order as discussed or described, unless explicitly identified as such. Additional or alternative steps may be used.

[0271] Exemplary preheating and thermoforming processes

[0272] As discussed above, in some respects, the articles and textiles mentioned above, for example Figure 3 The textile 300 can be formed into at least a portion of a wearable article (e.g., footwear or socks). In this respect, the textile can form the upper of a footwear or sock, wherein the upper includes a sole portion facing the ground.

[0273] In some aspects, the article or textile may be combined with additional materials forming the upper of the footwear or sock article. For example, in one or more aspects, the textile may be combined or layered with one or more of the following: ankle collar lining, ankle collar foam, upper lining, or upper foam layer. In some aspects, one or more of these additional materials may be attached to the textile, for example, by knitting, splicing, or bonding, prior to thermoforming the textile.

[0274] In some respects, internal support devices or soles may be provided to provide additional comfort and / or support to the wearer of footwear and socks made at least in part from the textiles described herein. Figure 12 and 13 Depicts a footwear article 1200 including a sole plate 1210. The footwear article 1200 includes a textile 1212 forming an upper 1214 having a sole portion 1216 facing the ground. In some aspects, such as... Figure 13 It is best seen in the middle, Figure 13A cross-section of footwear article 1200 is depicted, with sole plate 1210 located in the inner portion 1218 of footwear article 1200 and contacting the inner surface 1220 of textile 1212. In some aspects, sole plate 1210 may comprise a polymeric material, such as a high-processing-temperature polymeric material, such as polyether block amide, having a melting or deformation temperature higher than the temperature range in which thermoforming processes are performed, such that the polymeric material does not melt or deform during the thermoforming processes described herein.

[0275] In various aspects, for the wearer's heel support, the heel support frame 1222 may be located on the inner portion 1218 of the upper 1214, or on the outer portion of the upper 1214, or may form part of the upper 1214. In several aspects, similar to the sole plate 1210, the heel support frame 1222 may comprise a polymeric material, such as a high-processing-temperature polymeric material, such as a polyether block amide that is capable of not melting or deforming when exposed to thermoforming processes. In several aspects, similar to the sole plate 1210, the heel support frame 1222 may comprise portions formed of a low-processing-temperature polymeric composition and portions formed of a high-processing-temperature polymeric composition.

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

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

[0278] In some respects, for example Figure 14 The aspects described herein allow for the application of the ground-engaging anti-slip studs 1410 to the footwear article 1400. In several aspects, the footwear article 1400 may include elements as described above. Figure 12 and 13 The footwear and socks product 1200 has the same characteristics as the aforementioned product. For example, in... Figure 14As can be seen, the ground-engaging anti-slip studs 1410 can be applied to the ground-facing outsole area 1412 of the footwear 1400 to provide increased stability and grip. In some respects, the ground-engaging anti-slip studs 1410 can be applied to the ground-facing outsole area 1412 after the thermoforming process is completed. In other respects, the ground-engaging anti-slip studs 1410 can be applied to the ground-facing outsole area 1412 as part of the thermoforming process.

[0279] In various respects, prior to thermoforming footwear and sock products, any of the textiles discussed above, as well as additional materials, can be woven, knitted, or pre-formed into a general boot-like shape with a ground-facing outsole portion, for example... Figure 15 As depicted in the upper 1500. In this respect, the upper 1500 may also include a sole plate or heel support located on the interior 1510 of the upper 1500, such as those described above relative to... Figure 12 The discussion focuses on the base plate 1210 and the heel support frame 1222.

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

[0281] Figure 17 A cross-section of the upper 1500 located on the shoe last 1520 along cut line 17 is shown. Cross-section 1700 reveals the inner surface 1540 of the shoe last 1500 contacting the upper 1500. Cross-section 1700 also reveals the presence of two types of materials in the upper 1500. For example, cross-section 1700 reveals three types of textile areas forming the upper 1500. Figure 17 As can be seen, the textile area 1710 associated with the ground-facing outsole portion 1512 of the upper covers the bottom portion 1524 of the last 1520. In this respect, when the upper is a knitted textile forming a knitted upper, at least a portion of the yarn comprising a low-processing-temperature polymer composition covers at least a portion of the bottom portion 1524 of the last 1520.

[0282] Additionally, textile area 1714 covers the forefoot portion 1524 of last 1520, while textile area 1712 covers the midfoot portion 1528 of last. In some respects, textile areas 1710, 1712, and 1714 may each have the features described above. Figure 3 The properties discussed in textiles sections 302, 304a, and 306a may be any or all of them.

[0283] In some respects, a first layer may be placed on a molding surface (e.g., a shoe last) prior to the article of manufacture (e.g., footwear or a component thereof). For example, a first layer (e.g., a lining) may optionally be placed above the molding surface (e.g., the shoe last). For example, see reference... Figure 17To further demonstrate one aspect of the first layer, the first layer may optionally be placed on a molded surface (e.g., the shoe last) before the article and lining can be placed on top of the shoe last 1520, such that the forefoot area of ​​the lining covers the forefoot area 1524. Then, the upper, including textile areas 1710, 1712, and 1714, is placed such that it covers at least a portion of the lining. Thus, at least a portion of the yarn comprising a low-processing-temperature polymer composition covers at least a portion of the lining. It should be understood that, in some aspects, textile areas 1710, 1712, and 1714 may each have the features referenced above. Figure 3 The properties discussed in textiles sections 302, 304a, and 306a may be any or all of them.

[0284] In a further aspect, the outer layer may optionally be located on at least a portion of the article, situated on a molding surface and covering at least a portion of the article. The outer layer (which may be a film) may optionally be placed over at least a portion of the article (e.g., an upper), situated on a molding surface (e.g., a shoe last). For example, see... Figure 17 As a further example, one aspect of the outer layer may optionally be placed over at least a portion of the upper already located on the last, such that the textile area 1710 associated with the ground-facing outsole portion 1512 of the upper covers the bottom portion 1524 of the last 1520. Thus, at least a portion of the upper, including textile areas 1710, 1712, and 1714, may be covered by at least a portion of the outer layer. Therefore, at least a portion of the yarn comprising the low-processing-temperature polymer composition contacts at least a portion of the outer layer. It should be understood that, in some aspects, textile areas 1710, 1712, and 1714 may each have the features referenced above. Figure 3 The properties discussed in textile sections 302, 304a, and 306a may be any or all of the properties described. An outer layer may be used in conjunction with the first layer, as described in previous paragraphs.

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

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

[0287] In some respects, the protective sleeve 1800 may be used to provide patterns or markings on the outer surface of the upper 1500. For example, the inner surface 1810 of the protective sleeve 1800 may contain markings or patterns that, during the thermoforming process, are embossed or imprinted on the outer surface 1530 of the upper 1500 due to the melting and cooling of the low-processing-temperature polymer composition in the upper 1500, combined with the compressive forces applied to the upper 1500 by the protective sleeve 1800 (and optionally, a vacuum bag). In such respects, since the protective sleeve 1800 may cover the entire upper 1500, it is possible for the protective sleeve 1800 to emboss or imprint patterns on any portion of the outer surface 1530 of the upper 1500 containing the low-processing-temperature polymer composition.

[0288] In some respects, it may be desirable to use both protective sleeves and vacuum bags optionally. In such respects, the protective sleeve can be applied over the upper located on the shoe last. For example, as... Figure 18 and 19 As can be seen, the protective sleeve 1800 is positioned above the upper 1500 on the shoe last 1520. As disclosed above, the protective sleeve 1800 may be formed of an elastomeric polymer material (e.g., a silicone polymer) having a melting temperature Tm or degradation temperature greater than 250°C or greater than 300°C. Therefore, the protective sleeve 1800 is located on the shoe last and inside the vacuum bag 2010. As used herein, the term "vacuum bag" refers to any material that can be compressed onto the outer surface of an object. It should be understood that various methods of applying compressive force to the protective sleeve or vacuum bag as discussed in this invention can be used to apply compressive force to both the protective sleeve and the vacuum bag used together.

[0289] In some respects, such as compared to the same upper thermoformed under similar conditions without the use of the protective sleeve 1800, the use of the protective sleeve 1800 alone, and when used in a vacuum, can effectively reduce the number of bubbles trapped in the polymer material at low processing temperatures during the thermoforming process.

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

[0291] In some respects, the upper 1500 may be situated on the last 1520 (when formed of a rigid material), and the outer surface 1530 of the upper 1500 (with or without the protective sheath 1800) may be exposed to pressure above atmospheric pressure to create this pressure difference. In other respects, the upper 1500 may be situated on the last 1520, and a negative pressure may be applied between the inner surface 1540 of the upper 1500 and the last 1520 to compress the upper 1500 onto the rigid last 1520.

[0292] In several respects, the pressure difference across the inner surface 1540 and outer surface 1530 of the upper 1500 can also help form the three-dimensional structure of the footwear during the thermoforming process. That is, in such respects, as the polymer composition melts at a low processing temperature, the molten material and the upper 1500 are forced against a rigid last 1520, which, upon cooling, produces an upper 1500 that takes the shape of the last 1520.

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

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

[0295] exist Figure 20A As described herein, the vacuum bag 2010 may include a valve 2012 for reducing the pressure inside the vacuum bag 2010. For example, the pressure between the outer surface 1530 of the upper 1500 (or the outer surface of the protective sleeve 1800 on the upper 1500) and the interior 2014 of the vacuum bag 2010 may be reduced, which will compress the vacuum bag onto the outer surface 1530 of the upper 1500 (or the outer surface of the protective sleeve 1800 on the upper 1500). Figure 20B A vacuum bag 2010 is depicted compressed onto the outer surface 1530 of the upper 1500 (or the outer surface of the protective sleeve 1800 on the upper 1500). As discussed above, compressing the vacuum bag 2010 onto the upper 1500 provides at least part of the above-described method of reference. Figures 15 to 19 The pressure difference discussed.

[0296] Figure 21 Describe the thermoforming system 2100. Figure 21 The thermoforming system 2100 may include an upper 1500 located on a shoe last 1520, wherein a vacuum bag 2010 is compressed onto the upper 1500, as described above relative to... Figure 20A and 20B The discussion.

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

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

[0299] In various respects, it will be understood that, although heating used in thermoforming has been specifically discussed with regard to applications having an upper 1500, this is only an exemplary aspect of the heating and thermoforming of the disclosed articles and methods. That is, the present invention is contemplated to utilize any of the disclosed heating methods for providing a heating zone in a thermoforming system and process to heat any of the disclosed articles comprising a first forming component, a first film, a first textile, a first yarn, or a first fiber; and a second forming component, a second film, a second textile, a second yarn, or a second fiber, located on a molding surface, wherein all of it is at least partially covered by a vacuum bag, a protective sleeve, or a combination of a protective sleeve and vacuum, and subsequently heated to a temperature higher than Tm of the low-processing-temperature composition. The first forming component, the first film, the first textile, the first yarn, or the first fiber comprises a low-processing-temperature composition.

[0300] In several respects, heating the entire upper 1500 provides a more efficient, streamlined thermoforming process. For example, because the selection of molding components, films, textiles, fibers, and / or yarns comprising low-processing-temperature polymer compositions and high-processing-temperature polymer compositions, and because the target is a specific area of ​​the upper, it is unnecessary to thermoform only a portion of the upper (e.g., by shielding a portion of the upper or applying heat only to a portion of the upper), since the high-processing-temperature polymer compositions resist any deformation or melting under conditions where low-processing-temperature polymer compositions can be thermoformed. However, optionally, additional heat treatment steps can be performed on the thermoformed articles of the present invention. For example, one or more surfaces of the thermoformed article may undergo additional thermoforming processes, such as thermally attaching a splint to the ground-facing surface of a footwear or sock article prepared using the thermoforming process described herein.

[0301] As discussed above, it is desirable that thermoforming processes do not deform or alter molded parts, films, textiles, fibers, and / or yarns that include high-processing-temperature polymer compositions. In this respect, heating zone 2110 can heat the entire upper 1500 to a temperature below at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs of the high-processing-temperature polymer composition or the fibers and / or yarns that include the high-processing-temperature polymer composition.

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

[0303] In some respects, the temperature of the entire upper 1500 can increase within approximately 10 seconds to approximately 5 minutes. In several respects, the temperature of the entire upper 1500 can increase within approximately 30 seconds to approximately 5 minutes. In one respect, the temperature of the entire upper 1500 can increase within approximately 30 seconds to approximately 3 minutes.

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

[0305] In some respects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the heating zones 2110 discussed above for approximately 10 seconds to approximately 5 minutes. In other respects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the heating zones 2110 discussed above for approximately 30 seconds to approximately 5 minutes. In one respect, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the heating zones 2110 discussed above for approximately 30 seconds to approximately 3 minutes.

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

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

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

[0309] In some respects, heating can be performed so that heat is transferred from another material or object to the entire upper 1500. For example, the molded surface (e.g., the shoe last) can be directly heated itself, for example, via a configuration that acts as a resistance heating element. Alternatively, the molded surface (e.g., the shoe last) can be preheated to the desired temperature immediately before the upper, textile, or article is positioned on it. In the aforementioned respects, the molded surface itself can act as a heating zone for transferring heat to the entire upper.

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

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

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

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

[0314] In some respects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the cooling zones 2112 discussed above for approximately 10 seconds to approximately 5 minutes. In other respects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the cooling zones 2112 discussed above for approximately 10 seconds to approximately 3 minutes. In one respect, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the cooling zones 2112 discussed above for approximately 10 seconds to approximately 2.5 minutes.

[0315] In some respects, once the upper 1500 has cooled, as described above, the vacuum bag 2010 and protective cover 1800 can be removed. In such respects, any additional components can now be applied to the upper 1500, for example... Figure 14 1410 ground engagement anti-slip studs.

[0316] Figure 22 An exemplary method 2200 for manufacturing a shoe upper is depicted. Method 2200 may include step 2210 of receiving an upper comprising a first material or component formed of a low-processing-temperature polymer composition and a second material or component formed of a high-processing-temperature polymer composition.

[0317] according to Figure 22 And in the exemplary method 2200 of the present invention, the low-processing-temperature polymer composition typically exists in the form of fibers (e.g., fibers essentially composed of the low-processing-temperature polymer composition). The low-processing-temperature polymer composition may be present in the received upper in the form of yarns (e.g., yarns comprising the low-processing-temperature polymer composition, yarns formed entirely of fibers comprising the low-processing-temperature polymer composition, and yarns formed partially of fibers comprising the low-processing-temperature polymer composition). Alternatively or additionally, the low-processing-temperature polymer composition may exist in a form that is not part of the yarn structure. For example, the fibers may comprise, or may be essentially composed of, the low-processing-temperature polymer composition. The low-processing-temperature polymer composition may also exist in the form of textiles (including knitted, braided, woven and non-woven textiles), films, sheets, or molded articles (e.g., injection-molded articles). The low-processing-temperature polymer composition may also exist in the form of foam materials.

[0318] Although certain aspects of the invention have been demonstrated with reference to details concerning footwear or shoe uppers, the demonstrated aspects are generally to be understood as applicable to other disclosed aspects within the scope of the invention. For example, any of the disclosed low-processing-temperature compositions can be used to form, manufacture, or produce molded parts, films, textiles, or other articles, and used in the methods disclosed herein. Similarly, any of the disclosed high-processing-temperature compositions can be used to form, manufacture, or produce molded parts, films, textiles, or other articles, and used in the methods disclosed herein. Therefore, any such molded part, film, textile, or other article comprising a low-processing-temperature composition may optionally be contacted with a molded part, film, textile, or other article comprising a high-processing-temperature composition and located on a molding surface. In some aspects, the molding surface may be a mold, shell, or last. Protective sleeves and / or vacuum bags may be located on the molding surface to apply compressive forces to the molding surface and to provide a heated zone to the molding surface, as described in the invention.

[0319] In some respects, the second material formed from the high-processing-temperature polymer composition may exhibit at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs, which is greater than the melting temperature Tm of the low-processing-temperature polymer composition. The material formed from the low-processing-temperature polymer composition may contain any or all of the properties of the low-processing-temperature polymer composition described above. The second material formed from the high-processing-temperature polymer composition may contain any or all of the properties of the high-processing-temperature polymer composition described above. The second material formed from the high-processing-temperature polymer composition may be in the form of fibers (e.g., fibers essentially composed of the high-processing-temperature polymer composition). The high-processing-temperature polymer composition may be present in the received upper in the form of yarn (e.g., yarn comprising the high-processing-temperature polymer composition, yarn entirely composed of fibers comprising the high-processing-temperature polymer composition, yarn partially composed of fibers comprising the high-processing-temperature polymer composition). Alternatively or additionally, the high-processing-temperature polymer composition may be present in a form that is not part of the yarn structure. For example, the fibers may comprise the high-processing-temperature polymer composition, or may be essentially composed of the high-processing-temperature polymer composition. High-temperature processing polymer compositions can also be in the form of textiles (including knitted, braided, woven and non-woven textiles), films, sheets, or molded articles (e.g., injection-molded articles). High-temperature processing polymer compositions can also be in the form of foam materials. In some aspects, the upper may contain the same components as described above. Figures 15 to 21 Any or all of the properties of the shoe upper 1500 described above. Alternatively, any of the textiles described above may be used, for example... Figure 3 Textile 300 is used to form the shoe upper.

[0320] While the low-processing-temperature polymer composition and the high-processing-temperature polymer composition may exist as separate materials or components of the received upper (e.g., in separate fibers, yarns, textiles, films, etc.), they may also exist in the same component (e.g., yarns comprising fibers formed of the low-processing-temperature polymer composition and separate fibers formed of the high-processing-temperature polymer composition; textiles comprising yarns formed of the low-processing-temperature polymer composition and separate yarns formed of the high-processing-temperature polymer composition). In other words, in the received upper, the low-processing-temperature polymer composition and the high-processing-temperature polymer composition exist separately and at least in materials or components with different fiber grades.

[0321] In one or more aspects, in the first portion of the upper, when the upper comprises a knitted textile having a first yarn comprising a low-processing-temperature polymer composition and a second yarn comprising a high-processing-temperature polymer composition, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, for example... Figure 6 , 7A Or multiple interconnected coils as depicted in 9.

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

[0323] In step 2230 of method 2200, when on a shoe last, the temperature of the entire upper is increased (e.g., heated) to a temperature higher than the melting temperature Tm of the first yarn composition and lower than at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs of the second yarn composition. In various respects, the above-described relative to... Figure 21 The thermoforming system 2100 described above is used to heat the entire shoe upper. This can be achieved using the method described above relative to... Figure 21 The thermoforming system uses any or all of the parameters described above to heat the shoe upper.

[0324] In step 2240 of method 2200, while the upper is still on the last, after heating, the temperature of the entire upper is lowered to below the melting temperature Tm of the low-processing-temperature polymer composition. For example, while the entire upper is on the last, the entire upper can be cooled to form a thermoformed upper. In various respects, the above description relative to... Figure 21 The thermoforming system 2100 described above is used to cool the entire shoe upper. This can be achieved using the method described above relative to... Figure 21The thermoforming system uses any or all of the parameters described above to cool the shoe upper.

[0325] When a first material or component comprising a low-processing-temperature polymer composition has been deformed and its original structure has been modified or melted and solidified into a new physical structure, after the received upper has been thermoformed, as thermoforming is carried out at a temperature at or above the melting temperature Tm of the low-processing-temperature polymer composition, but below the creep relaxation temperature Tcr or heat distortion temperature Thd or Vicat softening temperature Tvs of the high-processing-temperature polymer composition, a second material or component comprising a high-processing-temperature polymer composition (fiber, yarn, textile, sheet, molded article, etc.) retains its original physical structure (e.g., fiber, yarn, textile, etc.).

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

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

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

[0329] In step 2320 of method 2300, the shoe upper is placed on the shoe last, for example... Figures 15 to 17The shoe last depicted in the text. In various aspects, the shoe last can be formed of a rigid material or it can be an expandable shoe last. In addition, as mentioned above, the upper may have a sole plate, heel support or other components inserted into the upper before being placed on the shoe last.

[0330] In step 2330 of method 2300, when on a shoe last, the entire upper is heated to a temperature higher than the melting temperature Tm of the low-processing-temperature polymer composition and lower than at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs of the high-processing-temperature polymer composition. In various respects, the above is relative to Figure 21 The description suggests that a thermoforming system 2100 can be used to heat the entire shoe upper. This can be achieved using the method described above relative to... Figure 21 The thermoforming system uses any or all of the parameters described above to heat the shoe upper.

[0331] In step 2340 of method 2300, after heating the entire upper, the entire upper is cooled while on the last to form a thermoformed upper. In various respects, the above description relative to... Figure 21 The thermoforming system 2100 described above is used to cool the entire shoe upper. This can be achieved using the method described above relative to... Figure 21 The thermoforming system uses any or all of the parameters described above to cool the shoe upper.

[0332] Figure 24 A method 2400 for manufacturing a shoe upper is described. Method 2400 may include the step 2410 of receiving an upper comprising one or more first fibers and one or more second fibers. The one or more first fibers may comprise a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The low-processing-temperature polymer composition may have any or all of the properties discussed above with respect to the low-processing-temperature polymer composition. The one or more second fibers comprise a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing-temperature polymer composition may have any or all of the properties discussed above with respect to the high-processing-temperature polymer composition. In some aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above with respect to thermoplastic polymers. Additionally, in some aspects, the first and second fibers may comprise any or all of the properties discussed above with respect to fibers.

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

[0334] In some respects, the upper may include a ground-facing outsole region, wherein at least a portion of the first fiber is present in the ground-facing outsole region.

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

[0336] Method 2400 may further include step 2430 of heating the entire upper, while on the shoe last, to a temperature above the melting temperature Tm of the low-processing-temperature polymer composition and below at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs of the high-processing-temperature polymer composition. In various respects, the above description is relative to... Figure 21 The description suggests that a thermoforming system 2100 can be used to heat the entire shoe upper. This can be achieved using the method described above relative to... Figure 21 The thermoforming system uses any or all of the parameters described above to heat the shoe upper.

[0337] In step 2440 of method 2400, after heating the entire upper, the entire upper is cooled while on the last to form a thermoformed upper. In various respects, the above description relative to... Figure 21 The thermoforming system 2100 described above is used to cool the entire shoe upper. This can be achieved using the method described above relative to... Figure 21 The thermoforming system uses any or all of the parameters described above to cool the shoe upper.

[0338] Figure 25 A method 2500 for manufacturing a knitted upper for footwear and socks is described. Method 2500 includes a step 2510 of knitting a first row, the first row comprising loops of a first yarn and a second yarn. In several aspects, the first yarn comprises a low-processing-temperature polymer composition, and the second yarn comprises a high-processing-temperature polymer composition. The low-processing-temperature polymer composition may comprise one or more first thermoplastic polymers, and the high-processing-temperature polymer composition may comprise one or more second thermoplastic polymers. In several aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above with respect to thermoplastic polymers. In some aspects, the upper may comprise the same parameters as described above. Figures 15 to 21 Any or all of the properties of the shoe upper 1500.

[0339] In some respects, the high-processing-temperature polymer composition may exhibit at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs, which is greater than the melting temperature Tm of the low-processing-temperature polymer composition. The low-processing-temperature polymer composition may contain any or all of the properties of the low-processing-temperature polymer composition described above. The high-processing-temperature polymer composition may contain any or all of the properties of the high-processing-temperature polymer composition described above. Furthermore, the first and second yarns may exhibit any or all of the properties and parameters discussed above.

[0340] Method 2500 may further include step 2520 of knitting a second loop column comprising a first yarn and a second yarn. In several aspects, any commercial knitting technique as described above may be used to knit the first and second loop columns. In several aspects, at least a portion of the first loop column and at least a portion of the second loop column form a plurality of interconnected loops, for example... Figure 6 The interconnecting coils depicted in the figure.

[0341] Figure 26 A method 2600 for forming a knitted article is described. Method 2600 may include step 2610 of knitting a first loop course comprising a first yarn and a second yarn. In several aspects, the first yarn comprises a low-processing-temperature polymer composition, and the second yarn comprises a high-processing-temperature polymer composition. The low-processing-temperature polymer composition may comprise one or more first thermoplastic polymers, and the high-processing-temperature polymer composition may comprise one or more second thermoplastic polymers. In several aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above with respect to thermoplastic polymers.

[0342] In some respects, the high-processing-temperature polymer composition may exhibit at least one of the creep relaxation temperature Tcr, heat distortion temperature Thd, or Vicat softening temperature Tvs, which is greater than the melting temperature Tm of the low-processing-temperature polymer composition. The low-processing-temperature polymer composition may contain any or all of the properties of the low-processing-temperature polymer composition described above. The high-processing-temperature polymer composition may contain any or all of the properties of the high-processing-temperature polymer composition described above. Furthermore, the first and second yarns may exhibit any or all of the properties and parameters discussed above.

[0343] Step 2620 of method 2600 includes knitting an anchoring yarn into one or more loops of a first yarn present in a first loop row. The anchoring yarn comprises an anchoring yarn composition, wherein the anchoring yarn composition comprises one or more polymers. The anchoring yarn composition exhibits an elongation less than that of a polymer composition at a low processing temperature. In several aspects, the anchoring yarn may have the features described above. Figure 4B , 4EAny or all of the properties of the anchoring yarns discussed in 10A and 10B.

[0344] In several aspects, the first loop row may exist on the outer surface of the knitted upper. In such aspects, the outer surface of the knitted upper may include a first region, a second region, and a third region, wherein the second region is located between the first and third regions. Additionally, in such aspects, the third region has an increased density of the first yarn compared to the second region. The first, second, and third regions may each contain elements referenced above. Figure 3 Textiles 300 discusses any or all of the properties of textiles in areas 306a, 304a and 302.

[0345] Figure 27 Method 2700 for manufacturing an upper for footwear and sock articles. Step 2710 of method 2700 includes forming a ground-facing outsole region comprising a first set of one or more first fibers. In this respect, the one or more first fibers may comprise a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers.

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

[0347] Textiles, yarns and fibers

[0348] As discussed above, the fibers, yarns, textiles, films, and forming components described herein may include the selective incorporation of low-processing-temperature polymer compositions and / or the selective incorporation of high-processing-temperature polymer compositions. In several aspects, such low-processing-temperature polymer compositions may be present in the form of fibers. In several aspects, fibers comprising low-processing-temperature polymer compositions are inherently free of high-processing-temperature polymer compositions. In other aspects, fibers comprising low-processing-temperature polymer compositions are inherently composed of low-processing-temperature polymer compositions. According to the invention, these fibers can be used to form yarns, which in turn can be used to form textiles, including knitted, woven, or braided textiles. According to the invention, these fibers can also be used to form nonwoven textiles.

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

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

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

[0352] In some respects, the fibers described herein may be fibers of different sizes, including fibers unsuitable for spinning into commercial yarns. The yarns described herein include yarns suitable for use in commercial knitting machines, as well as yarns not individually suitable for use in commercial knitting machines.

[0353] In some respects, the yarns and / or fibers described herein can be used to provide specific functionalities. For example, in some respects, yarns comprising low-processing-temperature polymer compositions can be thermoformed to form a membrane having waterproof or water-resistant properties. In such respects, a membrane on the outer surface of an article is provided by utilizing yarns and / or fibers of low-processing-temperature polymeric materials, including those on the outer portion of a textile (comprising a knitted structure forming the textile).

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

[0355] In some aspects, yarns comprising low-processing-temperature polymer compositions can exhibit toughness from about 1 g / filament to about 5 g / filament. In one or more aspects, yarns comprising low-processing-temperature polymer compositions can exhibit toughness from about 1.5 g / filament to about 4.5 g / filament. In one aspect, yarns comprising low-processing-temperature polymer compositions can exhibit toughness from about 2 g / filament to about 4.5 g / filament. As used herein, “toughness” refers to the property of a fiber or yarn and is determined using the appropriate test methods and sampling procedures described below in the Property Analysis and Characterization Procedures section.

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

[0357] As discussed above, in some respects, there may be a need to utilize yarns suitable for use on commercial knitting equipment. The independent shrinkage of yarn at 50°C is a predictable property of yarns suitable for use on commercial knitting machines. In some respects, yarns comprising low-processing-temperature polymer compositions may exhibit independent shrinkage from about 0% to about 60% when heated from 20°C to 50°C. In one or more respects, yarns comprising low-processing-temperature polymer compositions may exhibit independent shrinkage from about 0% to about 30% when heated from 20°C to 50°C. In another respect, yarns comprising low-processing-temperature polymer compositions may exhibit independent shrinkage from about 0% to about 20% when heated from 20°C to 50°C. The term "independent shrinkage" as used herein refers to the property of the yarn and the corresponding test methods described below in the Property Analysis and Characterization section.

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

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

[0360] In one or more aspects, when present in the form of a decorative panel, the low-processing-temperature polymer composition exhibits a modulus from about 1 MPa to about 500 MPa. In some aspects, in the form of a decorative panel, the low-processing-temperature polymer composition exhibits a modulus from about 5 MPa to about 150 MPa. In one aspect, in the form of a decorative panel, the low-processing-temperature polymer composition exhibits a modulus from about 20 MPa to about 130 MPa. In another aspect, in the form of a decorative panel, the low-processing-temperature polymer composition exhibits a modulus from about 30 MPa to about 120 MPa. In yet another aspect, in the form of a decorative panel, the low-processing-temperature polymer composition exhibits a modulus from about 40 MPa to about 110 MPa.

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

[0362] In various aspects, when a yarn comprising a low-processing-temperature polymer composition is present in a textile and has reached a temperature above the melting temperature Tm of the low-processing-temperature polymer composition, and subsequently reaches a temperature below the melting temperature Tm of the low-processing-temperature polymer composition, the resulting thermoformed material (or melted yarn component) exhibits cold rosflex from about 5,000 cycles to about 500,000 cycles when tested at about 20°C and 1 ATM. In one or more aspects, when a yarn comprising a low-processing-temperature polymer composition is present in a textile and has reached a temperature above the melting temperature Tm of the low-processing-temperature polymer composition, and subsequently reaches a temperature below the melting temperature Tm of the low-processing-temperature polymer composition, the resulting thermoformed material (or melted yarn component) exhibits cold rosflex from about 10,000 cycles to about 300,000 cycles when tested at about 20°C and 1 ATM. In some respects, when a yarn comprising a low-processing-temperature polymer composition is present in a textile and has reached a temperature above the melting temperature Tm of the low-processing-temperature polymer composition, and subsequently below the melting temperature Tm, the resulting thermoformed material (or melted yarn component) exhibits at least about 150,000 cycles of cold Ross flexure when tested at approximately 20°C and 1 ATM. As used herein, the term “cold Ross flexure” refers to the corresponding test method described below in the Properties and Characterization Procedures section.

[0363] In some respects, as discussed in detail below, anchoring yarns can be used to help limit the flow of molten material (e.g., low-processing-temperature polymer compositions) during thermoforming processes and / or to provide a degree of flexibility to the thermoformed material. In such respects, anchoring yarns may exhibit an elongation less than that of the low-processing-temperature polymer composition (e.g., yarns comprising the low-processing-temperature polymer composition, or molten yarn parts produced by thermoforming such yarns). For example, in several respects, anchoring yarns may exhibit an elongation at least 10% less than that of yarns comprising the low-processing-temperature polymer composition or molten yarn parts produced by thermoforming yarns comprising the low-processing-temperature polymer composition. In one respect, anchoring yarns may exhibit an elongation at least about 25% less than that of yarns comprising the low-processing-temperature polymer composition or molten yarn parts produced by thermoforming yarns comprising the low-processing-temperature polymer composition. On the other hand, the anchoring yarn may exhibit an elongation at least 50% less than that of a yarn comprising a low-processing-temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising a low-processing-temperature polymer composition. On yet another aspect, the anchoring yarn may exhibit an elongation at least 75% less than that of a yarn comprising a low-processing-temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising a low-processing-temperature polymer composition. Exemplary anchoring yarns comprise polyamide yarns, polyolefin yarns, and polyester yarns, comprising yarns having a toughness from about 5 grams per fineness to about 10 grams per fineness.

[0364] The anchoring yarn may be formed from a high-temperature polymer composition comprising one or more polymers. The one or more polymers in the high-temperature polymer composition of the anchoring yarn may be thermoplastic polymers. In some aspects, the one or more polymers in the high-temperature polymer composition of the anchoring yarn may be the same as the one or more polymers in the high-temperature polymer composition of the second yarn used in the textile comprising the anchoring yarn. In other aspects, the one or more polymers in the high-temperature polymer composition of the anchoring yarn may be different from the one or more polymers in the high-temperature polymer composition of the second yarn used in the textile comprising the anchoring yarn.

[0365] As discussed above, low-processing-temperature polymer compositions and high-processing-temperature polymer compositions possess different properties in certain respects. In various respects, these different properties allow the low-processing-temperature polymer composition to melt and flow during the thermoforming process when thermoforming is performed at a temperature lower than the creep relaxation temperature, heat distortion temperature, or Vicat softening temperature of the high-processing-temperature polymer composition, and subsequently cool and solidify into a structure different from that prior to the thermoforming process (e.g., thermoforming a yarn into a molten yarn component), while the high-processing-temperature polymer composition cannot deform or melt during this process and can maintain its structure (e.g., as a yarn). In such respects, the molten yarn component formed by the low-processing-temperature polymer composition during the thermoforming process can be integrally attached to an unaltered structure (e.g., yarn or fiber), which can provide a three-dimensional structure and / or other properties targeted at a specific point on a wearable article.

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

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

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

[0369] In some respects, the coated yarn may be monofilament or multifilament yarn. The yarn may be based on natural or synthetic fibers, including polyester, high-tenacity polyester, polyamide yarn, metallic yarn, drawn yarn, carbon yarn, glass yarn, polyethylene or polyolefin yarn, bicomponent yarn, PTFE yarn, ultra-high molecular weight polyethylene (UHMWPE) yarn, liquid crystal polymer yarn, decorative yarn, or reflective yarn, or multicomponent yarn comprising one or more of said yarns.

[0370] In some aspects, the thermoplastic coating composition includes TPU. In some aspects, the TPU can be any such material described in this invention, such as a TPU prepared by polymerizing an aromatic or aliphatic isocyanate with a polyether polyol or polycaprolactone using a short-chain ethylene glycol (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of disclosed TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

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

[0372] In some respects, as described herein, a thickener may be used during the preparation of the thermoplastic coating composition to improve productivity and desmoothing properties. In other respects, the thickener is silica powder, talc, or CaCO3. The thickener is used at least in part to increase the viscosity of the thermoplastic coating composition. In yet another respect, the thickener used in the disclosed thermoplastic coating composition may be an alloy containing a resin, such as a styrene-butadiene-styrene (SBS) block copolymer, a styrene-ethylene / butene-styrene (SEBS) resin, a polyacetal resin (POM), or a styrene-acrylonitrile resin (SAN), which can impart compatibility with thermoplastic polyurethanes.

[0373] In some respects, the thermoplastic coating composition may include processing aids to improve productivity. In other respects, processing aids may be lignite wax or fatty acid esters (C5-C9) containing pentaerythritol. Other processing aids are known to those skilled in the art and may also be used in the disclosed thermoplastic compositions. An exemplary commercially available processing aid is ESTANE 58277 (Lubrizol).

[0374] In some respects, coated yarns with the desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound for the coated yarn. In other respects, the TPU compound for the coated yarn can be prepared to have the desired stiffness by controlling the content of the raw materials. In yet another respect, the thickness of the coated yarn can be reduced depending on the thickness of the yarn made of polyester, nylon, spandex, etc.

[0375] In some aspects, coated yarns are prepared by combining a thermoplastic coating composition comprising a thermoplastic polymer (e.g., thermoplastic polyurethane), optionally also containing one or more additives, in a conventional extruder, and then applying the combined thermoplastic polyurethane coating composition to the surface of a yarn. In another aspect, a method for preparing coated yarns includes the steps of: 1) preparing shaped thermoplastic microspheres; and 2) producing coated yarns. Shaped thermoplastic microspheres can be prepared by the methods disclosed herein, by similar methods known to those skilled in the art, or obtained from commercially available sources.

[0376] The steps for preparing shaped thermoplastic microspheres may include the following steps: 1) mixing a thermoplastic polymer with various additives (e.g., thickeners and / or processing aids) and feeding the mixture into the hopper of a conventional chemical extruder; 2) melting, kneading, and chemically combining the mixture in the cylinder of the chemical extruder at a suitable temperature and pressure; 3) cutting the chemically coated thermoplastic composition, discharging it through a small square of the chemical extruder, and forming microspheres in cooling water; and 4) drying the shaped thermoplastic polyurethane microspheres at a suitable temperature for approximately a certain time period, and aging the dried microspheres at a suitable temperature for a suitable time period.

[0377] In a specific instance, the steps for preparing the shaped thermoplastic microspheres include at least the following steps: 1) mixing thermoplastic polyurethane with various additives (e.g., thickeners and / or processing aids) and feeding the mixture into the hopper of a conventional chemical extruder; 2) chemically combining the mixture in the cylinder of the chemical extruder at a temperature of about 150 to 250°C and a pressure of about 50 to 150 kgf; 3) cutting the chemically combined thermoplastic polyurethane and discharging it through a small square of the chemical extruder to form microspheres in cooling water; and 4) drying the shaped thermoplastic polyurethane microspheres at a temperature of 60 to 80°C for about 4 to 6 hours, and aging the dried microspheres at a temperature of 30 to 50°C for about 7 days or more.

[0378] In some respects, the steps of producing coated yarn may include the following: 1) mixing shaped thermoplastic polymer pellets prepared as described above with a masterbatch corresponding to the desired color, and feeding the mixture into the hopper of a yarn coating extruder; 2) melting the mixture of shaped thermoplastic polymer pellets and masterbatch in the cylinder of the yarn coating extruder at a suitable temperature and a suitable pressure; 3) coating the surface of the yarn passing through the joints and squares with the combined thermoplastic polymer and masterbatch to produce coated yarn; and 4) winding the coated yarn around a spool using a winding machine.

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

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

[0381] As discussed above, anchoring yarns can be used to assist in restricting the flow of molten material (low-processing-temperature polymer compositions) during thermoforming processes and / or to provide some flexibility to the thermoformed material. In this respect, the anchoring yarn may not melt or deform during the thermoforming process. Thus, in some aspects, the anchoring yarn may comprise an anchoring yarn composition comprising one or more third thermoplastic polymers, such that the anchoring yarn composition exhibits a creep relaxation temperature T. cr Vicat softening temperature T vs Heat distortion temperature T hd Or melting temperature T m At least one of them, the melting temperature T m The melting temperature T of the polymer composition is greater than that of the low-processing temperature. m In some respects, the anchoring yarn composition may have a specific range associated with these properties discussed above with respect to high-processing-temperature polymer compositions. In some respects, the anchoring yarn may be formed from a high-processing-temperature polymer composition, and therefore may include any of the thermoplastic polymers discussed above with reference to high-processing-temperature polymer compositions.

[0382] In all respects, when according to the AS T described below m When D3418-97 is tested, the fiber or yarn contains the melting temperature (T). m Polyamide or polyether block amide low-temperature treatment polymer compositions at approximately 90°C to 120°C. On the other hand, when according to the AST described below... m When D3418-97 is used for testing, the melting temperature (T) of polyamide or polyether block amide is... m The temperature is approximately 93°C to 99°C. Furthermore, when according to the AS T described below... mWhen D3418-97 is used for testing, the melting temperature (T) of polyamide or polyether block amide is... m The temperature is approximately 112°C to 118°C. In some respects, when according to the AS T described below... m When D3418-97 is used for testing, the melting temperature (T) of polyamide or polyether block amide is... m The melting temperatures (T) are approximately 90℃, 91℃, 92℃, 93℃, 94℃, 95℃, 96℃, 97℃, 98℃, 99℃, 100℃, 101℃, 102℃, 103℃, 104℃, 105℃, 106℃, 107℃, 108℃, 109℃, 110℃, 111℃, 112℃, 113℃, 114℃, 115℃, 116℃, 117℃, 118℃, 119℃, 120℃, or any combination of the above values. m Within the range of values, or at the above melting temperature (T) m Value combinations.

[0383] In all respects, when according to the AS T described below m When D3418-97 is used for testing, the glass transition temperature (T) of the fiber or yarn is determined. g Polyamide or polyether block amide low-temperature treatment polymer compositions at approximately -20°C to 30°C. On the other hand, when according to the AST described below... m When D3418-97 is used for measurement, the glass transition temperature (T) of polyamide or polyether block amide is... g The temperature is approximately -13°C to -7°C. Furthermore, when according to the AS T described below... m When D3418-97 is used for measurement, the glass transition temperature (T) of polyamide or polyether block amide is... g The temperature is approximately 17°C to 23°C. In some respects, when according to the AS T described below... m When D3418-97 is used for testing, the melting temperature (T) of polyamide or polyether block amide is... g The glass transition temperature (T) is approximately -20℃, -19℃, -18℃, -17℃, -16℃, -15℃, -14℃, -13℃, -12℃, -10℃, -9℃, -8℃, -7℃, -6℃, -5℃, -4℃, -3℃, -2℃, -1℃, 0℃, 1℃, 2℃, 3℃, 4℃, 5℃, 6℃, 7℃, 8℃, 9℃, 10℃, 11℃, 12℃, 13℃, 14℃, 15℃, 16℃, 17℃, 18℃, 19℃, 20℃, or any combination of the above values. g Within the range of values, or at the glass transition temperature (T) mentioned above. g Value combinations.

[0384] In all respects, when according to the AS T described below m When D1238-13 is tested at 160℃ using a 2.16kg weight, the melt flow index of the fiber or yarn is approximately 10cm³. 3 / 10min to 30cm 3 / 10min low-temperature treatment of polymer compositions of polyamide or polyether block amide. On the other hand, when according to the AST described below m When D1238-13 is tested at 160℃ using a 2.16kg weight, the melt flow index of the polyamide or polyether block amide is approximately 22cm⁻¹. 3 / 10min to 28cm 3 / 10min. In some respects, when according to AST as described below m When D1238-13 is tested at 160℃ using a 2.16kg weight, the melt flow index of the polyamide or polyether block amide is approximately 10cm². 3 / 10min, 11cm 3 / 10min, 12cm 3 / 10min, 13cm 3 / 10min, 14cm 3 / 10min, 15cm 3 / 10min, 16cm 3 / 10min, 17cm 3 / 10min, 18cm 3 / 10min, 19cm 3 / 10min, 20cm 3 / 10min, 21cm 3 / 10min, 22cm 3 / 10min, 23cm 3 / 10min, 24cm 3 / 10min, 25cm 3 / 10min, 26cm 3 / 10min, 27cm 3 / 10min, 28cm 3 / 10min, 29cm 3 / 10min, 30cm 3 / 10min, or any of the above values ​​within the range of melt flow index values, or a combination of the above melt flow index values.

[0385] In all aspects, when polyamide or polyether block amide thermoplastic substrates are tested according to the low-temperature Ross flexure test described below, the fibers or yarns contain low-temperature treated polymer compositions with a low-temperature Ross flexure test result of approximately 120,000 to 180,000. On the other hand, when polyamide or polyether block amide thermoplastic substrates are tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result of the polyamide or polyether block amide is approximately 140,000 to 160,000. Furthermore, when polyamide or polyether block amide thermoplastic substrates are tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result of the polyamide or polyether block amide is approximately 130,000 to 170,000. In some respects, when polyamide or polyether block amide thermoplastic substrates are tested according to the low-temperature Ross flex test described below, the low-temperature Ross flex test results for polyamide or polyether block amide are approximately 120,000, 125,000, 130,000, 135,000, 140,000, 145,000, 150,000, 155,000, 160,000, 165,000, 170,000, 175,000, 180,000, or any combination of the above low-temperature Ross flex test values, or combinations of the above low-temperature Ross flex test values.

[0386] In all respects, when according to the AS T described below m When measuring the modulus of polyamide or polyether block amide thermoplastic molding substrates according to the D412-98 standard tensile test for vulcanized rubber, thermoplastic rubber, and thermoplastic elastomers, the low-temperature treated polymer composition has a fiber or yarn modulus of approximately 5 MPa to 100 MPa. On the other hand, when measured according to the AST as described below... m When the modulus of polyamide or polyether block amide thermoplastic substrates is determined according to the D412-98 standard tensile test for vulcanized rubber, thermoplastic rubber and thermoplastic elastomers, it is approximately 20 MPa to 80 MPa. In some respects, when measured according to the AST as described below... m When the standard tensile test for vulcanized rubber, thermoplastic rubber and thermoplastic elastomers (D412-98) is performed on polyamide or polyether block amide thermoplastic substrates, the modulus of the polyamide or polyether block amide is approximately 5 MPa, 10 MPa, 15 MPa, 20 MPa, 25 MPa, 30 MPa, 35 MPa, 40 MPa, 45 MPa, 50 MPa, 55 MPa, 60 MPa, 65 MPa, 70 MPa, 75 MPa, 80 MPa, 85 MPa, 90 MPa, 95 MPa, 100 MPa, or any combination of the above modulus values, or a combination of the above modulus values.

[0387] In all respects, when according to the AS T described below m When D3418-97 is tested, the fiber or yarn contains the melting temperature (T). m A low-temperature treated polymer composition of polyamide or polyether block acyl at approximately 115°C; when according to the AST described below m When D3418-97 was measured, the glass transition temperature (T) was determined. g Approximately -10°C; when according to the AST described below m When D1238-13 is tested at 160℃ using a 2.16kg weight, the melt flow index is approximately 25cm². 3 / 10min; When polyamide or polyether block amide thermoplastic substrates are tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result is approximately 150,000; When tested according to the AST described below m When the D412-98 standard tensile test for vulcanized rubber, thermoplastic rubber and thermoplastic elastomers measures the modulus of polyamide or polyether block amide thermoplastic substrates, it is approximately 25 MPa to 70 MPa.

[0388] In all respects, when according to the AS T described below m When D3418-97 is tested, the fiber or yarn contains the melting temperature (T). m A polyamide or polyether block acyl low-temperature treated polymer composition at approximately 96°C; when according to the AST described below m When D3418-97 was measured, the glass transition temperature (T) was determined. g The temperature is approximately 20°C; when the thermoplastic substrate is tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result is approximately 150,000; when tested according to the AST test described below... m When the standard tension test for vulcanized rubber, thermoplastic rubber and thermoplastic elastomers (D412-98) is used to determine the modulus of thermoplastic molded substrates, the modulus is less than or equal to 10 MPa.

[0389] In all respects, when according to the AS T described below m When D3418-97 is tested, the fiber or yarn contains the melting temperature (T). m A low-temperature treated polymer composition of approximately 115°C—a mixture of polyamides or polyether block amides first prepared; when according to the AST described below. m When D3418-97 was measured, the glass transition temperature (T) was determined. gApproximately -10°C; when according to the AST described below m When D1238-13 is tested at 160℃ using a 2.16kg weight, the melt flow index is approximately 25cm². 3 / 10min; When the thermoplastic substrate is tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result is approximately 150,000; When tested according to the AST as described below m When the modulus of a thermoplastic substrate is determined according to the D412-98 standard tensile test for vulcanized rubber, thermoplastic rubber, and thermoplastic elastomers, it is approximately 25 MPa to 70 MPa; when measured according to the AST described below... m When D3418-97 is tested, the melting temperature (T) of the second prepared polyamide or polyether block amide is... m Approximately 96°C; when according to the AST described below m When D3418-97 was measured, the glass transition temperature (T) was determined. g The temperature is approximately 20°C; when the thermoplastic substrate is tested according to the low-temperature Ross flexure test described below, the low-temperature Ross flexure test result is approximately 150,000; when tested according to the AST test described below... m When the standard tension test for vulcanized rubber, thermoplastic rubber and thermoplastic elastomers (D412-98) is used to determine the modulus of thermoplastic molded substrates, the modulus is less than or equal to 10 MPa.

[0390] In all respects, the fineness of the yarn containing the low-temperature treated polymer composition is around 750 to 1100.

[0391] In each aspect, yarns comprising cryogenically treated polymer compositions, as modified below, have a yarn strength greater than or equal to 1.5 g / denier, as specified in EN ISO 2062. In another aspect, yarns comprising cryogenically treated polymer compositions, as modified below, have a yarn strength between 1.5 g / denier and 3.0 g / denier, as specified in EN ISO 2062. In yet another aspect, yarns comprising cryogenically treated polymer compositions, as modified below, have a yarn strength between 1.7 g / denier and 1.8 g / denier, as specified in EN ISO 2062. In yet another aspect, yarns comprising cryogenically treated polymer compositions, as modified below, have a yarn strength between 3.3 g / denier and 3.6 g / denier, as specified in EN ISO 2062. In some respects, yarns comprising low-temperature treated polymer compositions, as modified as described below, have yarn strengths measured according to EN ISO 2062 of 1.5 g / denier, 1.6 g / denier, 1.7 g / denier, 1.8 g / denier, 1.9 g / denier, 2.0 g / denier, 2.1 g / denier, 2.2 g / denier, 2.3 g / denier, 2.4 g / denier, 2.5 g / denier, 2.6 g / denier, 2.7 g / denier, 2.8 g / denier, 2.9 g / denier, 3.0 g / denier, any range of strength values ​​included in any of the above values, or any combination of the above strength values.

[0392] In all respects, when tested according to EN ISO 2062, with modifications as described below, yarns comprising low-temperature treated polymer compositions have a yarn elongation of less than or equal to about 150%. In another respect, yarns comprising low-temperature treated polymer compositions, with modifications as described below, have a yarn elongation of 30% to 130% as measured according to EN ISO 2062. In yet another respect, yarns comprising low-temperature treated polymer compositions, with modifications as described below, have a yarn elongation of 115% to 120% as measured according to EN ISO 2062. In yet another respect, yarns comprising low-temperature treated polymer compositions, with modifications as described below, have a yarn elongation of 120% to 140% as measured according to EN ISO 2062. In yet another respect, yarns comprising low-temperature treated polymer compositions, with modifications as described below, have a yarn elongation of 35% to 45% as measured on a thermoformed sheet (ether-block-amide) of polyamide or polymer according to EN ISO 2062. In some respects, yarns comprising low-temperature treated polymer compositions, as modified below, have an elongation of approximately 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, or 130% as specified in EN ISO 2062, any range of elongation values ​​included in any of the above values, or any combination of the above elongation values.

[0393] In each aspect, yarns comprising a low-temperature treated polymer composition exhibit a shrinkage rate of less than or equal to about 15% when measured at 50°C using the methods described herein. In another aspect, yarns comprising a low-temperature treated polymer composition exhibit a shrinkage rate of about 7% to 13% when measured at 50°C using the methods described herein. In yet another aspect, yarns comprising a low-temperature treated polymer composition exhibit a shrinkage rate of about 9.5% to 10.5% when measured at 50°C using the methods described herein. In yet another aspect, yarns comprising a low-temperature treated polymer composition exhibit a shrinkage rate of about 0% to 5% when measured at 50°C using the methods described herein. In some respects, yarns comprising low-temperature treated polymer compositions, when measured at 50°C using the methods described herein, have a shrinkage rate of approximately 0%, 0.5%, 1.0%, 1.5%, 2.0%, 2.5%, 3.0%, 3.5%, 4.0%, 5.5%, 6.0%, 6.5%, 7.0%, 7.5%, 8.0%, 8.5%, 9.0%, 9.5%, or 10%, any range of shrinkage rates included in any of the above values, or any combination of the above shrinkage rates.

[0394] In various aspects, yarns containing cryogenically treated polymer compositions have an enthalpy of melting (a measure of crystallinity) of approximately 15 J / g to 50 J / g, as measured by the methods described herein. On the other hand, yarns containing cryogenically treated polymer compositions have an enthalpy of melting of approximately 17 J / g to 23 J / g, as measured by the methods described herein. In yet another aspect, yarns containing cryogenically treated polymer compositions have an enthalpy of melting of approximately 35 J / g to 42 J / g, as measured by the methods described herein. In some aspects, yarns containing cryogenically treated polymer compositions have an enthalpy of melting of approximately 15 J / g, approximately 20 J / g, approximately 25 J / g, approximately 30 J / g, approximately 35 J / g, approximately 40 J / g, approximately 45 J / g, approximately 50 J / g, any range of enthalpy values ​​included in any of the above values, or any combination of the above enthalpy values.

[0395] In all respects, yarns comprising cryogenically treated polymer compositions, as modified as described below, shall have a yarn strength of approximately 2.0 to 2.2 g / denier as measured according to EN ISO 2062; a yarn elongation of 116% to 122% as measured according to EN ISO 2062; a yarn shrinkage of approximately 8% to 12% as measured at 50°C using the methods described herein; and a melting enthalpy of approximately 18 J / g to 22 J / g as measured using the methods described herein. The intended yarns include yarns having any values ​​within a given range, including values ​​equal to or approximately the lower or upper limit of the given range.

[0396] In all respects, yarns comprising cryogenically treated polymer compositions, as modified as described below, shall have a yarn strength of approximately 3.2 to 3.6 g / denier as measured according to EN ISO 2062; a yarn elongation of 37% to 43% as measured according to EN ISO 2062; a yarn shrinkage of approximately 0% to 3% as measured at 50°C using the methods described herein; and a melting enthalpy of approximately 35 J / g to 42 J / g as measured using the methods described herein. The intended yarns include yarns having any values ​​within a given range, including values ​​equal to or approximately the lower or upper limit of the given range.

[0397] In all respects, the yarn comprising the low-temperature treated polymer composition, the first yarn comprising, as modified below, has a yarn strength of approximately 2.0 to 2.2 g / denier as measured according to EN ISO 2062; as modified below, has a yarn elongation of 116% to 122% as measured according to EN ISO 2062; a yarn shrinkage of approximately 8% to 12% as measured at 50°C using the methods described herein; and a melting enthalpy of approximately 18 J / g to 22 J / g as measured using the methods described herein. The intended yarn includes yarns having any values ​​within a given range, including values ​​equal to or approximately equal to the lower or upper limit of the given range; the included second yarn, as modified below, has a yarn strength of approximately 3.2 to 3.6 g / denier as measured according to EN ISO 2062; as modified below, has a yarn elongation of 37% to 43% as measured according to EN ISO 2062; a yarn shrinkage of approximately 0% to 3% as measured at 50°C using the methods described herein; and a melting enthalpy of approximately 35 J / g to 42 J / g as measured using the methods described herein. The intended yarn includes yarns having any values ​​within a given range, including values ​​equal to or approximately equal to the lower or upper limit of the given range.

[0398] Formed products and films

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

[0400] Similarly, the high-processing-temperature polymer compositions described above can exist in the form of films or formed parts comprising high-processing-temperature polymer compositions. In some aspects, the films or formed parts comprising high-processing-temperature polymer compositions substantially do not contain low-processing-temperature polymer compositions. In other aspects, the films or formed parts comprising high-processing-temperature polymer compositions are substantially composed of high-processing-temperature polymer compositions. These formed parts can be manufactured by any suitable means known in the art for manufacturing formed parts, such as polymer extrusion, polymer blow molding, injection molding, and processing. These films can be manufactured by any suitable means known in the art for manufacturing films, such as polymer extrusion.

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

[0402] In some aspects, the membranes or shaped parts described herein can be used to provide specific functionalities. For example, in some aspects, membranes comprising low-processing-temperature polymer compositions can be thermoformed to form membranes with waterproof or water-resistant properties. In these aspects, membranes on the outer surface of articles can be provided using membranes comprising low-processing-temperature polymeric materials.

[0403] As discussed above, in some respects, films or formed parts may be colored, for example, for aesthetic purposes. In various respects, films or formed parts may be colored using conventional coloring techniques. In some respects, films or formed parts comprising low-processing-temperature polymer compositions are uncolored and may be formed from polymer compositions that are substantially free of pigments, colorants, or dyes, which may result in areas comprising the low-processing-temperature polymer composition being clear or nearly transparent (e.g., non-yarn or non-fiber materials after thermoforming).

[0404] In one or more aspects, films or formed parts comprising low-processing-temperature polymer compositions may exhibit moduli from about 1 MPa to about 500 MPa. In some aspects, yarns comprising low-processing-temperature polymer compositions may exhibit moduli from about 5 MPa to about 150 MPa. In one aspect, yarns comprising low-processing-temperature polymer compositions may exhibit moduli from about 20 MPa to about 130 MPa. In another aspect, yarns comprising low-processing-temperature polymer compositions may exhibit moduli from about 30 MPa to about 120 MPa. In yet another aspect, yarns comprising low-processing-temperature polymer compositions may exhibit moduli from about 40 MPa to about 110 MPa. As used herein, the term "modulo" refers to the corresponding test method described below in the Property Analysis and Characterization Procedures section.

[0405] In one or more aspects, when a film or formed part comprising a low-processing-temperature polymer composition is brought to a temperature T higher than the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then brought to a level below the melting temperature T of the polymer composition, which is lower than the low processing temperature. m When tested at temperatures around 20°C and 1 ATM, the resulting thermoformed materials (e.g., molten yarn components) can exhibit moduli ranging from about 1 MPa to about 500 MPa. In several aspects, when yarns comprising a low-processing-temperature polymer composition are brought to a melting temperature T above the low-processing-temperature polymer composition... m The temperature is then brought to a level below the melting temperature T of the polymer composition, which is lower than the low processing temperature. m When tested at temperatures around 20°C and 1 ATM, the resulting thermoformed materials (e.g., molten yarn components) exhibit moduli ranging from about 5 MPa to about 150 MPa. In one or more aspects, when yarns comprising a low-processing-temperature polymer composition are brought to a temperature T above the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then brought to a level below the melting temperature T of the polymer composition, which is lower than the low processing temperature. mWhen tested at temperatures around 20°C and 1 ATM, the resulting thermoformed materials (e.g., molten yarn components) can exhibit moduli ranging from about 20 MPa to about 130 MPa. In one or more aspects, when yarns comprising a low-processing-temperature polymer composition are brought to a temperature T above the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then brought to a level below the melting temperature T of the polymer composition, which is lower than the low processing temperature. m When tested at temperatures around 20°C and 1 ATM, the resulting thermoformed materials (e.g., molten yarn components) can exhibit moduli ranging from about 30 MPa to about 120 MPa. In one or more aspects, when yarns comprising a low-processing-temperature polymer composition are brought to a temperature T above the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then brought to a level below the melting temperature T of the polymer composition, which is lower than the low processing temperature. m When tested at temperatures of approximately 20°C and pressures of 1 ATM, the resulting thermoformed materials (e.g., molten yarn components) exhibit moduli ranging from approximately 40 MPa to approximately 110 MPa.

[0406] As discussed above, low-processing-temperature polymer compositions and high-processing-temperature polymer compositions possess different properties in certain aspects. In various aspects, these different properties allow the low-processing-temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from that prior to the thermoforming process (e.g., thermoforming from a film or formed part into a molten or partially molten film or formed part), whereas the high-processing-temperature polymer composition cannot deform or melt during the thermoforming process and can maintain its structure (e.g., as a film or formed part) when the thermoforming process is performed at temperatures below the creep relaxation temperature, heat distortion temperature, or Vicat softening temperature of the high-processing-temperature polymer composition. In these aspects, molten yarn parts formed from the low-processing-temperature polymer composition during the thermoforming process can be integrally attached to an unaltered structure (e.g., textiles or articles, or another film or formed part), which can provide a three-dimensional structure and / or other properties targeted at specific points on a wearable article.

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

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

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

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

[0411] In various aspects, the thermoplastic coating composition may further include additives, such as, but not limited to, one or more of thickeners, processing aids, dyes, or colorants. In another aspect, the additives are not optional and include at least one thickener. In yet another aspect, the additives are not optional and include at least one processing aid. In yet another aspect, the additives are not optional and include at least one thickener and at least one processing aid. In some aspects, the thickener may comprise an inorganic material, such as silica, talc, or calcium carbonate (CaCO3).

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

[0413] In some aspects, the thermoplastic coating composition may include a treatment agent to improve productivity. In another aspect, the treatment agent may be lignite wax or a fatty acid ester (C5-C9) having pentaerythritol. Other treatment agents are known to those skilled in the art and may also be used in the disclosed thermoplastic compositions. An exemplary commercially available treatment agent is ESTANE58277 (Lubrizol).

[0414] In some aspects, coated films or molded parts having a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound used for coating films or molded parts. In another aspect, TPU compounds for coating films or molded parts having a desired hardness can be prepared by controlling the inclusions of the raw materials.

[0415] In some aspects, a coated film or formed part can be prepared by compounding a thermoplastic coating composition comprising a thermoplastic polymer (e.g., thermoplastic polyurethane) and optionally one or more additives in a conventional extruder, and then coating the surface of the compounded thermoplastic polyurethane coating composition onto the surface of the film or formed part. In another aspect, the process for preparing a coated film or formed part comprises the steps of: 1) preparing shaped thermoplastic pellets; and 2) producing a coated film or formed part. The shaped thermoplastic pellets can be prepared by the methods disclosed herein, by similar methods known to those skilled in the art, or obtained from commercial sources.

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

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

[0418] In various respects, the formed parts or films contain polyamides or poly(ether block amides), when according to the AS T described herein. m D3418-97 was determined to have a melting temperature ranging from approximately 90°C to approximately 120°C (T). m In another aspect, polyamides or poly(ether block amides) are used according to the following AS T described herein. m D3418-97 was determined to have a melting temperature ranging from approximately 93°C to approximately 99°C (T). m In another aspect, polyamides or poly(ether block amides) are used according to the AST described herein as follows. m D3418-97 was determined to have a melting temperature (T) ranging from approximately 112°C to approximately 118°C. m In some respects, polyamides or poly(ether blo...

Claims

1. A process for manufacturing thermoformed knitted articles, the process comprising: A knitted textile is provided, the knitted textile comprising a first yarn and a second yarn in a monolithic knitted construction, wherein, in the monolithic knitted construction, the first yarn and the second yarn are knitted together, or the second yarn is knitted within the knitted structure, and the first yarn is at least partially embedded or otherwise inserted into the knitted structure to form the monolithic knitted construction, the first yarn comprising a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers, the second yarn comprising a high-processing-temperature polymer composition, the knitted textile comprising: a first region including the second yarn, a second region including the first yarn and the second yarn, and a third region including the first yarn. A third zone of a yarn, wherein a second zone is located between a first zone and a third zone, wherein the first zone comprises a second yarn of a higher concentration than the second zone, and wherein the third zone comprises a first yarn of a higher concentration than the second zone, wherein the first zone, the second zone, and the third zone are knitted together in a single-piece knitted structure, wherein the first zone and the second zone are directly connected to each other, and the second zone and the third zone are directly connected to each other, wherein the second zone comprises at least two sub-regions, wherein each sub-region comprises a first yarn and a second yarn of different concentrations in each zone, and each sub-region in the at least two sub-regions has an intersecting interface with other sub-regions; At least a portion of the knitted textile is placed on the molding surface; and A first region of the knitted textile is heated, wherein the first region of the knitted textile includes the second region and the third region, and the first region of the knitted textile is heated to thermoform the knitted textile while the at least a portion of the knitted textile is located on the molding surface.

2. The process according to claim 1, wherein the first region is substantially free of the second yarn.

3. The process of claim 1, wherein the knitted textile forms at least a portion of the upper for footwear articles, and wherein the third region forms at least a portion of at least one of the midfoot region, the heel region, and the toe area.

4. The process according to claim 3, wherein the second region forms at least a portion of at least one of the sole periphery region, the heel region, the toe area, and the midfoot region.

5. The process according to claim 4, wherein the first region forms at least a portion of at least one of the heel region, the midfoot region, the ground-facing outsole region, the forefoot opening region, and the ankle collar region.

6. The process of claim 1, wherein the one or more first thermoplastic polymers of the first yarn comprise one or more thermoplastic polymers selected from the group consisting of polyesters, polyethers, polyamides, polyurethanes, and polyolefins.

7. The process of claim 1, wherein the one or more first thermoplastic polymers comprise thermoplastic polyamides, thermoplastic poly(ether-block-amide) or thermoplastic polyurethanes, and the low-processing-temperature polymer composition exhibits a melting temperature T of 80°C to 135°C. m It exhibits a glass transition temperature T of 50°C or lower. g It demonstrates a melt flow index of 0.1 g / 10 min to 60 g / 10 min at 160 °C using a test weight of 2.16 kg, a melting enthalpy of at least 5 J / g, or a modulus of 1 MPa to 500 MPa.

8. The process of claim 7, wherein the low-processing-temperature polymer composition exhibits a melting temperature T of 80°C to 135°C. m .

9. The process of claim 1, wherein the high-processing-temperature polymer composition exhibits a melting temperature T above 140°C. m .

10. The process according to claim 1, wherein the knitted textile is a component of footwear, clothing, or sporting goods.

11. The process of claim 10, wherein the knitted textile is a component of a footwear article.

12. A process for manufacturing thermoformed knitted articles, the process comprising: A knitted textile is provided, the knitted textile comprising a first yarn and a second yarn in a monolithic knitted construction, wherein, in the monolithic knitted construction, the first yarn and the second yarn are knitted together, or the second yarn is knitted within the knitted structure, and the first yarn is at least partially embedded or otherwise inserted into the knitted structure to form the monolithic knitted construction, the first yarn comprising a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers, the second yarn comprising a high-processing-temperature polymer composition, the knitted textile comprising: a first region including the second yarn, a second region including the first yarn and the second yarn, and a third region including the first yarn. A third zone of a yarn, wherein a second zone is located between a first zone and a third zone, wherein the first zone comprises a second yarn of a higher concentration than the second zone, and wherein the third zone comprises a first yarn of a higher concentration than the second zone, wherein the first zone, the second zone, and the third zone are knitted together in a single-piece knitted structure, wherein the first zone and the second zone are directly connected to each other, and the second zone and the third zone are directly connected to each other, wherein the second zone comprises at least two sub-regions, wherein each sub-region comprises a first yarn and a second yarn of different concentrations in each zone, and each sub-region in the at least two sub-regions has an intersecting interface with other sub-regions; Heating a first region of the knitted textile, wherein the first region of the knitted textile includes the second region and the third region; At least a portion of the knitted textile is placed on the molding surface; and When at least a portion of the knitted textile is on the molding surface, heating the first region of the knitted textile includes increasing the temperature of the knitted textile to above the melting temperature T of the low-processing-temperature polymer composition. m And below the 1) creep relaxation temperature T of the high-processing-temperature polymer composition. cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs The temperature of at least one of them, thereby thermoforming the knitted textile; In the thermoformed knitted textile, the first region is flexible and pliable, the third region is rigid or semi-rigid, and the second region forms a seamless, integrated transition region from the rigid or semi-rigid third region to the flexible and pliable first region.

13. The process of claim 12, wherein the first region is substantially free of the second yarn.

14. The process of claim 12, wherein the knitted textile forms at least a portion of the upper for footwear articles, and The third region forms at least a portion of at least one of the midfoot region, the heel region, and the toe area.

15. The process of claim 14, wherein the second region forms at least a portion of at least one of the sole periphery region, the heel region, the toe area, and the midfoot region.

16. The process of claim 15, wherein the first region forms at least a portion of at least one of the heel region, the midfoot region, the ground-facing outsole region, the forefoot opening region, and the ankle collar region.

17. The process of claim 12, wherein the one or more first thermoplastic polymers of the first yarn comprise one or more thermoplastic polymers selected from the group consisting of polyesters, polyethers, polyamides, polyurethanes, and polyolefins.

18. The process of claim 12, wherein the one or more first thermoplastic polymers comprise thermoplastic polyamides, thermoplastic poly(ether-block-amide) or thermoplastic polyurethanes, and the low-processing-temperature polymer composition exhibits a melting temperature T of 80°C to 135°C. m It exhibits a glass transition temperature T of 50°C or lower. g It demonstrates a melt flow index of 0.1 g / 10 min to 60 g / 10 min at 160 °C using a test weight of 2.16 kg, a melting enthalpy of at least 5 J / g, or a modulus of 1 MPa to 500 MPa.

19. The process of claim 18, wherein the low-processing-temperature polymer composition exhibits a melting temperature T of 80°C to 135°C. m .

20. The process of claim 12, wherein the high-processing-temperature polymer composition exhibits a melting temperature T above 140°C. m .

21. The process according to claim 12, wherein the knitted textile is a component of footwear, clothing, or sporting goods.

22. The process of claim 21, wherein the knitted textile is a component of a footwear article.

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