Wearable items and methods for manufacturing wearable items

Abstract

This application relates to wearable articles and methods of manufacturing wearable articles. In an example, the wearable article (10) includes a nonwoven fabric sheet (14, 16) having a first portion (18, 28) and a second portion (20, 30) adjacent to the first portion (18, 28). The first portion (18, 28) has a first density and a first modulus of elasticity. The second portion (20, 30) has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. As an integral article (12A, 12B) of the wearable article (10), the first portion (18, 28) is shaped differently from the second portion (20, 30). The method of manufacturing the wearable article (10) may include thermoforming the first portion (18, 28), while the second portion (20, 30) adjacent to the thermoformed first portion (18, 28) is not thermoformed.

Description

[0001] This application is a divisional application of the application filed on November 22, 2019, with application number 201980053829.9 and invention title "Wearable Article and Method of Manufacturing Wearable Article".

[0002] Cross-references to related applications

[0003] This application claims the benefit of priority to U.S. Provisional Application No. 62 / 789,132, filed January 7, 2019, which is incorporated herein by reference in its entirety. Technical Field

[0004] This disclosure generally relates to wearable articles and methods of manufacturing wearable articles having a nonwoven fabric sheet having an integral portion formed into an integral implement of the wearable article. background

[0005] Wearable items such as bags, belts, and other garments should provide sufficient comfort while also being durable to perform functions such as support and closure repeatedly and reliably. Summary of the Invention

[0006] This application includes the following aspects.

[0007] 1) A wearable item, comprising:

[0008] A nonwoven fabric sheet having a first portion and a second portion adjacent to the first portion;

[0009] The first part has a first density and a first elastic modulus;

[0010] The second portion has a second density less than the first density and a second elastic modulus less than the first elastic modulus; and

[0011] Wherein, as an integral piece of the wearable article, the first part is shaped differently from the second part.

[0012] 2) The wearable article according to 1), wherein the thickness of the first part is in the range of about 10% less than the thickness of the second part to about 10% greater than the thickness of the second part.

[0013] 3) The wearable article according to 1), wherein the thickness of the first part is greater than the thickness of the second part by more than 10%, or the thickness of the second part is greater than the thickness of the first part by more than 10%.

[0014] 4) A wearable article according to any one of 1)-3), wherein the first portion defines a through-hole extending through the nonwoven fabric sheet.

[0015] 5) The wearable article according to any one of 1)-4) further comprises:

[0016] A fabric component; wherein the nonwoven fabric sheet is fixed to the fabric component.

[0017] 6) The wearable article according to any one of 1)-5) further comprises:

[0018] A fabric component; wherein the fibers of the second portion of the nonwoven fabric sheet are entangled with the fibers of the fabric component to secure the second portion to the fabric component.

[0019] 7) A wearable article according to any one of 1)-6), wherein the one-piece article is one of the concave or convex portions of a closure device.

[0020] 8) The wearable article according to 7), wherein the wearable article is a bag, strap or footwear, and the closure device is a buckle.

[0021] 9) The wearable article according to 8), wherein:

[0022] The wearable item is the bag, and the one-piece product is the convex portion of the buckle;

[0023] The pouch includes a flap and a base; and

[0024] The convex portion of the latch is disposed on a strip extending from the cover plate toward the concave portion of the latch disposed on the base, or disposed on a strip extending from the base toward the concave portion of the latch disposed on the cover plate.

[0025] 10) The wearable article according to 8), wherein:

[0026] The wearable item is the bag, and the one-piece product is the convex portion of the buckle;

[0027] The carry bag includes an additional nonwoven fabric sheet having a first portion formed into a single article, the single article of the first portion of the additional nonwoven fabric sheet being a concave portion of the clasp, and the additional nonwoven fabric sheet having a second portion adjacent to the first portion.

[0028] The first portion of the additional nonwoven fabric sheet has a higher density than the second portion of the additional nonwoven fabric sheet, and also has a higher elastic modulus than the second portion of the additional nonwoven fabric sheet; and

[0029] The convex portion is shaped and sized to be releasably fixed to the concave portion.

[0030] 11) The wearable article according to 1), wherein the wearable article is footwear, and the one-piece article is one of a closure device, a heel stabilizer, or a housing for a power source or electrical device.

[0031] 12) The wearable article according to 1), wherein the wearable article is a bag, footwear or clothing, and the one-piece article is a housing for a power source or electrical device.

[0032] 13) The wearable article according to 1), wherein:

[0033] The first portion comprises multiple stacked layers of nonwoven fabric; and

[0034] The plurality of stacked nonwoven fabric layers include a first outer layer, a second outer layer, and at least one intermediate layer disposed between the first outer layer and the second outer layer.

[0035] 14) The wearable article according to 13), wherein:

[0036] The edges of at least one intermediate layer are tapered; and

[0037] The tapered edge is adjacent to the second portion.

[0038] 15) A method of manufacturing a wearable article, the method comprising:

[0039] A first portion of a nonwoven fabric sheet is thermoformed into a one-piece article of the wearable article, the nonwoven fabric sheet having a second portion that is not thermoformed, the second portion being adjacent to the thermoformed first portion and shaped differently from the first portion;

[0040] Wherein, after thermoforming, the first portion has a first density and a first elastic modulus; and

[0041] The second portion that has not been thermoformed has a second density that is less than the first density and a second elastic modulus that is less than the first elastic modulus.

[0042] 16) The method according to 15) further includes:

[0043] Prior to thermoforming the first portion, a plurality of nonwoven fabric layers are stacked to define the first portion; wherein the plurality of nonwoven fabric layers include a first outer layer, a second outer layer and at least one intermediate layer disposed between the first outer layer and the second outer layer; and wherein the at least one intermediate layer extends only in the first portion.

[0044] 17) According to the method of 16), before stacking the plurality of nonwoven fabric layers, the nonwoven fabric sheet is divided only at the first portion to define the first outer layer and the second outer layer, the first outer layer and the second outer layer extending only in the first portion.

[0045] 18) The method according to 17) further includes:

[0046] After stacking the plurality of nonwoven fabric layers and before thermoforming the first portion, the plurality of nonwoven fabric layers are hot-pressed to each other.

[0047] 19) The method according to any one of 15)-18), wherein the wearable article comprises a fabric component, and the method further comprises:

[0048] After the first part is thermoformed, the second part is needled into the fabric component.

[0049] 20) The method according to any one of 15)-19), wherein the thermoforming is performed in a thermoforming mold, and the method further comprises:

[0050] Before thermoforming in the thermoforming mold, at least the first portion of the nonwoven fabric sheet is heated; and

[0051] After at least heating the first portion of the nonwoven fabric sheet, the first portion of the nonwoven fabric sheet is placed in the thermoforming mold, wherein the temperature of the mold surface of the thermoforming mold is lower than the temperature of the first portion of the nonwoven fabric sheet. Brief description of the attached diagram

[0052] The accompanying drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary and do not limit the scope of this disclosure.

[0053] Figure 1 It is a perspective view of a wearable article, which includes a closure device having a convex portion that can be releasably secured to a concave portion to close the wearable article.

[0054] Figure 2 yes Figure 1A perspective view of a wearable item with the closure mechanism open.

[0055] Figure 3 yes Figure 1 A close-up plan view of the closure device.

[0056] Figure 4 It is used for Figure 1 A schematic plan view of the mold for the concave part of the closing device.

[0057] Figure 5 It is formed before the through hole is created in the nonwoven fabric sheet. Figure 1 A partial perspective view of the concave portion of the closure device.

[0058] Figure 6 yes Figure 5 A partial perspective view of the concave portion of the closing device, wherein the sheet has a through hole.

[0059] Figure 7 It is a perspective view of a nonwoven fabric sheet including the concave portion of the closure device.

[0060] Figure 8 It is stacked on the fabric component Figure 7 A perspective view of the slice, with the needle-punching tool positioned above the slice.

[0061] Figure 9 It is fixed by needle puncture Figure 8 A perspective view of a piece of fabric component.

[0062] Figure 10 It is a partial perspective view of a wearable item, including details of its attachment to another component at the outer edge. Figure 8 The film.

[0063] Figure 11 It is used for Figure 1 A partial perspective view of the nonwoven fabric sheet of the convex portion of the closing device, including a close-up view of the fibers of the sheet.

[0064] Figure 12 It is in the process of division Figure 11 A partial perspective view of the film during its production.

[0065] Figure 13 This is a perspective view of the insert sheet used as an intermediate layer.

[0066] Figure 14 yes Figure 12 A perspective view of the segmented pieces, in which Figure 13 The middle layer is inserted into the dividing hole.

[0067] Figure 15It is fixed to the middle layer in the hot press. Figure 14 A partial perspective view of the segmented piece.

[0068] Figure 16 This is a partial perspective view of the segmented pieces that have been fixed to the intermediate layer after hot pressing.

[0069] Figure 17 It is used to form Figure 1 A perspective view of the convex portion of the closing device, the open thermoforming mold, and a partial perspective view of the hot-pressed segment and intermediate layer.

[0070] Figure 18 This is a partial perspective view of the convex portion of the closing device after thermoforming.

[0071] Figure 19 This is a partial perspective view of the convex portion of the closing device during the laser cutting process.

[0072] Figure 20 This is a perspective view of a punching machine used for cutting the convex portion of a closure device.

[0073] Figure 21 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0074] Figure 22 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0075] Figure 23 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0076] Figure 24 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0077] Figure 25 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0078] Figure 26 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0079] Figure 27 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0080] Figure 28 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0081] Figure 29 This is another aspect of the disclosure, used for Figure 1 A partial perspective view of the alternative convex portion of the closure device.

[0082] Figure 30 This is a perspective view of a wearable article in another aspect of this disclosure, the wearable article being a footwear article having a nonwoven fabric sheet including a heel counter.

[0083] Figure 31 This is a rear view of a wearable item, which is a backpack, having a nonwoven fabric sheet including a closure.

[0084] Figure 32 yes Figure 31 The front view of a wearable item, which is a backpack, has a nonwoven fabric panel that serves as a housing for a power device.

[0085] Figure 33 This is a front perspective view of a wearable item, which is a shirt having nonwoven fabric pieces including receptacles for power sources and electrical devices.

[0086] Figure 34 This is an external view of a wearable article, which is a footwear article having a nonwoven fabric sheet including a housing for a power source or electrical device.

[0087] describe

[0088] This disclosure generally relates to wearable articles and their manufacture. Wearable articles are disclosed comprising nonwoven fabric sheets having integral portions formed into a one-piece article. Methods of manufacturing the nonwoven fabric sheet provide the integral portion of the sheet having a defined shape and a sufficiently high modulus of elasticity to function as a one-piece article, while adjacent portions of the sheet maintain a lower modulus of elasticity for comfort, aesthetic appearance, or both. The wearable articles disclosed herein exhibit reduced complexity compared to wearable articles in which separate (e.g., non-one-piece) structural components of different materials are attached to the fabric sheet to provide the same function as a one-piece article. Furthermore, the nonwoven fabric sheet can be formed from recyclable materials.

[0089] In the example, the wearable article may include a nonwoven fabric sheet having a first portion formed as a one-piece article of wearable article. The nonwoven fabric sheet may also have a second portion adjacent to the first portion. The first portion may have a first density and a first modulus of elasticity. The second portion may have a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. For example, the modulus of elasticity may be the tensile modulus (Young's modulus). The first portion is formed differently from the second portion, and the shape, density, and modulus of elasticity of the first portion enable it to serve as a one-piece article of wearable article.

[0090] As used herein, for the purposes of this application and its claims, a "wearable article" is an article constructed for wearing on the human body and does not include durable goods not intended for wearing on the human body, such as furniture and vehicle interiors. Non-limiting examples of wearable articles include footwear, clothing, carry bags (e.g., backpacks, wallets, duffel bags, waist bags), and other types of portable containment structures intended for wearing on the human body. As used herein, for the purposes of this application and its claims, a "carry bag" is a containment device having one or more straps or handles or other features constructed for placement on the human body, and includes, but is not limited to, backpacks, wallets, duffel bags, and waist bags.

[0091] As used herein, for the purposes of this application and its claims, a "one-piece article" is a portion of a nonwoven fabric sheet that has a uniform structure with adjacent portions of the sheet and has a function that is at least partially achieved by its shape (including its outline) and by its rigidity sufficient to perform that function, as indicated by its modulus of elasticity. Examples of one-piece articles as defined herein include: closure devices, such as buckles (which include a convex portion and a concave portion of the buckle), snaps, buttons, and other types of closure devices; and receptacles, for example, for power sources or electrical devices (including batteries, lights, cellular phones, etc.). Other examples of one-piece articles include heel stabilizers for footwear.

[0092] The first and second portions of the nonwoven fabric sheet may initially have the same density and modulus of elasticity. The first portion may be thermoformed, for example, by heating and compressing its fibers together to increase its density and modulus of elasticity, thus enabling it to function as a monolithic article, while the less rigid, lower-density second portion does not function as a monolithic article but can be used to serve other purposes, such as where greater flexibility is required. As discussed herein, the fibers of different layers may melt together when heated and compressed during thermoforming, which may make the boundaries between the different layers less distinct. Heating of the first portion of the nonwoven fabric sheet may be performed via a heated thermoforming die tool. Alternatively or additionally, at least the first portion of the nonwoven fabric sheet may be heated before placing the first portion in the thermoforming die. In some configurations, the thermoforming die may be cooled to help keep the outer surface of the nonwoven fabric sheet below a predetermined temperature, thereby preventing some or all of the molten fibers at the outer surface of the first portion from melting during thermoforming.

[0093] In different configurations, the relative thicknesses of the first and second parts can be different. For example, the thickness of the first part can be in the range of being less than about 10% of the thickness of the second part to being greater than about 10% of the thickness of the second part, or in the range of being less than about 5% of the thickness of the second part to being greater than about 5% of the thickness of the second part, or in the range of being less than about 1% of the thickness of the second part to being greater than about 1% of the thickness of the second part. Alternatively, the thickness of the first part can be greater than the thickness of the second part by more than 10%, or the thickness of the second part can be greater than the thickness of the first part by more than 10%.

[0094] In one aspect, the first portion may define a through-hole extending through the nonwoven fabric sheet. For example, one or more laser-cut or punched through-holes may be formed in the first portion. In embodiments where the wearable article includes a closure device, the through-hole may be an opening in a concave portion of the closure device, at which a convex portion of the closure device is releasably secured.

[0095] On the other hand, wearable articles may include fabric components, which may be fabric sheets, and nonwoven fabric sheets may be attached to the fabric components. For example, the nonwoven fabric sheet may be attached to the fabric components, for example, by sewing or bonding. In other embodiments where wearable articles include fabric components, the fibers of a second portion of the nonwoven fabric sheet may be intertwined with the fibers of the fabric component to secure the second portion to the fabric component, for example, by needle punching. In such embodiments, the fabric component may be located below both the first and second portions. In one or more embodiments, the integral article of the first portion of the nonwoven fabric sheet may be either a concave or convex portion of a closure. For example, the wearable article may be a pouch or a drawstring, and the closure may be a buckle. In embodiments where the wearable article is a pouch, the integral article may be a convex or concave portion of a buckle. For example, a pouch may include a flap and a base. The convex portion of the latch can be provided on a strip extending from the cover plate to the concave portion of the latch on the base, or on a strip extending from the base to the concave portion of the latch on the cover plate. The convex portion of the latch can be provided at the cover plate or at the strip, for example at the end of the strip.

[0096] In an example where the wearable item is a pouch and the integral article is the convex portion of the clasp, the pouch may include an additional nonwoven fabric sheet having a first portion shaped as an integral article, which may be the concave portion of the clasp, and the additional nonwoven fabric sheet having a second portion adjacent to the first portion. The concave portion of the clasp may be an additional integral article of the pouch. The first portion of the additional nonwoven fabric sheet may have a density greater than that of the second portion of the additional nonwoven fabric sheet, and may have a greater elastic modulus than that of the second portion of the additional nonwoven fabric sheet. The convex portion may be shaped and sized to be releasably secured to the concave portion. In some embodiments, the closure may be a sternum strap clasp for a backpack, or a waist strap for a backpack.

[0097] In other embodiments, the wearable article can be footwear, and the one-piece article can be a heel stabilizer. However, the wearable article is not limited to handbags and footwear, and the one-piece article is not limited to closure devices and heel stabilizers. For example, the wearable article can be a handbag, footwear, or clothing item, and the one-piece article can be a housing for a power source or electrical device (e.g., a battery, a light, a cellular phone, etc.).

[0098] In one or more embodiments, the first portion may include a plurality of stacked nonwoven fabric layers, which may include a first outer layer, a second outer layer, and at least one intermediate layer disposed between the first outer layer and the second outer layer. The at least one intermediate layer may extend only in the first portion.

[0099] In one respect, the edge of at least one intermediate layer may be tapered. The tapered edge may be adjacent to the second part.

[0100] In one example, the carry-on bag may include a nonwoven fabric sheet having a first portion formed as a single article, which is part of a clasp, and a second portion adjacent to the first portion. The first portion may have a higher density and a higher elastic modulus than the second portion. The first portion of the clasp may be a concave portion of the clasp, and the carry-on bag may further include a nonwoven fabric strip having a first portion formed as a single article, which is a convex portion releasably secured to the concave portion as the clasp. The nonwoven fabric strip may have a second portion adjacent to the first portion of the nonwoven fabric strip. The first portion of the nonwoven fabric strip may have a higher density and a higher elastic modulus than the second portion of the nonwoven fabric strip.

[0101] In the example, a method of manufacturing a wearable article (such as the wearable article disclosed herein) may include thermoforming a first portion of a nonwoven fabric sheet into a one-piece article of the wearable article. The nonwoven fabric sheet may have an unthermoformed second portion adjacent to and shaped differently from the thermoformed first portion. After thermoforming, the first portion may have a first density and a first modulus of elasticity. The unthermoformed second portion may have a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity.

[0102] In one or more configurations, the method may include: heating at least a first portion of the nonwoven fabric sheet before thermoforming in a thermoforming mold. After heating at least the first portion of the nonwoven fabric sheet, the method may include placing the first portion of the nonwoven fabric sheet in the thermoforming mold. The temperature of the mold surface of the thermoforming mold may be lower than the temperature of the first portion of the nonwoven fabric sheet. For example, the mold surface may be at room temperature, or may be actively cooled to a temperature less than or equal to room temperature during the thermoforming process. The temperature difference between the thermoformed portion of the nonwoven fabric sheet and the mold surface may help maintain the original texture of the outer surface of the nonwoven fabric sheet, such as a relatively rough (e.g., fuzzy) felt texture, even if the sheet is compressed during thermoforming.

[0103] In one or more embodiments, the method may further include stacking a plurality of nonwoven fabric layers to define the first portion prior to thermoforming the first portion. The plurality of nonwoven fabric layers may include a first outer layer, a second outer layer, and at least one intermediate layer disposed between the first and second outer layers. The at least one intermediate layer may extend only within the first portion. The first and second outer layers may extend in both the first and second portions. For example, the first and second outer layers may be two separate nonwoven fabric sheets. In other embodiments, a single nonwoven fabric sheet forms the first and second portions, wherein only the first portion is segmented to produce the first and second outer layers. For example, the method may include segmenting the nonwoven fabric sheet only at the first portion prior to stacking the plurality of nonwoven fabric layers to define the first and second outer layers, the first and second outer layers extending only within the first portion. The method may further include inserting at least one intermediate layer into the segmentation between the first and second outer layers.

[0104] In one or more configurations, the method may further include: tapering the edge of at least one intermediate layer before inserting at least one intermediate layer between the first outer layer and the second outer layer. Inserting at least one intermediate layer between the first outer layer and the second outer layer may be accompanied by making the tapered edge adjacent to the second portion. In one aspect, the method may further include: hot-pressing the plurality of nonwoven fabric layers to each other after stacking the plurality of nonwoven fabric layers and before thermoforming the first portion.

[0105] In one or more embodiments, the method may further include creating at least one through-hole in the first portion, the at least one through-hole extending through the nonwoven fabric sheet. For example, creating at least one through-hole in the first portion may include laser cutting or punching at least one through-hole.

[0106] In one or more embodiments, the method may further include: after thermoforming the first portion, trimming the peripheral edge of the first portion. For example, the peripheral edge of the first portion may be trimmed by laser cutting. For example, in embodiments where the structural member is a convex portion of a latch, trimming the peripheral edge may define the prongs of the latch.

[0107] In one or more constructions, the wearable article may include a fabric component, and the method may further include: after thermoforming a first portion, attaching a nonwoven fabric sheet to the fabric component such that the nonwoven fabric sheet extends from the fabric component. For example, the nonwoven fabric sheet may be a flap of a bag attached to a fabric component of the bag at its outer edge. In one or more other constructions where the wearable article includes a fabric component, the method may further include: after thermoforming a first portion, needle-punching a second portion to the fabric component. For example, after needle-punching the second portion to the fabric component, the nonwoven fabric sheet may be adjacent to a surface of the fabric component, wherein both the first and second portions cover the fabric component at the surface, and at least the second portion is in contact with the surface. For example, when the one-piece article is a recessed portion for a clasp of a bag or a receiving portion for a power source or electrical device, the first and second portions may cover the fabric component. Subsequently, any through-holes in the recessed portion from the interior of the bag are blocked by the fabric component.

[0108] The above features and advantages, as well as other features and advantages, of this teaching will become apparent when combined with the accompanying drawings and from the following detailed description of the model for implementing this teaching.

[0109] Refer to the attached diagram. Figure 1 A wearable item 10 constructed and manufactured according to the teachings of this article is shown. Figure 1 In this context, wearable item 10 is a handbag, such as a wallet or backpack, and may be referred to as such herein. Wearable item 10 includes a closure device 12, which will be discussed in further detail herein. Closure device 12 is shown as a clasp, and may be referred to as such herein. Closure devices may be included in other wearable items within the scope of this teaching, such as drawstrings. Shoulder straps of wearable item 10 are not shown, but may be on the back of the wearable item.

[0110] Wearable article 10 comprises one or more nonwoven fabric sheets, such as nonwoven fabric sheets 14 and 16. Nonwoven fabric sheets 14, 16 may be felt material having relatively short and randomly arranged fibers 23. The felt material may include plastics, such as polyesters (including but not limited to thermoplastic polymers, such as polyethylene terephthalate (PET)), and may be made from recyclable plastics. For example, fiber 23 may be PET. One advantage of felt is that it is suitably soft for use as a wearable article and is available in sheet form, which can be manufactured according to the methods disclosed herein. In contrast to the ordered distribution found in woven materials, the random distribution of fibers 23 entangled together in the nonwoven fabric sheet allows the shapes of sheets 14, 16 to be designed and formed as described herein without the felt providing resistance that tends to pull the sheet back to its original flat shape, which may occur in materials with woven strands. As described herein, portions of one or both of the nonwoven fabric pieces 14, 16 can be shaped to achieve a nonplanar shape, which can serve as an integral article of the nonwoven fabric piece, while the adjacent remaining portions of the piece can remain planar, or at least have a shape different from the first portion.

[0111] The nonwoven fabric sheet 14 is constructed as the base of the carry-on bag 10, and may be referred to as such. The nonwoven fabric sheet 14 has a first portion 18, which is shaped and sized as a single piece of the wearable article 10. The first portion 18 is a concave portion 12A of the closure device 12. The nonwoven fabric sheet 14 also has a second portion 20, which is adjacent to the first portion 18 at its outer boundary 22. As discussed herein, the first portion 18 is thermoformed to achieve a different shape from the second portion 20, while the surrounding second portion 20 is not thermoformed. The first portion 18 of the nonwoven fabric sheet 14 is the portion within the outer boundary 22. Therefore, prior to thermoforming the first portion 18, the first portion 18 and the second portion 20 have the same density and modulus of elasticity, as well as the same relatively flat planar shape. Thermoforming compresses the first portion 18 relative to the second portion 20, resulting in the PET fibers 23 of the first portion 18 (shown in close-up circle A) establishing and maintaining a more compact arrangement relative to the PET fibers 23 of the second portion 20 (shown in close-up circle B). Heat and pressure can melt the fibers, allowing the PET material to flow and form the shape of the mold. Different percentages of molten fibers relative to unmolten fibers will result in different levels of hardness, stiffness, and strength in the thermoformed first portion 18.

[0112] For example, the molten fibers contained in PET fibers 23 can melt in a temperature range of 110°C to 140°C, where the molding process lasts between approximately 30 seconds and two minutes. The longer the molding process (e.g., the longer the nonwoven fabric sheet 14 is held in the thermoforming mold and / or the longer the pressure on the nonwoven fabric sheet 14 in the mold is maintained), the greater the percentage of molten fibers that will melt, and the greater the compression achieved. The higher the temperature, the greater the percentage of molten fibers that will melt, and the greater the compression achieved. As more molten fibers melt, the outer surface of the first portion 18 may become relatively smooth, thus losing its original relatively rough (e.g., fuzzy) texture caused by the randomly distributed fibers 23. If it is desired to retain more of the original texture on the outer surface, then instead of heating the mold tool, the nonwoven fabric sheet 14 can be preheated in an oven to a temperature sufficient to cause the molten fibers to melt, but at the lower end of the melting temperature range. Subsequently, the mold tool can be placed at room temperature, or even cooled to below room temperature. Subsequently, the contact between the die tool and the nonwoven fabric sheet 14 cools the outer surface of the nonwoven fabric sheet 14 relative to its preheated temperature, thus leaving largely intact original texture. Exemplary pressures that can be used to compress the nonwoven fabric sheet 14 during thermoforming can range from approximately 40 pounds per square inch (psi) to approximately 100 psi. Higher pressures result in greater compression, with corresponding increases in stiffness, rigidity, and strength.

[0113] In the finished carry-on bag 10, the thermoformed first portion 18 has a first density and a first elastic modulus, while the second portion 20 has a second density lower than the first density and a second elastic modulus lower than the first elastic modulus, for example, a tensile modulus lower than the tensile modulus (Young's modulus) of the first portion 18. Furthermore, thermoforming gives the first portion 18 a shape that enables it to function as an integral piece of the nonwoven fabric sheet 14.

[0114] The nonwoven fabric sheet 16 also includes a first portion 28, which is shaped and sized as a single piece, the single piece being a convex portion 12B of the latch 12, which is releasably secured to a concave portion 12A. Figure 1In the diagram, the first portion 28 (convex portion 12B) is shown releasably secured to the first portion 18 (concave portion 12A). The nonwoven fabric sheet 16 includes a flap 24 and a strip 26 extending from the flap 24. The strip 26 includes a first portion 28 and a second portion 30 adjacent to the first portion 28. The first portion 28 is located at the end of the strip 26. The second portion 30 is adjacent to the first portion 28 at a boundary 32 and extends to or includes the flap 24. When the convex portion 12B is secured to the concave portion 12A, the latch 12 is engaged, and the pouch 10 is closed. The flap 24 and the strip 26 are sized to allow the flap 24 to cover the top and a portion of the front of the pouch 10, wherein the strip 26 extends downward toward the concave portion 12A of the latch 12. Alternatively, the strip 26 having the convex portion 12B may extend from the nonwoven fabric sheet 14 (e.g., from the base of the pouch 10), and the concave portion 12A may be included in the cover 24 of the nonwoven fabric sheet 16.

[0115] As described herein, the first portion 28 is thermoformed in a mold, which compresses the fibers 23 of the first portion 28 (shown in close-up circle A) compared to the fibers 23 of the unthermoformed second portion 30 (shown in close-up circle B). Prior to thermoforming, the first portion 28 and the second portion 30 have the same density and modulus of elasticity. Only the first portion 28 is thermoformed, and as a result of thermoforming, the first portion 28 has a greater density and a greater modulus of elasticity than the second portion 30.

[0116] exist Figure 2 In the diagram, the convex portion 12B (first portion 28) is shown released from the concave portion 12A (first portion 18), causing the latch 12 to disengage and the pouch 10 to open at the opening 37, thereby allowing access to the cavity 38 formed at least partially by the base of the pouch 10 (e.g., by a nonwoven fabric sheet 14). The first portion 28 includes side forks 40 and a center fork 42. The side forks 40 have notches 44 on their outer sides, which define a first shoulder 46 and a second shoulder 48 in each of the side forks 40. The side forks 40 are relatively rigid. When inserted into the through-hole 50A of the concave portion 12A, the side forks 40 will be laterally pressed inward against the center fork 42 and will be outwardly biased back to their original position. Figure 2 The free orientation shown is such that it hooks onto the concave portion 12A at the through holes 50B, 50C. Therefore, the shape and size of the convex portion 12B, including the side fork 40, enable it to serve as an integral article of the nonwoven fabric sheet 16 (e.g., as a convex portion that can be secured to the concave portion 12A as a latch 12).

[0117] like Figure 3As best seen, the first portion 18 is shaped and sized as a single piece of wearable article 10. More specifically, due to the shape of the thermoforming die discussed herein, the first portion 18 and the remainder of sheet 14, including the second portion 20, are non-planar. The first portion 18 extends outward away from the second portion 20. The first portion 18 defines three through-holes 50A, 50B, and 50C extending through the nonwoven fabric sheet 14. For example, through-holes 50A, 50B, and 50C may be laser-cut or punched in the first portion 18. Through-hole 50A opens generally in the same direction as opening 37. Through-holes 50B and 50C are generally orthogonal to through-hole 50A.

[0118] The convex portion 12B (first portion 28) is shaped and sized to be releasably secured to the concave portion 12A (first portion 18) through the through hole 50A via the side forks 40, and latched to the first portion 18 by hooking the first portion 18 at the through holes 50A and 50B via the second shoulders 48 and by abutting the first portion 18 outside the through hole 50A via the first shoulders 46. When the side forks 40 are inserted into the through hole 50A, they are pressed inward toward the central fork 42 as they slide against the first portion 18 at both sides of the through hole 50A. Once the side forks have passed through the through hole 50A, they are released outward, and the spacing between the shoulders 48 is set to be wider than the width of the concave portion 12A (first portion 18), such that the shoulders 48 hook the first portion 18 at the through holes 50B and 50C. To release the convex portion 12B (first portion 28) from the concave portion 12A (first portion 18), the side fork 40 is manually pressed laterally inward at the through holes 50B, 50C, allowing the convex portion 12B (first portion 28) to disengage from the concave portion 12A (first portion 18) at the through hole 50A. The denser and stiffer thermoformed first portions 18, 28 allow their respective shapes to be maintained during repeated use, enabling the latch 12 to function for an extended period.

[0119] Figure 4 Two halves of a thermoforming mold 51 are shown. A male mold tool 52 and a female mold tool 54 are shown. The male mold tool 52 includes a mold surface 55 and a protrusion 56 extending from the mold surface 55. The female mold tool 54 includes a mold surface 57 of the same dimensions as the mold surface 55. The female mold tool 54 includes a groove 58 in the mold surface 57. The protrusion 56 of the male mold tool 52 fits within the groove 58. Figure 3The concave portion 12A (first portion 18) of the latch 12 is thermoformed in the mold 51 by placing a nonwoven fabric sheet 14 between mold surfaces 55, 57, wherein positioning portions 60 on mold tools 52, 54 are aligned with each other on a pin or the like. Mold tools 52, 54 can be heated, for example by resistance heating. Alternatively, instead of heating the mold tools 52, 54, the nonwoven fabric sheet 14 can be heated in an oven prior to thermoforming, and the mold tools 52, 54, or at least the mold surfaces of the mold tools 52, 54, can be at room temperature or even cooled (as discussed above) to cool the outer surface of the nonwoven fabric sheet 14 when it is placed in the mold 51, in order to help maintain the outer surface texture of the resulting thermoformed first portion 18. The first portion 18 of the latch 12 is formed where the nonwoven fabric sheet 14 is captured between the protrusion 56 and the groove 58 and is in contact with the protrusion 56 and the groove 58, thus presenting a non-planar shape for the first portion 18. The force applied to the nonwoven fabric sheet 14 by the mold 51 is not resisted by any woven strands because the felt material has only short, randomly arranged fibers 23.

[0120] Figure 5 A nonwoven fabric sheet 14 with a first portion 18 and a second portion 20 is shown after thermoforming, cooling, and removal from mold 51. A planar thermoformed portion 19 surrounds the first portion 18 and is formed on both sides of the nonwoven fabric sheet 14 where the mold surfaces 55, 57 contact. If heated, the mold 51 causes the nonwoven fabric sheet 14 to heat (and / or the nonwoven fabric sheet 14 to be preheated as discussed herein), and subsequently the fibers 23 are compressed together, and a proportion of the fibers melt (molten fibers), retaining a new nonplanar shape of the integral article (concave portion 12A) upon cooling, wherein the first portion 18 extends outward from the planar thermoformed portion 19. The second portion 20 does not fully contact the mold tools 52, 54 and thus retains the original density and modulus of elasticity of the nonwoven fabric sheet 14, while the density and modulus of elasticity of portions 18, 19 increase due to thermoforming. In other words, the mold 51 compresses the material of the nonwoven fabric sheet 14 at the first part 18 and the thermoformed part 19 of the plane, so that these parts are thinner and denser than they were before thermoforming.

[0121] Figure 6 A nonwoven fabric sheet 14 is shown, having through holes 50A, 50B, and 50C formed by laser cutting or punching through a thermoformed portion of the nonwoven fabric sheet 14. Figure 1In this embodiment, the nonwoven fabric sheet 14 is not supported by any other component at the thermoformed concave portion 12A of the closure device 12. Therefore, the through holes 50A, 50B, and 50C extend into the inner cavity 38. In some applications described herein, it may be desirable to isolate the closure device 12 from the inner cavity 38 so that access to the inner cavity 38 is prevented through the through holes 50A, 50B, and 50C, thereby better sealing the inner cavity 38 against moisture and debris that might otherwise pass through the through holes 50A, 50B, and 50C. Figure 7 A nonwoven fabric sheet 14 after thermoforming in the first part 18 is shown, having a concave portion 12A of a closing device 12 and a planar, unthermoformed second part 20.

[0122] Figure 8 Another configuration of the wearable article 110 is shown, in which a nonwoven fabric sheet 14 is stacked on a fabric component 62, which is located beneath both the first portion 18 and the planar thermoformed portion 19. The fabric component 62 is a planar fabric sheet as shown, but may have other configurations in other embodiments. The nonwoven fabric sheet 14 is secured to the fabric component 62 using a needle punching machine 64. The needle punching machine 64 includes a series of needles 66 that repeatedly extend in and out of the stacked sheet 14 and fabric component 62 at a non-thermoformed second portion 20. The fibers of the second portion 20 are wound around the fibers of the fabric component 62 to secure the nonwoven fabric sheet 14 to the fabric component 62.

[0123] Figure 9 The area of ​​the wound fibers, indicated by 70, is schematically shown, such that the periphery of the nonwoven fabric sheet 14 is integral with the fabric component 62 and is at least partially indistinguishable from it. For illustrative purposes, in Figure 9 The wound fiber 70 is magnified, but it may not be visually distinguishable from the surrounding fibers. After the second portion 20 is needled into the fabric component 62, the nonwoven fabric sheet 14 is adjacent to the surface 72 of the fabric component 62, wherein the first portion 18, the thermoformed planar portion 19, and the second portion 20 cover the fabric component 62 at the surface 72. The second portion 20 contacts the surface 72, and the first portion 18 is disposed above the surface, thereby creating a cavity between the surface 72 and the first portion 18, which is received in the cavity when the first portion 28 of the convex portion 12B of the closure device 12 is inserted through the through hole 50A.

[0124] Figure 10 Another construction of wearable item 210 is shown, for example, in a carry bag where the edge of nonwoven fabric piece 14 is secured to fabric part 62 at the edge of fabric part 62, rather than as... Figure 9The nonwoven fabric piece 14 is fixed above the fabric component 62, for example, by sewing or gluing the edge 74 of the nonwoven fabric piece 14 to the edge 76 of the fabric component 62. In this configuration, the nonwoven fabric piece 14 with a thermoformed concave portion 12A having a snap fastener 12 is sewn to the fabric component 62 such that the nonwoven fabric piece extends from the fabric component 62. In this configuration, the nonwoven fabric piece 14 can serve as a flap for the carry bag 210. When in the closed position, the flap can extend along the outside of the carry bag, rather than directly onto the surface. Figure 2 The opening 37 extends above the entrance opening, making it impossible to enter the opening through the through holes 50A, 50B, and 50C, and preventing dust or moisture passing through the through holes from entering the opening.

[0125] Because the thermoforming process tends to compress and melt the nonwoven fabric material, the thermoformed portion of the nonwoven fabric sheet can be thinner, denser, and stiffer than the adjacent unthermoformed portion of the sheet, and has a greater modulus of elasticity. In some embodiments, this thickness difference may be desirable or aesthetically pleasing. In other embodiments, it may be desirable for the thermoformed portion and the adjacent unthermoformed portion to appear to have substantially the same thickness. Desired different combinations of thicknesses between the thermoformed and unthermoformed portions can be achieved by stacking layers of the nonwoven fabric sheet, and / or by inserting intermediate layers of nonwoven fabric or other material between the split sheets or between the layers of the nonwoven fabric sheet prior to thermoforming. For example, in the area to be molded / thermoformed, the material thickness can initially be built up to increase wall thickness and stiffness after thermoforming. Otherwise, the thermoforming process may reduce the thickness too much, resulting in an unstable and brittle thermoformed portion. In one example, a combination of sheets or stacked sheets may have an initial thickness of approximately 28 millimeters (mm). After thermoforming, the resulting thermoformed portion (e.g., the first portion 28) will be compressed to a reduced thickness of approximately 4-5 mm.

[0126] Figure 11 An example of a nonwoven fabric sheet 16 prior to thermoforming is shown, which has a thickness T1 and a relatively low density (as demonstrated by the relatively loose and randomly arranged fibers 23 in a close-up circle C). Figure 12 The nonwoven fabric sheet 16 is shown to be divided inward from the outer edge 83 only at and through the first portion 28 to define a first outer layer 28A and a second outer layer 28B extending only in the first portion 28, which has not yet been thermoformed. Figure 13An intermediate layer 80 is shown, having an edge 82 that is tapered to create an upper slope 84A and a lower slope 84B. The tapered edge 82 may also be referred to as a thinned edge. The intermediate layer 80 has a thickness T2 before being inserted between layers 28A and 28B. The intermediate layer 80 can be a nonwoven fabric, a woven fabric, or other material. In the example using one or more intermediate layers (which are made of a different material than the outer layer of the sheet or more sheets in which the intermediate layers are inserted), the modulus of elasticity of the thermoformed portion formed by the stacked layers depends on the modulus of elasticity of each layer and the effective modulus of elasticity relative to its thickness.

[0127] Figure 14 The diagram shows an intermediate layer 80 inserted between a first outer layer 28A and a second outer layer 28B, with a tapered edge 82 adjacent to the second portion 30. The intermediate layer 80 may have a length equal to the length of the slit between the outer layers 28A and 28B, such that the tapered edge 82 abuts the nonwoven fabric sheet 16 at the end of the slit. The positioning of the tapered edge 82 of the intermediate layer 80 against the nonwoven fabric sheet 16 at the end of the slit prevents any gaps from appearing after thermoforming.

[0128] Figure 15 The stacked outer layers 28A, 28B and intermediate layer 80 are shown placed in a hot press 86 to provide substantially fixation of the outer layers 28A, 28B to the intermediate layer 80 prior to thermoforming. The first outer layer 28A, the intermediate layer 80 and the second outer layer 28B are thus stacked at the first portion 28. Figure 16 The outer layers 28A and 28B of the stack, after being removed from the hot press 86 and attached to the intermediate layer 80, are shown before thermoforming. At this stage of the manufacturing process, the total thickness T3 of the stacked layers at the first portion 28 is the sum of the thickness T1 of the divided first portion 28 and the thickness T2 of the intermediate layer 80. As discussed herein, for example, the thickness T1 can be about 4 mm to 5 mm, and the thickness T3 can be about 28 mm. Within the given range of pressure, temperature, and time in the thermoforming mold discussed herein, Figure 18 The thickness of the first part 28 of the thermoforming shown can also be thickness T1.

[0129] Figure 17An open thermoforming mold 88 is shown, comprising mold tools 88A and 88B, each mold tool having a cavity portion 86A and 86B. For example, mold tools 88A and 88B may be mold halves. Mold tools 88A and 88B are placed together with the cavity portions 86A and 86B, and together with stacked layers 28A and 28B and an intermediate layer 80 in the cavity portions 86A and 86B, and the stacked layers 28A, 28B and the intermediate layer 80 are thermoformed and cooled together to form a first portion 28 having the same thickness T1 as the unthermoformed second portion 30, such as... Figure 18 As shown in the diagram. For aesthetic or other reasons, it may be desirable for some applications to manufacture the first part 28 and the second part 30 to have the same thickness. Similar to the discussion about Figure 4 The mold tools 88A and 88B discussed can be heated, for example by resistance heating. Alternatively, instead of heating the mold tools 88A and 88B, the stacked layers 28A and 28B and the intermediate layer 80 can be heated in an oven before thermoforming, and at least the mold surface of the mold tools 88A and 88B can be at room temperature or even cooled (as described above) to cool the outer surfaces of the stacked layers 28A and 28B when they are placed in the mold 88, in order to help maintain the surface texture of the resulting thermoformed first portion 28.

[0130] exist Figure 19 In this process, the first portion 28 is cut, for example by laser cutting, as shown by a laser 90 having a laser beam 92 directed at the first portion 28, to cut the peripheral edge 83 of the first portion 28 into the shape of the convex portion 12B of the latch 12, thereby providing the side forks 40 and the center fork 42. Thus, the convex portion 12B of the latch 12 has the same thickness at both the thermoformed first portion 28 and the unthermoformed second portion 30, providing a pleasing aesthetic feature while still allowing the first portion 28 to have a first density greater than the second density of the second portion 30, and a first elastic modulus greater than the second elastic modulus of the second portion 30, so that the first portion 28 can be used as an integral article of the nonwoven fabric sheet 16, in this case, the convex portion of the latch. Figure 19 Alternatives to the laser cutting shown, such as Figure 20 As shown, the outer peripheral edge 83 of the first portion 28 can be punched into the shape of the outer peripheral edge 83 (e.g., by the blade 94 of the punching machine 96).

[0131] Figure 21The construction of the convex portion 12B is shown, wherein two nonwoven sheets 16A and 16B are stacked together and thermoformed, with no intermediate layer between the sheets. Sheets 16A and 16B serve as the first and second outer layers, respectively, each extending within both the first portion 28 and the second portion 30. This construction is suitable for applications where the thickness difference between the thermoformed first portion 28 and the unthermoformed second portion 30 is desirable or at least aesthetically acceptable. The thickness T4 of the unthermoformed second portion 30 can be twice the thickness T1 of the two stacked sheets 16A and 16B. Due to thermoforming, the thickness of the thermoformed first portion 28 is compressed from thickness T4 to a smaller thickness T5, resulting in the first portion 28 having a first thickness T5 that is less than the second thickness T4 and a first elastic modulus that is greater than the second elastic modulus of the second portion 30.

[0132] like Figure 19 and Figure 21 As shown, the relative thicknesses of the first portion 28 and the second portion 30 can vary in different configurations. For example, the thickness of the first portion 28 can be in the range of being less than about 10% of the thickness of the second portion 30 to being greater than about 10% of the thickness of the second portion 30, or in the range of being less than about 5% of the thickness of the second portion to being greater than about 5% of the thickness of the second portion, or in the range of being less than about 1% of the thickness of the second portion 30 to being greater than about 1% of the thickness of the second portion 30. Alternatively, the thickness of the first portion 28 can be greater than the thickness of the second portion 30 by more than 10%, or the thickness of the second portion 30 can be greater than the thickness of the first portion 28 by more than 10%.

[0133] Figure 22 An example of a segmented nonwoven fabric piece 16 is shown, which is similar to that relative to... Figure 19 The example described, except that the thermoforming mold used is configured such that, after thermoforming, the first thermoformed portion 28 is more than 10% thicker than the unthermoformed second portion 30. Figure 23 A similar configuration is shown, except that the thermoforming die used is configured such that the thickness of the thermoformed first portion 28 is equal to, or in the range of being less than, about 1% less than, the thickness of the unthermoformed second portion 30 to being greater than, 1% more than the thickness of the unthermoformed second portion 30. Finally, Figure 24 An arrangement is shown in which the thermoforming die is configured such that the first thermoformed portion 28 has a thickness that is more than 10% less than the thickness of the unthermoformed second portion 30.

[0134] Figure 25 It shows something similar to Figure 21 The structure comprises two stacked nonwoven fabric sheets 16A and 16B, wherein the intermediate layer 80 extends only in the first portion 28. Figure 25 In the construction, the thermoforming mold is configured such that after thermoforming, the thickness of the first part 28 is more than 10% greater than the thickness of the unthermoformed second part 30. Figure 26 A similar construction is shown, except that the thermoforming mold used is configured such that, after thermoforming, the first portion 28 has a thickness equal to, or in the range of, less than the thickness of the unthermoformed second portion 30 by about 1% to greater than the thickness of the unthermoformed second portion 30 by 1%. Finally, Figure 27 An arrangement is shown in which the thermoforming die is configured such that the thickness of the thermoformed first portion 28 is more than 10% less than the thickness of the unthermoformed second portion 30.

[0135] Figure 28 A configuration is shown in which a plurality of intermediate layers 80 are inserted into slits in a nonwoven fabric sheet 16, wherein the slits extend only in a first portion 28, such that the first portion 28 defines a first outer layer 28A and a second outer layer 28B extending only in the first portion 28. The edges of the intermediate layers 80 are tapered, such that the intermediate layers 80 abut the second portion 30 without any gaps in the slits after thermoforming. The intermediate layers 80 have both an upper and a lower slope. The uppermost intermediate layer has only a single slope, as does the lowermost intermediate layer. The first portion 28 is shown after thermoforming and has a thickness greater than the thickness of the unthermoformed second portion 30 by more than 10%.

[0136] Figure 29 A configuration is shown in which multiple intermediate layers 80 are inserted between two stacked nonwoven fabric sheets 16A, 16B. Figure 28 In this configuration, the edges of the intermediate layer 80 are tapered, resulting in no gaps between sheets 16A and 16B after thermoforming. The first portion 28 is shown after thermoforming and has a thickness greater than the unthermoformed second portion 30 by more than 10%. The thermoforming die can be selected such that even in a configuration with multiple intermediate layers 80, the thickness obtained at the thermoformed first portion 28 can be less than the thickness of the unthermoformed second portion 30.

[0137] Figure 30A wearable article, specifically footwear article 310, is shown. Footwear article 310 has an upper 312 comprising a nonwoven fabric sheet 316 having a thermoformed first portion 328, which is shaped and sized to form a one-piece article of wearable article. More specifically, the first portion 328 is thermoformed to form a heel stabilizer. An unthermoformed second portion 330 of the nonwoven fabric sheet 316 is adjacent to the first portion 328 at a boundary 32. The first portion 328 has a first density and a first modulus of elasticity, and the second portion 330 has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. The denser and stiffer first portion 328 enables it to function as a one-piece article, in this application, as a heel stabilizer. As described herein, only the first portion 328 is thermoformed, resulting in a more densely packed fiber 23 in the nonwoven fabric sheet 316 than in the second portion 330, as shown by the denser fiber 23 in the close-up circle D than in the close-up circle E.

[0138] Figure 31 The back of backpack 410 is shown, which includes two closure devices 412A and 412B within the scope of this disclosure. For example, backpack 410 has two shoulder straps 411A and 411B. The first closure device 412A is a latch for sternal straps 414A and 416A, which, when worn, cross the front of the body and attach to the shoulder straps 411A and 411B. The first closure device 412A includes an integral article of the sternal straps 414A and 416A. For example, the sternal straps 414A and 416A include a first nonwoven fabric sheet 414A having a first portion 18 that is thermoformed into an integral article, which is a concave portion of the closure device 412A and, as shown in the reference... Figure 1 As described. The first part 18 has a first density and a first elastic modulus. The first nonwoven fabric sheet 414A also includes a second part 20 that has not been thermoformed, as shown in reference. Figure 1 As described. The second part 20 has a second density less than the first density and a second elastic modulus less than the first elastic modulus.

[0139] The sternal bands 414A and 416A also include a second nonwoven fabric sheet 416A having a first portion 28, which is thermoformed into a one-piece article that is the convex portion of the closure device 412A and, as shown in the reference... Figure 1 As described. The first portion 28 has a first density and a first modulus of elasticity. The second nonwoven fabric sheet 416A also includes a second portion 30 that has not been thermoformed, having a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity.

[0140] Backpack 410 also includes a second closure 412B, which is a buckle on the waist straps 414B, 416B of backpack 410 for securing the lower portion of the backpack around the waist when worn, and is configured to be substantially the same as the first closure 412A. The second closure 412B includes an integral piece of the waist straps 414B, 416B. For example, the waist straps 414B, 416B include a first nonwoven fabric piece 414B having a first portion 18, which is thermoformed into an integral piece that is a concave portion of the closure 412B and, as referenced... Figure 1 As described. The first portion 18 has a first density and a first elastic modulus. The first nonwoven fabric sheet 414B also includes a second, unthermoformed portion 20, which is adjacent to the first portion and as described in reference. Figure 1 As described. The second part 20 has a second density less than the first density and a second elastic modulus less than the first elastic modulus. Due to thermoforming, the density and elastic modulus of the first part 18 are greater than those of the second part 20.

[0141] The waist belts 414B and 416B also include a second nonwoven fabric piece 416B, which has a first portion 28 that is thermoformed into a one-piece article. This one-piece article is the convex portion of the closure device 412B and, as shown in the reference... Figure 1 As described. The first portion 28 has a first density and a first modulus of elasticity. The second nonwoven fabric sheet 416B also includes an unthermoformed second portion 30 adjacent to the first portion 28, which has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. Due to thermoforming, the density and modulus of elasticity of the first portion 28 are greater than those of the second portion 30.

[0142] The sternal bands 414A, 416A and the lumbar bands 414B, 416B may also include other components and materials, such as cushioning materials, length adjustment sliders, etc. Furthermore, the density and elastic modulus values ​​of the various parts 18, 20, 28, 30 of each closure device in closure devices 412A, 412B may be different for each of these closure devices and may differ from other closure devices and integral articles disclosed herein (e.g., Figure 1 The density and elastic modulus of the closing device 12).

[0143] Figure 32 yes Figure 31A front view of backpack 410. The backpack includes a nonwoven fabric sheet 414C, which includes a thermoformed first portion 418, which is an integral article of the sheet 414C. More specifically, the thermoformed first portion 418 is a housing for a power source or electrical device 491 and may be referred to herein as such. In the illustrated embodiment, the electrical device 491 is a lamp that provides visibility for the wearer of backpack 410. Alternatively, a power source such as a solar cell may be provided in the housing. The nonwoven fabric sheet 414C also has an unthermoformed second portion 420, which is adjacent to the first portion 418 at boundary 22, as described herein. Due to thermoforming, the first portion 418 has a first density and a first modulus of elasticity, and the second portion 420 has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. As an integral article of wearable article, the first portion 418 is shaped differently from the second portion 420. The first part 418 includes laser-cut or punched through-holes 50A and 50D. Through-hole 50A allows insertion and withdrawal of the device 491. Through-hole 50D is a window into the pocket formed by the first part 418 and provides additional access to the electrical device, for example, by exposing light emitted from the electrical device 491. Similar to... Figure 12 The nonwoven fabric sheet 414C can cover and be needled or otherwise secured to the fabric sheet, making it impossible for dust or moisture to enter the interior of the bag through the through holes 50A, 50D, and preventing dust or moisture from entering the backpack 410 through the through holes.

[0144] Figure 33This is a front perspective view of a wearable article, namely shirt 510. Although depicted as a shirt, the wearable article could alternatively be a vest, jacket, sweater, underwear, shorts, or any other wearable garment. Shirt 510 comprises nonwoven fabric sheets 514A, 514B, which include thermoformed portions 518A, 518B, which are integral articles of sheets 514A, 514B. More specifically, the thermoformed first portions 518A, 518B are receptacles for a power source or electrical device and may be referred to herein as such. In the illustrated embodiment, the thermoformed first portion 518A is a bag-like receptacle and houses an electrical device 591, which is a light providing visibility to the wearer of shirt 510. Alternatively, different electrical devices may be provided in the receptacle. The nonwoven fabric sheet 514A also has a second, unthermoformed portion 520A adjacent to the first portion 518A at boundary 22, as described herein. Due to thermoforming, the first portion 518A has a first density and a first modulus of elasticity, and the second portion 520A has a second density and a second modulus of elasticity less than the first density. As a one-piece article of wearable article, the first portion 518A is shaped differently from the second portion 520A. The first portion 518A includes laser-cut or punched through-holes 50A and 50D. Through-hole 50A allows insertion and withdrawal of the device 591. Through-hole 50D is a window to the bag formed by the first portion 518A and provides additional access to the electrical device, for example, by exposure to light emitted from the electrical device 591. Similar to Figure 12 The nonwoven fabric sheet 514A can cover and be needled or otherwise secured to the fabric sheet so that it cannot reach the wearer of the shirt through the through holes 50A, 50D, and dust or moisture passing through the through holes will not come into contact with the wearer.

[0145] In the illustrated embodiment, the thermoformed first portion 518B is a bag-like receiving portion that houses a power device 592, depicted as a cellular telephone. Alternatively, different power devices may be disposed in the receiving portion. The nonwoven fabric sheet 514B also has an unthermoformed second portion 520B adjacent to the first portion 518B at boundary 22, as described herein. Due to thermoforming, the first portion 518B has a first density and a first modulus of elasticity, and the second portion 520B has a second density and a second modulus of elasticity less than the first density. As a one-piece article of wearable article, the first portion 518B is formed differently from the second portion 520B. The first portion 518B includes laser-cut or punched through-holes 50E, 50F, 50G, and 50H. Through-hole 50E allows insertion and withdrawal of the device 592. Through-hole 50F is a window leading to the pocket formed by the first portion 518B and provides additional access to the power device 592, for example, through a screen exposing the power device 592. Through-holes 50G and 50H are provided and shaped to allow access to input features of the power device 592, such as volume, power, and charging ports. Similar to Figure 12 The nonwoven fabric sheet 514B may cover and be needled or otherwise secured to the fabric sheet so that it cannot reach the wearer of the shirt through the through holes 50E, 50F, 50G and 50H, and dust or moisture passing through the through holes will not come into contact with the wearer.

[0146] Figure 34The outer side of a wearable article, specifically footwear 610, is shown. The footwear 610 has an upper 613 comprising a nonwoven fabric sheet 616A. This nonwoven fabric sheet 616A has a thermoformed first portion 618A, which is formed and sized to be a one-piece article of the wearable article. More specifically, the first portion 618A is thermoformed to form, for example, a receiving portion for a power source or electrical device 691. Alternatively, different electrical devices may be disposed within the receiving portion. The nonwoven fabric sheet 616A also has an unthermoformed second portion 620A adjacent to the first portion 618A at boundary 22, as described herein. Due to thermoforming, the first portion 618A has a first density and a first modulus of elasticity, and the second portion 620A has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. As a one-piece article of wearable item, the first part 618A is formed differently from the second part 620A. The first part 618A includes laser-cut or punched through-holes 50J and 50K. Through-hole 50J allows insertion and removal of the device 691. Through-hole 50K is a window leading to the pocket formed by the first part 618A and provides additional access to the electrical device 691, such as by exposing light emitted by the electrical device 691, the screen of the electrical device 691, or for other purposes to provide access to the electrical device 691. Similar to... Figure 12 The nonwoven fabric sheet 616A can cover and be needled or otherwise secured to the fabric sheet so that the wearer of the footwear cannot be approached through the through holes 50J and 50K, and dust or moisture passing through the through holes will not come into contact with the wearer.

[0147] The footwear article 610 also includes a closure device 612, which is a latch for securing the upper 613 to the foot when the footwear article is worn. The closure device 612 includes a first nonwoven fabric sheet 614A having a first portion 18, which is thermoformed into a single piece that is the concave portion of the closure device 612 and, as shown in reference... Figure 1 As described. The first portion 18 has a first density and a first elastic modulus. The first nonwoven fabric sheet 614A also includes a second portion 20 that has not been thermoformed, as shown in reference. Figure 1 As described. The second part 20 has a second density less than the first density and a second elastic modulus less than the first elastic modulus. The second part 20 can be fixed to the outer side of the footwear article 610.

[0148] The closure device 612 also includes a second nonwoven fabric sheet 616A having a first portion 28, which is thermoformed into a one-piece article that is the convex portion of the closure device 612 and, as shown in the reference... Figure 1 As described. The first portion 28 has a first density and a first elastic modulus. The second nonwoven fabric sheet 616A also includes an unthermoformed second portion 30, which has a second density less than the first density and a second elastic modulus less than the first elastic modulus. The second portion 30 can be secured to the inner side of the footwear article 610.

[0149] Therefore, the wearable articles disclosed herein include nonwoven fabric sheets with one-piece articles, offering reduced complexity, pleasing aesthetics, and the option to form individual sheets using recyclable materials. The methods for manufacturing the nonwoven fabric sheets disclosed herein allow for relatively different thicknesses between the thermoformed and unthermoformed portions of the sheet to accommodate a variety of applications. One-piece articles of various shapes can be provided using different thermoforming dies. The one-piece articles of the sheet can be configured to have a sufficiently high modulus of elasticity to provide the functionality of the article, while adjacent portions of the sheet retain a lower modulus of elasticity for comfort, aesthetic appearance, or both.

[0150] The following terms provide exemplary constructions of wearable articles and methods for manufacturing the wearable articles disclosed herein.

[0151] Clause 1: A wearable article comprising: a nonwoven fabric sheet having a first portion and a second portion adjacent to the first portion; wherein the first portion has a first density and a first modulus of elasticity; wherein the second portion has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity; and wherein, as an integral article of the wearable article, the first portion is shaped differently from the second portion.

[0152] Clause 2: The wearable article as described in Clause 1, wherein the thickness of the first part is in the range of about 10% less than the thickness of the second part and about 10% greater than the thickness of the second part.

[0153] Clause 3: The wearable article as described in Clause 2, wherein the thickness of the first part is in the range of about 5% less than the thickness of the second part and about 5% greater than the thickness of the second part.

[0154] Clause 4: Wearable articles as described in Clause 3, wherein the thickness of the first part is in the range of about 1% less than the thickness of the second part and about 1% greater than the thickness of the second part.

[0155] Clause 5: A wearable article according to any one of Clauses 1-4, wherein the thickness of the first part is greater than the thickness of the second part by more than 10%.

[0156] Clause 6: A wearable article according to any one of Clauses 1-4, wherein the thickness of the second part is greater than the thickness of the first part by more than 10%.

[0157] Clause 7: A wearable article pursuant to any one of Clauses 1-6, wherein the first part defines a through-hole extending through a nonwoven fabric sheet.

[0158] Clause 8: The wearable article according to any one of Clauses 1-7 further comprises: a fabric component; wherein a nonwoven fabric piece is attached to the fabric component.

[0159] Clause 9: The wearable article according to any one of Clauses 1-8 further comprises: a fabric component; wherein the fibers of a second portion of the nonwoven fabric sheet are entangled with the fibers of the fabric component to secure the second portion to the fabric component.

[0160] Clause 10: A wearable article as described in Clause 9, wherein the fabric component is located below both the first part and the second part.

[0161] Clause 11: A wearable article according to any one of Clauses 1-10, wherein the one-piece article is either a concave or convex portion of a closure device.

[0162] Clause 12: Wearable articles as described in Clause 11, wherein the wearable article is a bag, strap or footwear, and the closure device is a buckle.

[0163] Clause 13: The wearable article as described in Clause 12, wherein: the wearable article is a bag, and the one-piece article is a convex portion of the clasp; the bag includes a flap and a base; and the convex portion of the clasp is disposed on a strip extending from the flap to a concave portion of the clasp disposed on the base, or disposed on a strip extending from the base to a concave portion of the clasp disposed on the flap.

[0164] Clause 14: The wearable article as described in Clause 12, wherein: the wearable article is a bag, and the integral article is a convex portion of the clasp; the bag includes an additional nonwoven fabric sheet having a first portion formed into an integral article, the integral article being a concave portion of the clasp, and the additional nonwoven fabric sheet having a second portion adjacent to the first portion; wherein the first portion of the additional nonwoven fabric sheet has a density greater than the density of the second portion of the additional nonwoven fabric sheet, and has a greater elastic modulus than the second portion of the additional nonwoven fabric sheet; and wherein the convex portion is shaped and sized to be releasably secured to the concave portion.

[0165] Clause 15: Wearable articles as described in Clause 1, wherein the wearable article is footwear, and the one-piece article is one of a closure, a heel stabilizer, or a housing for a power source or electrical device.

[0166] Clause 16: Wearable articles as described in Clause 1, wherein the wearable article is a bag, footwear, or clothing, and the integral article is a housing for a power source or electrical device.

[0167] Clause 17: The wearable article according to Clause 1, wherein: the first part comprises a plurality of stacked nonwoven fabric layers; and the plurality of stacked nonwoven fabric layers comprise a first outer layer, a second outer layer and at least one intermediate layer disposed between the first outer layer and the second outer layer.

[0168] Clause 18: A wearable article as described in Clause 17, wherein: at least one intermediate layer has a tapered edge; and the tapered edge is adjacent to the second portion.

[0169] Clause 19: A handbag comprising: a nonwoven fabric sheet having a first portion formed into a monolithic article which is part of a clasp, the nonwoven fabric sheet having a second portion adjacent to the first portion; wherein the first portion has a density greater than that of the second portion and has a modulus of elasticity greater than that of the second portion.

[0170] Clause 20: The handbag according to Clause 19, wherein the clasp portion is a concave portion of the clasp, and the handbag further comprises: a nonwoven fabric strip having a first portion formed as an integral article, the integral article being a convex portion of the clasp releasably secured to the concave portion; wherein the nonwoven fabric strip has a second portion adjacent to the first portion of the nonwoven fabric strip; and wherein the first portion of the nonwoven fabric strip has a density greater than the density of the second portion of the nonwoven fabric strip, and has an elastic modulus greater than the elastic modulus of the second portion of the nonwoven fabric strip.

[0171] Clause 21: A method of manufacturing a wearable article, the method comprising: thermoforming a first portion of a nonwoven fabric sheet into an integral article of wearable article, the nonwoven fabric sheet having an unthermoformed second portion adjacent to and shaped differently from the thermoformed first portion; wherein, after thermoforming, the first portion has a first density and a first modulus of elasticity; and wherein the unthermoformed second portion has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity.

[0172] Clause 22: The method according to Clause 21 further includes: stacking a plurality of nonwoven fabric layers to define the first portion prior to thermoforming the first portion; wherein the plurality of nonwoven fabric layers include a first outer layer, a second outer layer and at least one intermediate layer disposed between the first outer layer and the second outer layer; and wherein the at least one intermediate layer extends only in the first portion.

[0173] Clause 23: The method described in Clause 22, wherein the first outer layer and the second outer layer extend in both the first part and the second part.

[0174] Clause 24: According to the method of Clause 22, before stacking multiple nonwoven fabric layers, the nonwoven fabric sheet is divided only at a first portion to define a first outer layer and a second outer layer, the first outer layer and the second outer layer extending only in the first portion.

[0175] Clause 25: The method described in Clause 24 further includes inserting at least one intermediate layer between the first outer layer and the second outer layer.

[0176] Clause 26: The method according to Clause 25 further includes: taperting the edge of at least one intermediate layer before inserting at least one intermediate layer between the first outer layer and the second outer layer; and wherein inserting at least one intermediate layer between the first outer layer and the second outer layer causes the edge of at least one intermediate layer to be adjacent to the second portion.

[0177] Clause 27: The method according to Clause 24 further includes: hot-pressing the plurality of nonwoven fabric layers to each other after stacking the plurality of nonwoven fabric layers and before thermoforming the first portion.

[0178] Clause 28: The method according to any one of Clauses 21-27 further comprises: creating at least one through hole extending through the nonwoven fabric sheet in the first part.

[0179] Clause 29: The method according to Clause 28, wherein creating at least one through hole in the first part comprises laser cutting at least one through hole or punching at least one through hole.

[0180] Clause 30: The method according to any one of Clauses 21-29 further includes: after thermoforming the first part, trimming the outer edge of the first part.

[0181] Clause 31: The method according to Clause 30, wherein the outer edge of the first part is cut by laser cutting.

[0182] Clause 32: The method according to any one of Clauses 21-31, wherein the wearable article includes a fabric component, and the method further includes: after thermoforming the first portion, securing a nonwoven fabric sheet to the fabric component such that the nonwoven fabric sheet extends from the fabric component.

[0183] Clause 33: The method according to any one of Clauses 21-32, wherein the wearable article comprises a fabric component, and the method further comprises: after thermoforming the first portion, needle-punching the second portion onto the fabric component.

[0184] Clause 34: The method according to Clause 33, wherein, after the second portion is needled into the fabric part, a nonwoven fabric sheet is adjacent to the surface of the fabric part, wherein both the first portion and the second portion cover the fabric part at the surface, and wherein at least the second portion is in contact with the surface.

[0185] Clause 35: The method according to any one of Clauses 21-34, wherein thermoforming is performed in a thermoforming mold, and the method further comprises: heating at least a first portion of the nonwoven fabric sheet before thermoforming in the thermoforming mold; and placing the first portion of the nonwoven fabric sheet in the thermoforming mold after at least heating the first portion of the nonwoven fabric sheet, wherein the temperature of the mold surface of the thermoforming mold is lower than the temperature of the first portion of the nonwoven fabric sheet.

[0186] To aid and clarify the description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Furthermore, all references mentioned are incorporated herein in their entirety.

[0187] "Article of footwear," "footwear article of manufacture," and "footwear" can be considered as both machines and manufactured goods. Assembled, wearable footwear (such as shoes, sandals, boots, etc.) as well as the separate components of footwear before final assembly into wearable footwear (such as the midsole, outsole, upper components, etc.) are considered in this document in the singular or plural form and may be referred to as "(multiple) footwear articles."

[0188] The terms “A,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate at least one of the items present. Multiple such items may exist unless the context clearly indicates otherwise. Unless otherwise explicitly or clearly indicated in the context, all numerical values ​​(e.g., quantities or conditions) of parameters in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” indicates that the stated numerical value allows for some slight imprecision (slightly close to the accuracy of the value; approximately or moderately close to the value; almost close to the value). If the imprecision provided by “about” cannot be understood in this ordinary sense in the art unless otherwise otherwise, then “about” as used herein at least indicates a variation that may arise from ordinary methods of measuring and using such parameters. As used in the specification and appended claims, a value is considered “approximately” equal to the stated value if it is neither greater than the stated value by more than 5% nor less than the stated value by more than 5%. Furthermore, the disclosure of a range should be understood as specifically disclosing all values ​​within that range and further subdivisions of the range.

[0189] The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed where possible, and additional or alternative steps may be used. As used in this specification, the term “or” includes any and all combinations of the associated listed items. The term “any of” should be understood to include any possible combination of the referenced items, including “any one of” among the referenced items. The term “anyof” should be understood to include any possible combination of the claims referenced in the appended claims, including “any one of” among the referenced claims.

[0190] For consistency and convenience, directional adjectives may be used throughout this detailed description corresponding to the illustrated embodiments. Those skilled in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” and “bottom” may be used descriptively with respect to the drawings and are not intended to limit the scope of the invention as defined by the claims.

[0191] The term "longitudinal" refers to the direction that extends the length of a component. For example, the longitudinal direction of a shoe extends between the forefoot and heel areas. The terms "forward" or "anterior" refer to the general direction from the heel area toward the forefoot area, while the terms "rearward" or "posterior" refer to the opposite direction, i.e., from the forefoot area toward the heel area. In some cases, a component may be identified by a longitudinal axis and the forward and rearward longitudinal directions along that axis. The longitudinal direction or longitudinal axis may also be referred to as the front-rear direction or front-rear axis.

[0192] The term "transverse" refers to the direction that extends the width of a component. For example, the transverse direction of a shoe can extend between the outer and inner sides of the shoe. The transverse direction or transverse axis can also be referred to as the lateral direction or axis, or the medial-lateral direction or axis.

[0193] The term "vertical" refers to a direction that is generally perpendicular to both the horizontal and vertical directions. For example, in the case where the sole is placed flat on the ground, the vertical direction can extend upwards from the ground. It will be understood that each of these directional adjectives can be applied to various parts of the sole. The term "upward" or "upwards" refers to a vertical direction pointing towards the top of a part, which may include the instep, fastening area, and / or throat of the upper. The term "downward" or "downwards" refers to a vertical direction opposite to the upward direction, pointing towards the bottom of the part, and generally can point towards the bottom of the sole structure of footwear articles.

[0194] In relation to an object, the terms "interior," "inner side," and "proximal" refer to the parts of the object that are closer to the center of the object than its "exterior," "outer side," and "distal" parts when the object is assembled. Therefore, the terms interior and exterior can be understood as providing generally opposite terms to describe the relevant spatial location, as can interior and exterior, and proximal and distal.

[0195] Although various embodiments have been described, the description is intended to be illustrative and not restrictive, and it will be apparent to those skilled in the art that further embodiments and implementations are possible within the scope of these embodiments. Any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment, unless specifically limited thereto. Therefore, the embodiments are not limited except as provided in the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

[0196] While several modes of implementing many aspects of this teaching have been described in detail, those skilled in the art to which this teaching pertains will recognize various alternative aspects for practicing this teaching within the scope of the appended claims. It is intended that everything contained in the foregoing description or shown in the accompanying drawings be construed as encompassing the entire range of illustrative and exemplary alternative embodiments, and those skilled in the art will recognize that these alternative embodiments are structurally and / or functionally equivalent to what is contained, or otherwise become apparent based on what is contained, and are not limited to only those embodiments explicitly depicted and / or described.

Claims

1. A method for manufacturing a wearable article, the method comprising: A first portion of a nonwoven fabric sheet is thermoformed into a one-piece article of the wearable article, the nonwoven fabric sheet having a second portion that is not thermoformed, the second portion being adjacent to the thermoformed first portion and shaped differently from the first portion; Prior to thermoforming the first portion, multiple layers of nonwoven fabric are stacked to define the first portion; The plurality of nonwoven fabric layers include a first outer layer, a second outer layer, and at least one intermediate layer disposed between the first outer layer and the second outer layer; Wherein, the at least one intermediate layer extends only in the first part; The first part has a first density and a first elastic modulus after thermoforming; The unthermoformed second portion has a second density lower than the first density and a second elastic modulus lower than the first elastic modulus; and The thermoforming process is performed in a thermoforming mold, and the method further includes: Before thermoforming in the thermoforming mold, at least the first portion of the nonwoven fabric sheet is heated; and After at least heating the first portion of the nonwoven fabric sheet, the first portion of the nonwoven fabric sheet is placed in the thermoforming mold, wherein the temperature of the mold surface of the thermoforming mold is lower than the temperature of the first portion of the nonwoven fabric sheet.

2. The method of claim 1, wherein before stacking the plurality of nonwoven fabric layers, the nonwoven fabric sheet is divided only at the first portion to define the first outer layer and the second outer layer, the first outer layer and the second outer layer extending only in the first portion.

3. The method of claim 2, further comprising inserting the at least one intermediate layer between the first outer layer and the second outer layer.

4. The method according to claim 3, further comprising: Before inserting the at least one intermediate layer between the first outer layer and the second outer layer, the edges of the at least one intermediate layer are tapered.

5. The method according to claim 4, wherein, The at least one intermediate layer is inserted between the first outer layer and the second outer layer such that the edge of the at least one intermediate layer is adjacent to the second portion.

6. The method according to claim 2, further comprising: After stacking the plurality of nonwoven fabric layers and before thermoforming the first portion, the plurality of nonwoven fabric layers are hot-pressed to each other.

7. The method according to claim 1, wherein, The wearable article includes fabric components, and the method further includes: After the first part is thermoformed, the second part is needled into the fabric component.

8. The method according to claim 1, wherein, The first outer layer and the second outer layer extend in both the first portion and the second portion.

9. The method according to claim 1, further comprising: At least one through-hole is created in the first portion, extending through the nonwoven fabric sheet.

10. The method according to claim 9, wherein, Creating at least one through hole in the first part includes laser cutting at least one through hole or punching at least one through hole.

11. The method according to claim 1, further comprising: After thermoforming the first part, the outer edges of the first part are trimmed.

12. The method according to claim 11, wherein, The outer edge of the first part is cut using laser cutting.

13. The method according to claim 1, wherein, The wearable article includes fabric components, and the method further includes: After thermoforming the first part, the nonwoven fabric sheet is secured to the fabric component such that the nonwoven fabric sheet extends from the fabric component.

14. The method of claim 13, wherein: The nonwoven fabric sheet is secured to the fabric component by needle-punching the second portion of the fabric component; and After the second portion is needled into the fabric component, the nonwoven fabric sheet is adjacent to the surface of the fabric component, wherein both the first portion and the second portion cover the fabric component at the surface, and wherein at least the second portion is in contact with the surface.

15. A method of manufacturing a wearable article, the method comprising: A first portion of a nonwoven fabric sheet is thermoformed into a one-piece article of the wearable article, the nonwoven fabric sheet having a second portion that is not thermoformed, the second portion being adjacent to the thermoformed first portion and shaped differently from the first portion; The first portion, after thermoforming, has a first density and a first elastic modulus; and The second portion that has not been thermoformed has a second density that is less than the first density and a second elastic modulus that is less than the first elastic modulus; Thermoforming is performed in a thermoforming mold, and the method further includes: Before thermoforming in the thermoforming mold, at least the first portion of the nonwoven fabric sheet is heated; and After at least heating the first portion of the nonwoven fabric sheet, the first portion of the nonwoven fabric sheet is placed in the thermoforming mold, wherein the temperature of the mold surface of the thermoforming mold is lower than the temperature of the first portion of the nonwoven fabric sheet.

16. The method according to claim 15, wherein, The wearable article includes fabric components, and the method further includes: After the first part is thermoformed, the second part is needled into the fabric component.

17. A method of manufacturing a wearable article, the method comprising: At least the first portion of the nonwoven fabric sheet is heated; After at least heating the first portion of the nonwoven fabric sheet, only the first portion of the nonwoven fabric sheet is placed in a thermoforming mold, wherein the temperature of the mold surface of the thermoforming mold is lower than the temperature of the first portion of the nonwoven fabric sheet; and In the thermoforming mold, the first portion of the nonwoven fabric sheet is thermoformed into a one-piece article of the wearable article, the nonwoven fabric sheet having a second portion that is not thermoformed, the second portion being adjacent to the thermoformed first portion and formed differently from the first portion; The first portion, after thermoforming, has a first density and a first elastic modulus; and The second portion that has not been thermoformed has a second density that is less than the first density and a second elastic modulus that is less than the first elastic modulus.

18. The method of claim 17, further comprising: Prior to thermoforming the first portion, a plurality of nonwoven fabric layers are stacked to define the first portion; wherein the plurality of nonwoven fabric layers include a first outer layer, a second outer layer, and at least one intermediate layer disposed between the first outer layer and the second outer layer.

19. The method according to claim 18, wherein, The at least one intermediate layer extends only within the first portion.

20. The method of claim 17, wherein, The wearable article includes fabric components, and the method further includes: After thermoforming the first part, the nonwoven fabric sheet is secured to the fabric component such that the nonwoven fabric sheet extends from the fabric component.

21. The method according to claim 20, wherein, The nonwoven fabric sheet is secured to the fabric component by needle-punching the second portion into the fabric component.

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