Knitted components and articles for improved ball control and durability

Abstract

The invention relates to knitted components and articles for improved ball control and durability. A knitted component having a surface including a first region and a second region, the first and second regions having different relative coefficients of friction and forming an alternating pattern. The first area of the first surface accounts for 40-80% of the total surface area of the first surface. The alternating pattern may be in the form of a concentric shape. The alternating pattern may have linear and curvilinear boundaries between the first and second regions. The first region may be formed from a first yarn having a core and a coating. The coating at least partially surrounds the core.

Description

[0001] This application is a divisional application of an application with an application date of September 15, 2021, application number 202180102393.5, and invention name “Knitted components and articles for improving ball control and durability”. Field of the Invention

[0002] The present disclosure relates to knitted textiles, components of articles, and articles such as articles of footwear, and methods of making the same. Background of the Invention

[0003] Various articles including footwear are formed by textiles, and textiles are usually formed by weaving or interweaving (e.g., knitting) one or more than one yarn. In particular, the upper for footwear articles can be formed by knitted textiles. In order to increase durability and / or water resistance, non-textile parts can be added and fixed (e.g., glued, sewed) to textiles. For example, cross-linked polyurethane can be used as a durable cover layer, synthetic leather textile or laminated film layer. However, the addition of any additional layer or even film can reduce the ability of the article to fit the wearer and provide proprioceptive feedback, which may be particularly important for the article in some sports activities. For example, in the footwear articles for football (football) (also referred to as English football (soccer) in other geographic areas), it may be important for the wearer to be able to feel the ball through textiles and have a certain level of adhesion friction or grip for ball control and dribbling. At the same time, excessive grip in footwear may interfere with the ability of the wearer to perform quick touch and ball control. Summary of the invention

[0004] This disclosure provides the following items: 1. A knitted component having a first surface and an opposing second surface, the first surface of the knitted component comprising: a first area having a first coefficient of friction, the first area comprising a first yarn having a core and a coating, the coating at least partially surrounding the core; and a second area having a second coefficient of friction different from the first coefficient of friction, the second area comprising a second yarn, wherein the first area forms an alternating pattern with the second area such that the first area occupies 40% to 80% of the total surface area of ​​the first surface.

[0005] 2. A knitted component according to item 1, wherein the coating comprises a thermoplastic elastomer.

[0006] 3. A knitted component according to item 1, wherein the first area of ​​the first region comprises a thermoformed network of interwoven yarns comprising the core and the coating, wherein the coating consolidates the thermoformed network of interwoven yarns by surrounding at least a portion of the core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns.

[0007] 4. A knitted component according to item 1, wherein the first coefficient of friction is greater than the second coefficient of friction.

[0008] 5. A knitted component according to item 1, wherein the first friction coefficient and the second friction coefficient are dynamic friction coefficients.

[0009] 6. A knitted component according to item 1, wherein at least a portion of the second yarn does not include the coating.

[0010] 7. A knitted component according to item 1, wherein the alternating pattern is a concentric pattern.

[0011] 8. A knitted component according to item 1, wherein a first area in the first area and a second area in the second area are continuous in the alternating pattern, and wherein a boundary between the first area and the second area is curved.

[0012] 9. A knitted component according to item 1, wherein a first area in the first area and a second area in the second area are continuous in the alternating pattern, and wherein a boundary between the first area and the second area is linear.

[0013] 10. A knitted component according to item 1, wherein the first area of ​​the first area and the second area of ​​the second area are continuous in the alternating pattern, and wherein the first raised portion of the first surface extends continuously across the first area and the second area.

[0014] 11. A knitted upper for an article of footwear having an outward-facing surface portion and an opposing inward-facing surface portion, the outward-facing surface comprising: a first area having a first coefficient of friction, the first area comprising a first yarn; and a second area having a second coefficient of friction different from the first coefficient of friction, the second area comprising a second yarn, wherein the first area and the second area form a first alternating pattern in a first zone of the outward-facing surface portion, such that the first area accounts for 40% to 80% of the total surface area of ​​the outward-facing surface portion in the first zone.

[0015] 12. A knitted footwear article upper according to item 11, wherein the first area and the second area form a second alternating pattern in a second zone of the outward-facing surface portion, such that the first area accounts for 40% to 80% of the total surface area of ​​the outward-facing surface portion in the second zone.

[0016] 13. The knitted footwear upper of item 12, wherein the first area is on a medial portion of the knitted footwear upper and the second area is on a lateral portion of the knitted footwear upper.

[0017] 14. A knitted footwear article upper according to item 13, wherein the first alternating pattern is a concentric pattern.

[0018] 15. A knitted footwear article upper according to item 13, wherein the first alternating pattern includes at least one of a curvilinear boundary between a first area in the first area and a second area in the second area or a linear boundary between the first area in the first area and the second area in the second area.

[0019] 16. A knitted footwear article upper according to item 11, wherein the first area of ​​the first area comprises a thermoformed network of interwoven yarns each having a core, such that the thermoplastic elastomer consolidates the interwoven yarns by surrounding at least a portion of the core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns.

[0020] 17. The knitted article of footwear upper of item 11, wherein the first zone extends across at least a portion of a forefoot region of the knitted article of footwear upper.

[0021] 18. The knitted footwear upper of item 11, wherein the first zone extends across at least a portion of a forefoot region of the knitted footwear upper and at least one of a medial side and a lateral side of the knitted footwear upper.

[0022] 19. A method for manufacturing a knitted component having a first surface and an opposing second surface, the method comprising: knitting a first yarn and a second yarn into the knitted component; and thermoforming the first surface of the knitted component, wherein the first surface of the knitted component comprises: a first region having a first coefficient of friction, the first region comprising a thermoformed network of interwoven yarns each having a core, such that a thermoplastic elastomer consolidates the interwoven yarns by surrounding at least a portion of each core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns, and a second region having a second coefficient of friction different from the first coefficient of friction, the second region comprising a second yarn, wherein the first region forms an alternating pattern with the second region such that the first region occupies 40% to 80% of the total surface area of ​​the first surface.

[0023] 20. The method of item 19, wherein thermoforming the first surface further comprises molding the first surface to have one or more raised portions of the first surface, the one or more raised portions extending across more than one first region and more than one second region. BRIEF DESCRIPTION OF THE DRAWINGS

[0024]

[0011] Further aspects of the present disclosure will be readily understood when the detailed description described below is read in conjunction with the accompanying drawings.

[0025] Figure 1A is a side perspective view of an article of footwear according to aspects herein.

[0026] Figure 1B According to the various aspects of this article Figure 1A A medial perspective view of an article of footwear.

[0027] Figure 1C is according to aspects of the present invention with alternative patterns Figure 1A A medial perspective view of an article of footwear.

[0028] Figure 2A is a schematic diagram of three interconnected rows of stitches according to aspects herein, wherein a middle row of stitches is formed from a first yarn and outer rows of stitches are formed from a second yarn.

[0029] Figure 2B According to the various aspects of this article Figure 2A Schematic diagram of the interconnected coil rows of coils after being exposed to a thermoforming process.

[0030] Figure 3A-3C Depicted are exemplary perspective views of various protrusions and ridges molded into an exterior-facing surface of a knitted component according to aspects herein.

[0031] Figure 4 is a medial perspective view of another article of footwear according to aspects herein.

[0032] Figure 5A is a lateral perspective view of yet another alternative article of footwear according to aspects herein.

[0033] Figure 5B According to the various aspects of this article Figure 5A An inside perspective view of an item.

[0034] Figure 6 A flow chart of a method of forming a knitted component according to the present disclosure is depicted. DETAILED DESCRIPTION OF THE INVENTION

[0035] The subject matter of the present invention is specifically described herein to meet statutory requirements. However, the description itself is not intended to limit the scope of the present disclosure. On the contrary, the inventors have contemplated that the claimed or disclosed subject matter may also be embodied in other ways, in conjunction with other existing or future technologies, to include different steps or combinations of steps similar to the steps described in this document. In addition, although the terms "step" and / or "box" may be used herein to identify different elements of the method employed, unless and in addition to the order of the individual steps being explicitly stated, these terms should not be interpreted as implying any particular order among or between the various steps disclosed herein.

[0036] Various articles including footwear are formed by textiles, which are usually formed by interweaving (e.g., knitting) one or more than one yarns. In particular, the uppers for footwear articles can be formed by knitted textiles. In order to increase durability and / or water resistance, non-textile components can be added and fixed (e.g., adhered, sewed) to the textile. For example, polyurethane (e.g., cross-linked polyurethane), synthetic leather textiles, or laminated film layers can be used as durable covering layers. However, the addition of any additional layer or even film can reduce the ability of the article to fit the wearer and provide proprioceptive feedback, which may be particularly important for articles in certain sports activities. For example, in footwear articles for football, it may be important for the wearer to be able to feel the ball through the textile and have a certain level of adhesion or grip for ball control and dribbling. At the same time, excessive grip in the footwear may interfere with the wearer's ability to quickly touch the ball and control the ball. In addition, since different parts of the footwear can be used for different types of sports, it may be necessary to have textiles for the uppers with different characteristics (e.g., patterns) in different parts.

[0037] As will be discussed in detail below, grip or adhesion friction for object (e.g., ball) control is achieved by alternating patterns of first and second regions with varying grip. These alternating patterns help fine-tune ball control so that a desired amount of grip is obtained. For example, a textile described herein, such as a knitted component or a footwear upper, may include an alternating pattern of a first region with a first coefficient of friction and a second region with a second coefficient of friction, wherein the second coefficient of friction is different from or lower than the first coefficient of friction. This alternation between the first region and the second region on the surface of the footwear upper achieves an interaction between the footwear upper and an object such as a ball, which interaction can enhance the sense of control of the wearer of the footwear upper. In addition, it is expected that the surface of the footwear upper with the alternating pattern of the first region and the second region effectively achieves a potentially enhanced sense of control for the wearer of the footwear upper, wherein the first region accounts for 40% to 80% of the total surface area of ​​the outward-facing surface of a portion of the footwear upper (e.g., a ball contact area).

[0038] Determined that the thermoplastic elastomer that can be incorporated into polymer composition, this polymer composition provides a certain level of wear resistance, adhesion friction (it can also be referred to as grip) or both, make them suitable for needing the article of wear resistance or adhesion friction, such as clothing article, footwear article and sports equipment article.In many cases, the wear resistance, adhesion friction or both levels provided by these polymer compositions are equal to or better than the standard vulcanized rubber composition for making footwear, clothing and sports equipment.Different from vulcanized rubber, due to the thermoplastic properties of these polymer compositions, and their properties in solid state and molten state, can easily form them into the coated yarn with the suitable properties of knitting or braiding equipment for industrial scale.These properties make yarn can be easily incorporated in multiple articles, and described articles comprise and use conventional manufacturing process such as knitting and braiding and for making the textile of the industrial scale process of non-woven textile. And, unlike vulcanized rubber, these textiles and articles into which these textiles are incorporated can then be thermoformed in such a way that the polymer composition of the coated yarns reflows and creates a wear-resistant surface or high grip surface on the textile or article without damaging other components of the textile or article, such as, for example, other yarns, other textiles, foams, molded resin parts, etc.

[0039] At a high level, various aspects of the present disclosure relate to incorporating these thermoplastic elastomers into textiles in articles to maximize certain desired functions such as ball control and durability. Specifically, a knitted component may include a first yarn having a first core yarn (also referred to herein as a "core") and a first coating (also referred to herein as a "coating") comprising a thermoplastic elastomer. The thermoplastic composition includes one or more thermoplastic elastomers at least partially surrounding the first core yarn. The knitted component also includes a second yarn different from the first yarn. On a first surface of the knitted component (e.g., an outwardly facing surface of an article formed with the knitted component), a first region is formed by the first yarn, while a second region is formed by the second yarn. Due at least in part to the materials of the first yarn and the second yarn, the first region and the second region have different coefficients of friction relative to ordinary materials. Specifically, the first region may have a higher coefficient of friction than the second region to provide increased grip in the first region relative to the second region. For example, the coefficient of friction between the first region and the surface of the ball may be higher than the coefficient of friction between the second region and the same surface of the ball. Additionally, the first and second areas may form an alternating pattern wherein the first areas constitute 40% to 80% of the total surface area of ​​a first surface (e.g., a ball contacting portion of a footwear upper), which may provide improved levels of traction on the knitted component.

[0040] When the knitted component is integrated into the upper of a footwear article such as a soccer shoe, the alternating pattern of the first area and the second area can improve ball control and dribbling and provide wear resistance. In some aspects, the alternating pattern includes a pattern of concentric shapes on the inner side of the upper (e.g., a curved boundary between the first area and the second area). In some aspects, the first area and the second area can form different alternating stripe patterns (e.g., a linear boundary between the first area and the second area). In an example, the stripes generally extend from the bite line to the shoe throat such as on the outer side of the upper. Although the concentric shape pattern of the first area and the second area on the inner side may be desirable for passing, catching and kicking, the more linear pattern on the outer side may be desirable for dragging or lightly pushing the ball.

[0041] In addition, in some aspects, the knitted component can be thermoformed so that the first coating flows and occupies at least a portion of the space between the rows of coils of the first yarn or the rows of coils of the first core yarn. This arrangement can advantageously integrate 360-degree ball control directly into the knitted component without the need for a laminated surface layer, streamlining the surface into a single functional layer. When the textile is used for the upper of a shoe or football boot, this single functional layer can help the wearer get closer to the ball by removing layers therefrom, which thereby increases proprioceptive feedback to the wearer and further improves ball control. In addition, not including a laminated surface layer improves manufacturing efficiency by reducing post-knitting processes.

[0042] Aspects of the present disclosure may also include a method for manufacturing a knitted component. The method may include knitting a knitted component with a first yarn knitted integrally with a second yarn. As described above, the first yarn may include a first core yarn and a first coating, the first coating at least partially surrounding the first core yarn and including a polymer composition comprising one or more thermoplastic elastomers, the coating at least partially surrounding the first core yarn. In addition, within the knitted component, the first yarn forms a first area on a first surface of the knitted component, and the second yarn forms a second area on the first surface of the knitted component, wherein the first area has a different coefficient of friction from the second area. In addition, as described above, the first area may form an alternating pattern with the second area.

[0043] Aspects also include methods for manufacturing knitted components for uppers. As described above, a knitted component having a first yarn integrally knitted with a second yarn can be thermoformed so that a first coating can be reflowed and resolidified to produce a thermoformed network of interwoven yarns. The thermoformed network includes a first core yarn and a first coating that surrounds at least a portion of the first core yarn and occupies space between at least some portions of the yarns in the thermoformed network. The method may also include molding a first surface to produce a raised portion of the thermoformed network, wherein the raised portion may form a concentric pattern within the knitted component. Additional aspects of the present disclosure may include methods for manufacturing an article of footwear by attaching an upper including a thermoformed knitted component to a sole structure.

[0044] As discussed above, some aspects relate to one or more knitted components or thermoformed knitted components. In some aspects, such knitted components or thermoformed knitted components form at least a portion of sports equipment articles or articles of wear (including footwear articles). In illustrative examples, aspects relate to the upper of footwear articles formed by knitted components. Footwear articles traditionally include an upper and a sole structure. The upper is fixed to the sole structure and forms a cavity for comfortably and securely accommodating foot in the footwear article. As used herein, the term "upper" refers to the footwear component that extends along the medial and lateral sides of the foot and around the heel region of the foot on the instep area and toe area of ​​the foot to form a cavity for accommodating the foot of the wearer. The illustrative, non-limiting examples of the upper can include the uppers that are incorporated into basketball shoes, bicycle shoes, cross-training shoes, global football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes and walking shoes. Moreover, in other aspects, the uppers can also be incorporated into non-athletic shoes (such as dress shoes, loafers, and sandals).Thus, the concepts disclosed with respect to articles of footwear are applicable to a variety of footwear types.

[0045] Positional terms, such as top, bottom, front, side, rear, upper, lower, lateral, medial, right, left, inwardly and outwardly facing, and the like, used when describing the upper are used relative to the upper as it is intended to be worn when a wearer stands upright with the wearer's foot in the foot-receiving cavity and the wearer's ankle or leg extending through the ankle opening. However, it should be understood that the use of positional terms does not depend on the actual presence of a person for purposes of explanation.

[0046] The term "knitted component" refers to a textile piece formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of interlocking loops defining rows and wales. As used herein, the term "row" refers to a primarily horizontal row of knitted loops (in an upright textile being a knitted fabric) produced by adjacent needles during the same knitting cycle. A row of loops may include one or more weave types, such as knitted weave, held weave, float weave, tuck weave, transfer weave, rib weave, etc., as known in the art of knitting. As used herein, the term "knitted weave" refers to the basic weave type in which the yarn is cleared from the needle after the loop of the yarn is pulled from the back to the front of the textile by the previous weave. As used herein, the term "wale" is a primarily vertical column of interlocking or interwoven knitted loops, typically produced by the same needle in consecutive (but not necessarily all) rows or knitting cycles. The knitted components described herein may include weft knitted components or warp knitted components.

[0047] As used herein, the term "integrally knitted" may mean a knitted textile in which yarns from one or more knitted courses in one area are interwoven with one or more knitted courses in another area. Interweaving may be by simple knitting, tucking, holding, floating or floating stitches, etc. In this way, areas knitted integrally together have seamless transitions.

[0048] As used herein, the term "double knitted construction" refers to a textile or textile portion knitted on a machine having two sets of needles in two needle beds or needle cylinders. Some aspects of this document contemplate a machine including a weft knitting (knitting flat) machine. When describing a knitting flat machine, the term "needle bed" is generally used. However, it should be understood that aspects of this document may also relate to a warp knitted component. In order to describe in a different way, the term double knitted construction means a textile having a front row of coils formed on a first needle bed and a rear row of coils formed on a second needle bed. The front row of the textile of the double knitted construction is a row of coils of the interwoven tissue forming the front layer of the textile, and the rear row of coils is a row of coils of the interwoven tissue forming the rear layer of the textile, so that the front layer and the rear layer of the textile can be formed substantially simultaneously. As used herein, the term "front layer" refers to a textile layer configured to face the outside when an article (such as a shoe upper) incorporating the textile is worn, and the term "rear layer" refers to a textile layer configured to face the skin surface of the wearer when the article is worn.

[0049] Additionally, various measurements are provided herein. Unless otherwise indicated, the term "about" or "substantially" with respect to a measurement means within ±10% of the indicated value.

[0050] Turning now to the drawings, in particular Figure 1A and Figure 1B , article of footwear 100 is depicted as an exemplary article of wear. Figure 1A and Figure 1B Article of footwear 100 is depicted, but it should be understood that the present disclosure also contemplates other articles of wear, including but not limited to apparel (e.g., shirts, jerseys, pants, shorts, gloves, eyeglasses, socks, hats, caps, jackets, underwear) and containers (e.g., backpacks, bags). Figure 1A and Figure 1B The article of footwear 100 may generally include a ground-facing outsole region 110, an ankle collar region 112, a lateral midfoot region 114a, a medial midfoot region 114b, a forefoot region 116, and a heel region 118. In addition, the article of footwear 100 may include more than one eyelet 120, a tongue 124, and a throat region 126. Figure 1A and Figure 1B As shown in FIG. 1 , article of footwear 100 is intended for use with a right foot; however, it should be understood that the following discussion may also apply to a mirror image of article of footwear 100 intended for use with a left foot.

[0051] In some aspects, the article of footwear 100 includes a sole structure 104 and an upper 102. The sole structure 104 is fixed to the upper 102 and extends between the foot and the ground when the article of footwear 100 is worn. In some aspects, the sole 104 includes a midsole 107 and an outsole 109. The midsole 107 can be fixed to the lower area of ​​the upper 102, such as a strobel (not shown), and can include a cushioning element that contains an elastic material, such as a polymer foam or another suitable material. In other configurations, the cushioning element of the midsole 107 can be incorporated into a fluid-filled chamber, a plate, a regulator and / or other elements that further attenuate force, improve stability or affect the movement of the foot. The outsole 109 can be fixed to the lower surface of the midsole 107, and can include a wear-resistant elastomeric material, such as a natural rubber material or a synthetic rubber material. Outsole 109 may be textured to impart traction, or may include one or more traction elements. The traction elements may be separate elements secured to outsole 109, or may be integrally formed with outsole 109.

[0052] The upper 102 may be formed of various elements (e.g., lace stays, tongue collar, medial side, lateral side, vamp, toe cap, heel counter) that combine to provide a structure for securely and comfortably accommodating the foot. Although the configuration of the upper 102 may vary significantly, the various elements generally define a cavity within the upper 102 for accommodating the foot and securing the foot relative to the sole structure 104. The surface of the cavity within the upper 102 is shaped to accommodate the foot and may extend over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of ​​the foot.

[0053] At least a portion of upper 102 may be formed from at least one knitted component 130, such as by a weft knitting process or a warp knitting process on a flat knitting machine. Knitted component 130 may be formed as a single, unitary, one-piece element during a knitting process such as weft knitting, warp knitting, or any other suitable knitting process. Figure 1A and Figure 1B In the depicted example, knitted component 130 forms an outer sheath of upper 102, forming at least an outer surface of lateral midfoot region 114a, medial midfoot region 114b, forefoot region 116, and at least a portion of throat region 126 of upper 102. In some aspects, knitted component 130 also forms an inner surface of upper 102.

[0054] The upper 102 may also include one or more additional components, such as a textile component 140, which may be knitted, woven, non-woven, or another type of textile. The textile component 140 may form at least a portion of the heel region 118, the ankle collar region 112, and the tongue 124. The textile component 140 may be a single textile component, or may be formed by a plurality of textile components fixed together. In addition, in aspects, the textile component 140 may be integrally knitted with the knitted component 130. Alternatively, the textile component 140 may be fixed to the knitted component 130 via at least one of stitching, bonding, etc.

[0055] Knitted component 130 can include one or more different types of yarns for imparting different functions. For example, knitted component 130 can include a first yarn and a second yarn. The first yarn (also referred to herein as a first coated yarn or coated yarn) includes a first core yarn and a first coating that provides a first set of properties for the first yarn. The second yarn can have a material composition different from that of the first yarn. For example, the second yarn can include at least a coating different from the first coating of the first yarn, so that the second yarn exhibits properties different from those of the first yarn.

[0056] In addition, in the first yarn, the first core yarn and the first coating can have different material compositions to provide different properties. For example, as described herein, the first coating can include a low processing temperature polymer composition, while the first core yarn can include a high processing temperature polymer composition, so that the first coating can melt or deform at a temperature that keeps the core yarn intact. In one aspect, the deformation temperature of the polymer composition of the core yarn of the first yarn is at least 20 degrees Celsius higher than the melting temperature of the polymer composition of the first coating (such as a polymer composition including a thermoplastic composition). This allows the core yarn to be coated with the coating when the coating is in a molten state.

[0057] The first core yarn of the first yarn may include a monofilament yarn or a multifilament yarn, such as a commercially available polyester or polyamide yarn, having properties (such as denier and tenacity) sufficient to enable the yarn to be handled by industrial-scale knitting equipment. In addition, the yarn may be based on natural or artificial fibers, including polyester, high-tenacity polyester, polyamide yarn, metallic yarn, drawn yarn, carbon yarn, glass yarn, polyethylene yarn or polyolefin yarn, bicomponent yarn, PTFE yarn, ultra-high molecular weight polyethylene (UHMWPE) yarn, liquid crystal polymer yarn, specialty decorative yarn or reflective yarn or a multicomponent yarn comprising one or more of the yarns. In an exemplary aspect, the core yarn comprises a thermoplastic material comprising polyester.

[0058] In various aspects, the first core yarn can be coated by any method known in the art. In one aspect, the polymer composition for the first coating disclosed herein is suitable for manufacturing by pultrusion of the yarn and / or pulling through a bath of liquid polymer material. In another aspect, regardless of the coating process, sufficient coating material is provided on the first yarn so that when knitted alone or knitted with one or more other yarns in a variety of configurations and then thermoformed and allowed to reflow and resolidify, depending on the arrangement of the first yarn within the knitted structure, the coating material (e.g., a polymer composition comprising a thermoplastic elastomer) forms a structure with a sufficient concentration of coating material on one or more surfaces and / or within the first core yarn.

[0059] The first coating of the first yarn comprises a polymer composition, and the polymer composition comprises a thermoplastic composition comprising a thermoplastic elastomer. Although the polymer composition as a thermoplastic elastomer composition can be extruded and directly formed into fiber, filament, yarn or film by the polymer composition, due to its elastomeric properties, the polymer composition of these forms will have a high level of stretching and thermal shrinkage. This means that fiber, filament, yarn or film may tend to stretch around a machine guide (machine guide) rather than slide through them, and may tend to the temperature shrinkage usually encountered in knitting and weaving equipment on an industrial scale. However, by applying the polymer composition as a coating to a core yarn suitable for being mechanically manipulated, the resulting coated first yarn keeps the toughness and tensile resistance of the core yarn, while also providing the excellent adhesion friction and wear resistance provided by the polymer composition of the coating due to its elastomeric properties. For example, it has been discovered that a 150 denier core yarn having a tensile strength at break of at least 1 kilogram-force and a strain at break of less than 20% and a heat shrinkage of less than 20% can be coated with a polymer composition up to a nominal average outer diameter of about 1.0 millimeter and still retain its ability to be knitted or inlaid using commercial flat-knitting equipment. Due to the ability to use such yarns on industrial-scale equipment, this first yarn may also allow new manufacturing methods that will allow polymer compositions to be differently arranged in textiles and articles containing textiles with a higher level of specificity in both location and amount compared to conventional manufacturing processes.

[0060] In addition, when the melting temperature of the polymer composition is sufficiently lower than the deformation temperature of the first core yarn, the thermoplastic properties of the polymer composition make it possible to melt the composition and use it to cover the first core yarn, and then thermoform the knitted component 130 to produce a thermoformed network, which includes both the first core yarn and the refluxed and resolidified polymer composition that consolidates the first core yarn. In one aspect, the thermoplastic elastomer of the polymer composition of the coating has a glass transition temperature lower than minus 20 degrees Celsius, which allows the thermoplastic elastomer present in the polymer composition to be in their "rubber" state, even when the knitted component 130 is used in a cold environment. In another aspect, the melting temperature of the polymer composition of the coating is at least 100 degrees Celsius, which can ensure that the polymer composition will not melt when the knitted component 130 is transported or stored under hot conditions. In another aspect, the melting temperature of the polymer composition of the coating is at least 130 degrees Celsius, which ensures that the polymer composition will not melt when the knitted component 130 undergoes conditions such as steam processes that are often encountered during the manufacture of textiles in footwear articles, clothing articles, or sports equipment articles. In another aspect, the melting temperature of the polymer composition of the coating is less than 170 degrees Celsius, which ensures that knitted component 130 can be thermoformed at a temperature that does not negatively affect other textiles or components that may form part of upper 102. In another aspect, the melting enthalpy of the thermoplastic elastomer of the polymer composition of the coating can be less than about 30 joules / gram or 25 joules / gram, which means that, during the thermoforming process, less heat and a shorter heating time are required to fully melt the polymer composition and achieve good flow of the molten polymer composition to better consolidate the network of yarns in knitted component 130. In another aspect, the recrystallization temperature of the thermoplastic elastomer of the polymer composition of the coating can be above 60 degrees Celsius or above 95 degrees Celsius, which can promote rapid resolidification of the polymer composition after thermoforming, which can reduce the amount of time required to cool the textile after thermoforming, and can avoid the need to provide active cooling of the textile, thereby reducing cycle time and reducing energy consumption.

[0061] Because the knitted component 130 includes a second yarn in addition to the first yarn (i.e., the covered yarn), the thermoformed network of yarns (i.e., the core yarn from the first yarn and the second yarn) is consolidated by the reflowed and resolidified polymer composition. The presence of the reflowed and resolidified polymer composition can play one or more roles in the thermoformed textile, such as controlling the level of stretch throughout the knitted component 130 or only within a region thereof, forming a surface layer with high wear resistance and / or adhesion friction across the entire surface of the knitted component 130 or only within a region thereof, improving the water resistance of the entire surface of the knitted component 130 or only within a region thereof, or bonding all or only a region of the knitted component 130 to a substrate.

[0062] The use of the first yarn in the knitted component 130 can also reduce the number of different materials required to form the article. The coating of the first yarn can form a surface layer on the surface of the knitted component 130 when thermoforming. Alternatively or additionally, the coating of the first yarn can act as an adhesive when thermoforming, or bond the yarns in the knitted component 130 together, or bond other elements to the surface of the knitted component 130. The use of the thermoformed knitted component 130 described herein can replace one or more of the independent elements conventionally added to increase wear resistance or produce adhesion friction, reduce waste and simplify the manufacturing process, and improve the recyclability of the article. In addition, these properties are produced in the knitted structure of the knitted component 130, rather than as an additional layer, which helps the knitted component 130 to form the shape of the wearer's foot, and can achieve more proprioceptive feedback when, for example, dribbling a football. It should be noted that other balls can be used with the footwear article described herein without departing from the scope of the present invention.

[0063] The thermoformed network of the thermoformed textile may form an exterior-facing surface of an upper, such as Figure 1A and Figure 1B The first surface 105 of the knitted component 130 in the embodiment of the present invention is a knitted fabric. Unexpectedly, the thermoformed network formed by thermoforming the textile has excellent ball contact properties because the properties of the thermoformed network can be equal to or better than the properties of kangaroo leather in terms of the spin rate imparted to the ball by the upper when the ball is kicked. For example, it has been found that the use of a polymer composition having a durometer hardness (Shore A) of about 65 to about 85 results in an upper having an improved ball spin rate. It has also been found that the upper comprising the textile described herein is equal to or better than a synthetic leather or knitted upper coated with a surface layer in terms of traction friction in wet and dry conditions.

[0064] As described herein, the second yarn can be integrally knitted with the first yarn to form a thermoformed network in at least some areas of the knitted component 130. Specifically, as Figure 1A and Figure 1B As shown, the knitted component 130 may have a first surface 105 that forms an exterior-facing surface of the upper 102. The knitted component 130 may also include an opposing second surface that may form an interior-facing surface of the upper 102 and may be provided at a position adjacent to the upper 102. Figure 1A and Figure 1B The first surface 105 may include more than one first region and more than one second region (e.g., the first region 108 and the second region 106). Figure 1A and Figure 1BOf these regions, the first region 108 is depicted as having a lighter shade than the second region 106. However, it should be understood that the shading should not necessarily limit the relative coloring of these regions 108 and 106.

[0065] The first area 108 on the first surface 105 includes a first yarn, and the second area 106 on the first surface 105 includes a second yarn. In various aspects, the second area 106 does not include the first yarn at all or substantially. In some aspects, the first area 108 does not include the second yarn at all or substantially. In other aspects, the first area 108 can have a trace amount of the first yarn and / or the second area 106 can have a trace amount of the second yarn without departing from the technology described herein. "Trace amount" is defined herein as approximately less than 10% by weight of a particular yarn. For example, less than 10% by weight of the first yarn or less than 10% by weight of the second yarn.

[0066] As described above, the first yarn can have a first core yarn and a first coating comprising a thermoplastic polymer composition. The thermoplastic polymer composition can include one or more thermoplastic elastomers that at least partially surround the first core yarn. The second yarn can include a filament of a thermoplastic material comprising polyester. However, in an example, the second yarn does not include the thermoplastic polymer composition that constitutes the first coating.

[0067] As previously described, the first yarn and the second yarn can have different physical properties. For example, the first coating of the first yarn has a first deformation temperature, and the second yarn has a second deformation temperature greater than the first deformation temperature. In some aspects, the second deformation temperature is the lower of the second melting temperature or the second decomposition temperature. Therefore, the first yarn or at least the coating of the first yarn can melt, flow or become molten to produce the thermoforming network described herein, while the structure of the second yarn remains intact. In various aspects, the deformation temperature of the coating is at least 20 degrees Celsius lower than the second deformation temperature of the second yarn. For example, in various aspects, the melting temperature of the coating of the first yarn is at least 100 degrees Celsius, at least 130 degrees Celsius or at least 170 degrees Celsius, and in each case, the second deformation temperature can be at least 20 degrees Celsius higher than the melting temperature of the coating of the first yarn.

[0068] At least in part due to the selective use of the first yarn and the second yarn, the first area 108 has a different coefficient of friction from the second area 106. When relative coefficients of friction are mentioned herein, common test standards are applied to both the first area and the second area. For example, a sample having only the first area can be tested using ASTM D1894 to determine the static or dynamic coefficient of friction of the first area described herein. Similarly, a sample having only the second area can be tested using ASTM D1894 to determine the static or dynamic coefficient of friction of the second area described herein. However, as described below, as long as common test standards are applied to both the first area and the second area, a modified version of ASTM D1894 or other tests can be used without departing from the technical scope of this article. In other words, when the first area has a higher coefficient of friction than the second area, the same test (e.g., the same test standard and / or process) and the same conditions (e.g., wet, dry, temperature) are used to measure both the exclusive first area sample and the exclusive second area sample, so that in this example, the only variable is the change in the material (e.g., the first area and the second area) that determines the coefficient of friction. Thus, a relative coefficient of friction may be determined between the first region and the second region (eg, the first region having a higher coefficient of friction than the second region).

[0069] In some aspects, the first area 108 has a higher coefficient of friction than the second area 106. The coefficient of friction can be based on wet conditions or dry conditions. In various aspects, the first area 108 has a higher coefficient of friction than the second area under both wet conditions and dry conditions. In one aspect, the dry dynamic friction coefficient of the first area 108 as tested on a dry sample of football material is from about 0.90 to about 1.50. In addition, the wet dynamic friction coefficient of the first area 108 as tested on a wet sample of football material can be from about 0.50 to about 0.80. In addition, in some aspects, the difference between the dynamic friction coefficient of the first area 108 on the dry sample of football material and the dynamic friction coefficient of the first area 108 on the wet sample of football material is less than 40%. In this way, the first yarn forming the first area 108 can enable the first area 108 to have adhesion friction or grip on an object such as football under both dry conditions and wet conditions. In this way, the first yarn can enable the wearer to have good ball control under various weather conditions, and can reduce the sliding of football when wet. All coefficient of friction values ​​disclosed herein can be obtained using the Textile-Ball Coefficient of Friction Test described below.

[0070] Although grip (which can be expressed as a coefficient of friction) helps control the ball, too much grip can reduce the speed at which the wearer manipulates the ball. In some activities such as football, gentle, quick contact is sometimes required, and therefore, having an area that offsets the coefficient of friction from the first area 108 can help provide an optimal level of overall grip and ball control. Therefore, the second area 106 that does not include the first yarn has a lower coefficient of friction than the first yarn under wet conditions and dry conditions. For example, the coefficient of friction (wet or dry) of the second area 106 can be in the range of from about 10% to about 75% less than the coefficient of friction (wet or dry) of the first area 108, in the range of from about 15% to about 60% less than the coefficient of friction (wet or dry) of the first area 108, or in the range of from about 20% to about 50% less than the coefficient of friction (wet or dry) of the first area 108.

[0071] The first region 108 and the second region 106 may also have other different physical properties. For example, the first yarn, or the first coating of the first yarn and the second yarn may be different based on at least one of the hue, value, and chroma of its color. Therefore, the first region 108 and the second region 106 may be different based on at least one of the hue, value, and chroma of its color. Other visual differences between the first yarn and the second yarn and between the first region 108 and the second region 106 may be used without departing from the scope of the present invention. However, in some aspects, the visual difference between the first region and the second region 108 and 106 may be minimal or non-existent, while differences in other physical characteristics still exist.

[0072] like Figure 1A and Figure 1BAs shown, the first area 108 and the second area 106 form an alternating pattern on the surface of the upper 102. For example, one of the first areas 108 can be positioned between two of the second areas 106, or in other words, one of the second areas 106 can be positioned between two of the first areas 108. Alternating the first area 108 and the second area 106 in this manner can provide optimal grip within the area of ​​the upper 102 for improved ball control. In various aspects, the size and dimensions of each of the first area 108 and the second area 106 can vary depending on the amount of grip and / or ball control required. For example, the size and dimensions of the first area 108 can be similar or different to the size and dimensions of the second area 106, however, the ratio of the total surface area of ​​the first area 108 to the total surface area of ​​the second area 106 depends on the amount of grip and / or ball control required. For example, in the case where more grip and / or ball control is needed, the ratio of the total surface area of ​​the first area 108 to the total surface area of ​​the second area 106 can be larger, and in the case where less grip is needed, the ratio of the total surface area of ​​the first area 108 to the total surface area of ​​the second area 106 can be smaller. In some aspects, the first area 108 constitutes the percentage of the total surface area in the zone of the first surface 105 of the knitted component 130, and the percentage is in the range of from about 40% to about 80%, in the range of from about 50% to about 70%, and / or in the range of from about 55% to about 65%. The scope provided herein includes the value at either end of the scope. For example, the range of 40% to 80% includes 40% and 80%. Therefore, the second area 106 can form the percentage of the total surface area of ​​the first surface 105 of the knitted component 130, and the percentage is in the range of from about 20% to about 60%, in the range of from about 30% to about 50%, and / or in the range of from about 55% to about 65%.

[0073] Figure 1A The outer side of the upper 102 depicted in the figure includes a first area 108 and a second area 106, and when the upper 102 is in a configuration when worn with the sole structure 104 contacting the ground, the first area 108 and the second area 106 are arranged into an alternating stripe pattern extending substantially vertically. Therefore, the first area 108 and the second area 106 can generally extend from the bottom edge 150 of the knitted component 130 toward the shoe throat area 126. At least a portion of the bottom edge 150 of the knitted component 130 can be aligned with the bite line 152 of the upper 102 connecting the sole structure 104. The stripes formed by alternating the first area 108 and the second area 106 on the outer side can extend in the outer side mid-shoe area 114a and the forefoot area 116. In addition, in the aspect that the knitted component 130 extends to the heel area 118, the stripes can also extend in the heel area 118. The stripes are an example of an alternating pattern including a linear boundary between the first area 108 and the second area 106.

[0074] At least some of the stripes can have a zigzag configuration, a wavy line configuration, a parallel line configuration and / or any other stripe configuration, such as stripes that follow the curvature of the knitted component 130. Additionally or alternatively, at least a portion of the stripes can have a variable width along its length. For example, the variable width can be in the range of from as narrow as 3 mm to as wide as 1 cm. Any number of stripes formed by alternating the first area 108 and the second area 106 can be included on the knitted component 130. In some aspects, the first area 108 forms stripes between 10 and 40 on the first surface 105 of the knitted component 130, and in other aspects, the first area 108 forms stripes between 25 and 35 on the first surface 105 of the knitted component 130. However, the number and configuration of the stripes depend on the amount of grip and / or ball control required, and then depend on the ratio of the total surface area of ​​the first area 108 and the total surface area of ​​the second area 106 as discussed above.

[0075] exist Figure 1B , the first area 108 and the second area 106 are alternated to form a concentric shape pattern, or in other words, a "swirl" or "convolution" pattern. In this example, the concentric pattern of the first area 108 and the second area 106 includes irregularly shaped circles. The vortex pattern or convolution pattern is an example of an alternating pattern with a curved border between the first area 108 and the second area 106. Additionally or alternatively, the concentric shapes can be triangles, circles, ovals, parallelograms, pentagons, hexagons, stars, hearts, any combination thereof, or concentric shapes without departing from the scope of the technology described herein. The pattern is concentric because at least the first area 108 and the second area 106, which are part of the concentric pattern, are coaxial and share a common center. Figure 1B The center of the concentric pattern in is located in medial midfoot region 114b and helps impart spin to a ball, such as a soccer ball, when kicked. In the area of ​​the concentric pattern closer to the center in medial midfoot region 114b, second area 106 can cover more of first surface 105 than covered by first area 108 in that area of ​​the upper.

[0076] In some aspects, the concentric pattern within medial midfoot region 114b may be nested between a series of stripes formed by alternating additional first regions 108 and additional second regions 106. Figure 1B As shown, one or more of the stripes adjacent to the concentric pattern may have a curvature or angle corresponding to the curvature or angle of the shape forming the concentric pattern.

[0077] Figure 1CAnother aspect of the alternating pattern of first areas 108 and second areas 106 on the medial side of upper 102 is depicted. In this configuration, first areas 108 and second areas 106 may still generally form a pattern of concentric shapes, but these shapes may be formed by fold lines of different lengths and curvatures that cooperatively form shapes within the concentric pattern.

[0078] The use of different types of alternating patterns of the first area 108 and the second area 106 on the outside and inside of the upper 102 reflects different types of sports that can be performed in certain activities. For example, in football, the inside of the foot is generally used for passing, catching and / or kicking, while the outside of the foot is used for other ball manipulations, such as dragging or gently pushing the ball. Therefore, the different ratios and patterns of the first area 108 and the second area 106 can provide different gripping patterns suitable for specific activities. For example, the concentric pattern in the medial mid-shoe area 114b provides a more all-round change in the coefficient of friction between the first area 108 and the second area 106, which can achieve better ball control for catching, passing and / or kicking sports. As discussed above, the concentric pattern can also enable the wearer to give the ball more or less rotation when kicking. In contrast, the striped pattern on the outside provides a change in the coefficient of friction of the first area 108 and the second area 106 in a more longitudinal direction (i.e., extending from the front area 116 of the shoe to the direction of the heel area 118), which can achieve better control of the ball when dragging or gently pushing.

[0079] Although aspects described herein feature concentric and striped patterns on the upper of an article of footwear, it should be noted that such patterns may additionally or alternatively be disposed on the sole or bottom of the article of footwear to reflect different types of motion that may be performed during certain activities. Specifically, the pattern may be customized to include different variations in the coefficient of friction of the first and second regions on the front or toe region of the outsole 109 and the coefficient of friction on the rear or heel region of the outsole 109.

[0080] As described above, some aspects of the knitted component 130 are double-sided knitted structures formed on two knitting beds. Both the first yarn and the second yarn can be used to form knitted loops on the front needle bed within a course and / or along a wale, and to form loops on the back needle bed, so that the first yarn and the second yarn can alternately form the first surface 105 of the knitted component. For example, the first yarn can form loops on the needles of the front needle bed to form the first area 108, while the second yarn floats or forms loops on the needles of the back needle bed. When the second yarn forms loops on the needles on the front needle bed and the first yarn floats or forms loops on the needles on the back needle bed, the second area 106 can be formed.

[0081] In some aspects, knitted component 130 includes a third yarn containing elastic fiber (elastane) or elastic polyurethane material. In an exemplary aspect, the third yarn is knitted on the second surface of knitted component 130 opposite to first surface 105. Specifically, the third yarn can be knitted on the second surface in an area opposite to first area 108 and second area 106 on first surface 105. In some aspects, the third yarn is knitted only on one needle bed such as a back needle bed, so that the third yarn is only on the second surface, and not on the first surface 105. Including a third yarn with elastic fiber or elastic polyurethane material on the second surface (e.g., the surface facing the inside) of knitted component 130 provides some elasticity for knitted component 130, which enhances the proprioceptive feedback to the wearer when the knitted component 130 on upper 102 contacts with an object such as a ball.

[0082] As discussed above, the first yarn has a coating that can be melted or deformed by thermoforming and subsequently solidified to form a thermoformed network with the core yarn of the first yarn and portions of one or more other yarns, such as the second yarn and the third yarn in some aspects. In this way, the thermoforming process can change at least a portion of the knitted structure of the knitted component 130. For example, after knitting, the knitted component 130 may include interconnected rows of coils of the first yarn and the second yarn, and after thermoforming, the knitted component 130 may not include interconnected rows of coils of the first yarn and the second yarn in the thermoformed portion, which is at least partially due to the deformation or melting of the coating of the first yarn. At the same time, the core yarn of the first yarn can still form interconnected coils with the second yarn, and the remaining coils can still be connected via the melted and resolidified coating material.

[0083] Figure 2A Schematically depicts a portion 200 of an exemplary knitted component prior to a thermoforming process, the exemplary knitted component may be Figure 1A-Figure 1C The knitted component 130. The portion 200 includes interconnected rows of first yarn 210 and second yarn 208, the first yarn 210 can be the first covered yarn described herein, and the second yarn 208 can be about Figure 1A-Figure 1C Portion 200 includes first course 202 and second course 204 having second yarn 208, and third course 206 of first yarn 210. In such aspects, third course 206 of stitches of first yarn 210 may be interconnected (e.g., interwoven) with first course 202 and second course 204 having second yarn 208.

[0084] Figure 2BDepicted is the portion 200 after exposure to a thermoforming process. Figure 2A and Figure 2B As can be seen, the first yarn 210 comprising a thermoplastic polymer composition as described herein is thermoformed from a solid yarn structure into a molten yarn component 212, wherein the core yarn 214 of the first yarn 210 remains in its interwoven configuration. In certain aspects, the heating step of the thermoforming process at least partially causes the coating in the first yarn 210 to melt and flow, and then subsequently solidify into the molten yarn component 212 by completing the thermoforming process. The molten yarn component 212 is the coating after the coating around the core yarn 214 of the first yarn 210 is melted, flowed, and resolidified. Figure 2B The molten yarn component 212 in the embodiment is depicted as contacting and at least partially surrounding the core yarn 214 of the first yarn 210 at least in the portion of the first and second rows 202, 204 interlaced with or close to the third row 206, and contacting and at least partially surrounding a portion of the second yarn 208, thereby forming a network. However, without departing from the technology described herein, the molten yarn component 212 can be thermoformed to form a network. Figure 2B The described spreading to a greater or lesser extent on the outwardly facing surface of the textile.

[0085] The area with the molten yarn component 212 produced by thermoforming can have increased wear resistance and increased water resistance compared to the area without the thermoformed molten yarn component 212. In addition, because these properties are provided by the knitted structure, rather than applied as an additional layer or film, the portion 200 of the knitted component can remain relatively thin and flexible. Therefore, the molten yarn component 212 can be used in high-flexion areas of the upper, such as the area between the throat and the forefoot area, without premature wear or breakage.

[0086] It should be noted that Figure 2A and Figure 2B This is merely an example of knitting and thermoforming as described herein. Other knitting patterns with any more than one adjacent row and / or any more than one adjacent loop of primarily the first yarn 210 or primarily the second yarn 208 may be used to form a first area (such as a Figure 1A-Figure 1C a first region 108) or a second region (such as Figure 1A-Figure 1C The second region 106 of the present invention may be one of the knitted parts without departing from the technical scope of the present invention. For example, for simplicity of illustration, portion 200 is shown with only a single knit layer. However, it is contemplated that some aspects of the present disclosure may include a knitted component having a double-sided knit structure formed using needles on two needle beds. For example, a first yarn 210 may be knitted on a front needle bed to form a double-sided knit structure on a front needle bed. Figure 2AIn the third course 206 of the knitted fabric, a stitch is formed which can form a first surface of the knitted component, and in another course, such as a course knitted simultaneously with the first course 202, a first yarn 210 can be knitted on the rear needle bed to form at least a portion of the second surface of the knitted component. Similarly, a second yarn 208 can be knitted on the front needle bed to form at least a portion of the second surface of the knitted component. Figure 2A In the first and second rows 202 and 204 of the portion 200, a coil is formed that can form a first surface of the knitted component, and in another row of coils, such as a row of coils knitted simultaneously with the third row 206, a second yarn 208 can be knitted on the back needle bed to form at least a portion of the second surface of the knitted component. In some aspects, the first yarn 210 and / or the second yarn 208 can move back and forth between the front and back needle beds within a single row of coils. In addition, in some aspects where the portion 200 is part of a double-sided knitted structure, the coils forming the rows of coils for the second surface can be formed by a third yarn having an elastic fiber or an elastic polyurethane material. In addition, in some aspects having a double-sided knitted structure, the molten yarn component 212 can extend between the knitted layers, but cannot extend completely through the back layer to form the second surface. In an optional configuration, the molten yarn component 212 can still extend completely through the two knitted layers of the double-sided knitted structure.

[0087] Figure 3A-3CEach depicts an exemplary outward-facing surface of a knitted component that is thermoformed with multiple textures or patterns. The knitted component, for example, can be a knitted component 130 with an alternating first region 108 and second region 106 as described herein, wherein the first region 108 is made of a first yarn, and the second region 106 is made of a second yarn. The thermoforming of such a knitted component can be used to reflow and resolidify the coating of the first yarn as described herein, so that the coating material then occupies at least a portion of the space between the yarns in the thermoforming network of the yarn. As further described below, during thermoforming, when the knitted component 130 contacts a molding surface such as a flat plate or a conventional two-piece mold, pressure can be applied. In some aspects, the molding surface can include recesses and / or raised elements to form a texture with raised elements on the first surface 105 of the knitted component 130. The raised elements molded into the knitted structure of the knitted component 130 can advantageously be used to adjust the gripping effect of the knitted component, such as the amount of grip between the first surface (which can be the outer surface of the upper) of the knitted component 130 and the football. Specifically, the raised elements mitigate the higher coefficient of friction (i.e., greater grip) of the first area 108 due to the first yarn. Therefore, the raised elements can be arranged in portions of the knitted component 130 where the first area 108 forms a larger portion of the surface area. Furthermore, in some aspects, the raised elements can be located on the outside of the upper rather than on the inside, or the inside of the upper can have fewer raised elements than the outside.

[0088] The raised elements 160 can take on a variety of shapes, sizes, and arrangements within the knitted component 130. Figure 3A In the embodiment, the raised elements 160 form elongated ridges or grooves that are closely spaced and extend parallel to each other. In this exemplary pattern, the ridges can have different lengths. In addition, Figure 3A The ridges in the upper extend across both the first area 108 and the second area 106. In addition, the ridges can extend substantially perpendicular to the longitudinal direction of the first area 108 and the second area 106. Since the ridges can form a recessed area similar to a groove between the ridges, the ridges can also operate to allow moisture and other small debris to escape from the first surface 105 of the knitted component 130, which allows a better contact surface with the ball, and then allows better grip and / or ball control under wet conditions and / or dirty conditions. In addition, the elongated parallel grooves on the outside of the upper may be particularly advantageous for dragging, light pushing and other such technologies. In some aspects, the width of the grooves or recesses between the ridges and / or the spacing between each other are between 1 millimeter and 1 centimeter or approximately between 1 millimeter and 1 centimeter. However, as described above, the pattern, width and / or spacing of the ridges can be adjusted as needed to adjust grip and / or ball control.

[0089] exist Figure 3B , the raised elements 160 are in the form of tetrahedral or pyramidal protrusions extending from the first surface 105 of the knitted component 130. Figure 3B The protrusions in the embodiment may be positioned in both the first region 108 and the second region 106. In other aspects, the protrusions are only positioned in the first region 108. In addition, the protrusions may be positioned in a manner such as Figure 3B The arrays may be arranged in a generally linear pattern as shown, or may be arranged in a more clustered pattern or a random pattern.

[0090] exist Figure 3C In the exemplary pattern, the raised elements 160 form elongated ridges that are closely spaced together. The ridges can be spaced approximately equidistant from one another. In addition, the grooves can each be curved or arched. In this exemplary pattern, the ridges can be of different lengths and can cooperatively form a slightly curved track or a curved track of multiple rows and / or columns of elongated ridges or grooves. Similar to Figure 3A The raised element 160, Figure 3C The ridges in the knitted component 130 extend across both the first region 108 and the second region 106. In addition, the ridges can extend nearly perpendicular to the longitudinal direction of the first region 108 and the second region 106. Because the ridges can form recessed areas similar to grooves between the ridges, the ridges can also operate to allow moisture and other small debris to escape from the first surface 105 of the knitted component 130, which allows for a better contact surface with the ball. In some aspects, the width of the grooves or recesses between the ridges and / or the spacing from each other is between 1 millimeter and 1 centimeter or approximately between 1 millimeter and 1 centimeter. It should be noted that Figure 3A-3C The raised elements 160 depicted in FIG. 1 are merely exemplary patterns, and the first surface 105 of the knitted component 130 may be thermoformed to have a flat, glossy, bumpy, or matte texture or pattern without departing from the scope of the technology described herein.

[0091] Figure 4 and Figure 5A-Figure 5B Various aspects of a knitted component for an article of footwear are described, the knitted component having a Figure 1A-Figure 1C An alternating pattern of different first and second regions is shown. Figure 4 An article of footwear 400 is depicted having a sole structure 404 and an upper 402. Various aspects of the sole structure 404 may have aspects related to Figure 1A-1B The sole structure 104 of the embodiment of the present invention may be substantially the same as described above. In addition, various aspects of the upper 402 may have the same configuration as described above. Figure 1A-1B Thus, the upper may be at least partially formed by knitted component 430, and various aspects of knitted component 430 may have aspects related to Figure 1A-1BThe knitted component 130 describes substantially the same configuration, with the exceptions noted below.

[0092] The knitted component 430 is formed by at least a first yarn and a second yarn having different material compositions and different properties. Figure 1A-1B The knitted component 430 is formed of the materials and techniques discussed above for component 130. The first surface 405 of the knitted component 430 may form an exterior-facing surface of an upper and has a first one or more regions (first regions 408) formed by a first yarn and a second one or more regions (second regions 406) formed by a second yarn.

[0093] Similar to Figure 1A-1B The first area 108 and the second area 106, the first area 408 and the second area 406 may have different friction coefficients. For example, the wet friction coefficient and the dry friction coefficient of the first area 408 may be greater than the wet friction coefficient and the dry friction coefficient of the second area 406. In addition, the first area 408 and the second area 406 may be arranged in an alternating pattern at least on the inner side of the upper 402. Specifically, the first area 408 and the second area 406 may alternate to form a pattern of concentric shapes, such as irregular circles and / or ellipses. The central area of ​​the concentric pattern may be positioned within the medial midshoe area 414. Figure 1A and Figure 1B Unlike the knitted component 130 of the embodiment of the present invention, in the concentric shapes near the central area, the second area 406 may not have a significantly greater width than the first area 408. Instead, the concentric circles or ellipses forming the first area 408 in the central area may have a surface area similar to the surface area of ​​the concentric circles or ellipses forming the second area 406 in the central area. Therefore, the central area of ​​the concentric pattern on the medial midshoe area 414 may provide a greater width than the first area 408. Figure 1B The concentric pattern on the medial midsole region 114b provides greater traction in the central area.

[0094] It should be understood that the first area 408 and the second area 406 may also form an alternating pattern on the outside of the upper, similar to the Figure 1A It should also be understood that at least some of the first areas 408 on the first surface 405 of the knitted component 430 may be thermoformed to produce a pattern similar to Figure 2A and Figure 2B 4. In some aspects, the thermoformed first surface 405 can be molded to include raised structures within the first region 408 and / or the second region 406. These raised structures can include about Figure 3A-3C Any pattern described.

[0095] Figure 5A and Figure 5BAnother configuration of an alternating pattern according to some aspects herein is depicted. Figure 5A and Figure 5B An article of footwear 500 is depicted having a sole structure 504 and an upper 502. Various aspects of the sole structure 504 may have similar characteristics to those described above. Figure 1A-1B The sole structure 104 of the embodiment of the present invention is generally the same configuration as described above. In addition, various aspects of the upper 502 can have the same configuration as described above. Figure 1A-1B Thus, the upper may be at least partially formed by knitted component 530, and various aspects of knitted component 530 may have aspects related to Figure 1A-1B The knitted component 130 described herein has substantially the same configuration, materials and / or characteristics, except for the exceptions noted below.

[0096] The first surface 505 of the knitted component 530 may form an exterior-facing surface of an upper (similar to Figure 1A-1B 105) and having a first one or more regions (first regions 508) formed by the first yarn and a second one or more regions (second regions 506) formed by the second yarn. Figure 1A-1B The first region 108 and the second region 106, the first region 508 and the second region 506 may have different friction coefficients. For example, the wet friction coefficient and the dry friction coefficient of the first region 508 may be greater than the wet friction coefficient and the dry friction coefficient of the second region 506.

[0097] Furthermore, first area 508 and second area 506 may be arranged in an alternating pattern formed on concentric shapes on the medial side of upper 502. Figure 5B As shown, the first area 508 and the second area 506 can alternate to form a pattern of concentric triangle shapes in at least the medial midshoe area 514. In some aspects, the concentric triangles can have rounded corners or pointed corners. In some aspects, the concentric pattern in the medial midshoe area 514 can be nested within a zigzag pattern formed on the rest of the knitted component 530, such as in the forefoot area 516, the heel area 518, and the lateral midshoe area 512 (e.g., Figure 5A shown).

[0098] The zigzag pattern of the first area 508 and the second area 506 can be positioned on the outside of the upper 502. In this pattern, the first area 508 and the second area 506 can extend generally from the bottom edge 550 of the knitted component 530 toward the shoe throat area 526 of the upper 502. At least a portion of the bottom edge 550 of the knitted component 530 can be aligned with the bite line 552 of the upper 502 connecting the sole structure 504. The zigzag stripes formed by alternating the first area 508 and the second area 506 on the outside can extend in the outside mid-shoe area 512 and the forefoot area 516. In addition, in the aspect that the knitted component 530 extends to the heel area 518, the stripes can also extend in the heel area 518.

[0099] The zigzag pattern can have various sizes. The stripes in the zigzag pattern can be generally parallel to each other in some aspects. In addition, in some aspects, at least some points or corners of at least some of the stripes with the zigzag pattern on the medial side can be aligned with at least one point or corner of the outermost of the concentric triangles in the medial mid-shoe area 514, so that the outermost triangle is nested in the corner of one of the stripes in the zigzag pattern.

[0100] In addition, Figure 5A and Figure 5B In the depicted aspect, upper 502 includes a textile component 556 that forms the exterior of throat area 526. This textile component 556 can act as an exterior shield to cover laces and eyelets (similar to Figure 1A and Figure 1B ). Textile component 556 can be integrally knitted and have an integral knitted construction with knitted component 530 having first area 508 and second area 506. Alternatively, textile component can be formed separately from knitted component 503 and secured to knitted component 530 at one or more locations via stitching, bonding, and the like.

[0101] Figure 6A flowchart of an example method 600 for manufacturing a knitted component is included, the knitted component being such as the knitted component 130, 430 and / or 530 described above. The steps provided in method 600 are merely illustrative, and method 600 may include additional steps not shown. At least some of the steps of method 600 are indicated as being performed on a knitting machine, which may be an automatic knitting machine. Thus, one or more of these steps may be performed and / or controlled using a control unit having a processor or computer that is communicatively coupled to or integrated into the knitting machine with the knitting machine. In an exemplary aspect, the knitting machine used to perform the steps of method 600 is a V-bed knitting machine having two needle beds - a front needle bed and a rear needle bed - which are angled relative to each other to form a V-bed. However, it should be understood that this is an example, and other knitting machines may be used to form a knitted component or a portion thereof. Similarly, in an exemplary aspect, the knitting step within method 600 may be a weft knitting process, but in an optional aspect, a warp knitting process may be used.

[0102] At box 602, method 600 includes knitting a knitted component with a first yarn that is integrally knitted with a second yarn. As described above, the first yarn may include a first core yarn and a first coating comprising a polymer composition, wherein the polymer composition includes one or more thermoplastic elastomers at least partially surrounding the first core yarn. Knitting the knitted component at box 602 may include knitting the first yarn so that the first yarn forms a first area on a first surface of the knitted component, and knitting the second yarn so that the second yarn forms a second area on the first surface of the knitted component. To form the first area, the first yarn may form a coil around a needle on a first (i.e., front) needle bed when a second yarn float needle forms a coil behind a coil of the first yarn and / or around a needle on a second (e.g., rear) needle bed. To form the second area, the second yarn may form a coil around a needle on the first needle bed when the first yarn float needle forms a coil behind a coil of the second yarn and / or around a needle on the second needle bed. Exemplary aspects of the first area and the second area formed at box 602 may be about Figure 1A-Figure 5B In addition, method 600 may also include knitting a third yarn having an elastic fiber or elastic polyurethane material on a second needle bed so that the third yarn forms a second (ie, back or interior-facing) surface of the knitted component.

[0103] At box 604, method 600 includes thermoforming at least a first area of ​​the knitted component so that the first coating of the first yarn flows and occupies at least a portion of the space between the rows of coils of the first yarn or the rows of coils of the first core yarn. Additionally or alternatively, thermoforming can allow the first coating to flow and occupy at least a portion of the space between the rows of coils of the first core yarn and the second yarn. Thermoforming can cause the polymer composition of the coating to produce a thermoformed network of interwoven yarns, the interwoven yarns including the first core yarn and the first polymer composition surrounding at least a portion of the first core yarn and occupying the space between at least some portions of the yarns in the thermoformed network. The thermoformed network can extend primarily through the first area on the first surface of the knitted component, but it should be understood that at least a portion of the second yarn forming the second area of ​​the knitted component can contact and at least partially surround the molten and resolidified thermoplastic polymer composition, thereby producing a thermoformed network.

[0104] In addition, the thermoforming step at box 604 includes raising the temperature of the thermoplastic polymer composition (i.e., the coating of the first yarn) to a temperature that causes at least a portion of the thermoplastic polymer composition as described herein to melt and flow or deform. In addition, the thermoforming process includes subsequently reducing the temperature of the thermoplastic polymer composition to cure the reflowed thermoplastic polymer composition as described herein into a desired configuration and / or shape, such as an article of footwear.

[0105] Knitted components can be thermoformed using a molding surface, such as a plate or a two-piece mold. Knitted components can be heated before contacting the molding surface, or can be heated while contacting the molding surface. In some aspects, the temperature of the thermoplastic polymer composition can be increased for about 10 seconds to about 5 minutes. In aspects, the temperature of the thermoplastic polymer composition can be increased for about 30 seconds to about 5 minutes. In one aspect, the temperature of the thermoplastic polymer composition can be increased for about 30 seconds to about 3 minutes. In addition, in some aspects, the thermoplastic polymer composition can be repeatedly exposed to the heating temperature before experiencing cooling.

[0106] For cooling, the knitted component can be moved to a cooling zone having a reduced temperature. Cooling allows the thermoplastic polymer composition to be resolidified in a position where it flows back, in which the thermoplastic polymer composition occupies at least a portion of the space between the courses of the first yarn and / or the courses of the first core yarn. In addition, the first polymer composition (e.g., a polymer composition including a thermoplastic composition comprising a thermoplastic elastomer) can be cooled to be resolidified in a position where it flows back, in which the first polymer composition occupies at least a portion of the space between the courses of the first core yarn and the courses of the second yarn.

[0107] In addition, in some aspects, pressure can be applied during or after applying heat. In some aspects, thermoforming exposes the material on the mold surface to a pressure of about 50 kPa to about 300 kPa. In aspects, thermoforming exposes the material on the mold surface to a pressure of about 50 kPa to about 250 kPa. In one aspect, thermoforming exposes the material on the mold surface to a pressure from about 100 kPa to about 300 kPa.

[0108] In some aspects of method 600, a textured molding surface can be used to impart a three-dimensional texture on a first surface of a knitted component. For example, by applying heat and optionally pressure, the textured molding surface can cause the molten thermoplastic polymer composition to form raised elements in the first surface. The raised elements can be in the form of Figure 3A-3C The textured molding surface can be used for the first application of heat or subsequent applications of heat during thermoforming.

[0109] By selectively incorporating the first yarn (having a coating comprising a thermoplastic polymer) into the first region of the knitted component via knitting prior to thermoforming, the manufacturing process can be streamlined. Specifically, it enables the entire knitted component to be exposed during thermoforming without the need to mask or protect certain regions (i.e., the second region) while maintaining the selective arrangement of the thermoforming network, resulting in a more time-saving and energy-saving manufacturing process.

[0110] In some aspects, method 600 includes forming a knitted component into a shoe upper at frame 606. The knitted component may have been knitted into the shape of a shoe upper and may be formed into a shoe upper by folding one or more parts and / or connecting one or more edges to create a cavity to accommodate a foot. In some aspects, the knitted component may be a larger piece of textile material and may be cut into the shape of a shoe upper or a part of a shoe upper such as an outer sheath. In some aspects, frame 606 includes fixing a thermoformed knitted component to one or more textile components by stitching, bonding, and the like.

[0111] In some aspects, method 600 may include the step of attaching an upper or another such thermoformed knitted component to the sole structure, as indicated at block 608. Attachment may be accomplished via thermoforming the upper or knitted component and the sole structure together, and / or may be accomplished via mechanical techniques or other attachment techniques known in the art.

[0112] Exemplary Properties of the First Yarn As discussed above, textiles and formed parts can include the selective incorporation of yarns as described (referred to above as first yarns) alone or in combination with other materials (e.g., second yarns that are not fibers, filaments, and yarns described herein). In some aspects, the yarns and / or fibers described herein can be used to provide specific functions. For example, in some aspects, yarns as described herein can be thermoformed to form films having waterproof or water-resistant properties.

[0113] In one aspect, the covered yarns described herein, such as the first yarn, have a breaking strength from about 0.6 to about 0.9 kilograms of applied force, or from about 0.7 to about 0.9 kilograms of applied force, or from about 0.8 to about 0.9 kilograms of applied force, or greater than 0.9 kilograms of applied force.

[0114] In aspects, the yarns described herein can be produced from fibers or filaments comprising only a single thermoplastic elastomer. In other aspects, the fibers can comprise a blend of two or more different thermoplastic elastomers.

[0115] In one aspect, the yarn is a covered yarn, wherein the core yarn comprises a second polymer composition, and a coating is disposed on the core yarn, the coating comprising a first polymer composition, wherein the first polymer composition has a first melting temperature. In one aspect, the second polymer composition is a second thermoplastic composition having a second deformation temperature, and the second deformation temperature is at least 20 degrees Celsius greater, at least 50 degrees Celsius greater, at least 75 degrees Celsius greater, or at least 100 degrees Celsius greater than the first melting temperature of the first polymer composition. In another aspect, the second polymer composition is a second thermoplastic composition having a second melting temperature or a second deformation temperature, and the second deformation temperature is about 20 degrees Celsius, about 50 degrees Celsius, about 75 degrees Celsius, or about 100 degrees Celsius greater than the first melting temperature of the first polymer composition.

[0116] In one aspect, the first polymer composition comprises a polymer component. In one aspect, the first polymer composition can comprise a single polymer component (e.g., a single thermoplastic elastomer). In other aspects, the first polymer composition can comprise two or more polymer components (e.g., two or more different thermoplastic elastomers).

[0117] In one aspect, the second polymer composition is a first thermosetting composition. In one aspect, the second polymer composition includes a second thermosetting composition. The core yarn can be any material that maintains its strength at a temperature at which the first polymer material is extruded during the coating process. The core yarn can be a natural fiber or a regenerated fiber or silk, or a synthetic fiber or silk. In one aspect, the core yarn can include cotton, silk, wool, rayon, nylon, elastic fiber, polyester, polyamide, polyurethane or polyolefin. In one aspect, the core yarn includes polyethylene terephthalate (PET). In one aspect, the second polymer composition has a deformation temperature greater than 200 degrees Celsius, greater than 220 degrees Celsius, greater than 240 degrees Celsius or between about 200 degrees Celsius and about 300 degrees Celsius.

[0118] In one aspect, the core yarn is a short yarn, a multifilament yarn or a monofilament yarn. In one aspect, the core yarn is multi-twisted. In one aspect, the core yarn has a linear density of about 100 denier to about 300 denier, or about 100 to about 250 denier, or about 100 to about 200 denier, or about 100 to 150 denier, or about 150 to 300 denier, or about 200 to 300 denier, or about 250 to 300 denier. In one aspect, the core yarn has a thickness of about 60 microns to 200 microns, about 60 to 160 microns, about 60 to 120 microns, about 60 to 100 microns, about 100 to 200 microns, or about 140 to 200 microns.

[0119] In one aspect, the core yarn is polyethylene terephthalate having a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to 160 denier. In one aspect, the core yarn is polyethylene terephthalate having a percent elongation of about 20% to about 30%, about 22% to about 30%, about 24% to about 30%, about 20% to about 28%, or about 20% to about 26%. In one aspect, the core yarn is polyethylene terephthalate having a tenacity of about 1 gram per denier to about 10 grams per denier, about 3 grams per denier to about 10 grams per denier, about 5 grams per denier to about 10 grams per denier, about 1 gram per denier to about 7 grams per denier, or about 1 gram per denier to about 5 grams per denier.

[0120] In one aspect, the coated yarn can be produced by extruding coating (that is, the first polymer composition) onto the core yarn via an annular die or orifice so that coating is axially centered around the core yarn. The thickness of the coating applied to the core yarn can vary depending on the application of the yarn. In one aspect, the coated yarn is used to produce knitted textiles. In one aspect, the coated yarn has a nominal average outer diameter of up to 1.00 millimeters, or up to about 0.75 millimeters, or up to about 0.5 millimeters, or up to about 0.25 millimeters, or up to about 0.2 millimeters, or up to about 0.1 millimeters. In another aspect, coating has a nominal average outer diameter of about 0.1 millimeters to about 1.00 millimeters, or about 0.1 millimeters to about 0.80 millimeters, or about 0.1 millimeters to about 0.60 millimeters. In another aspect, the coating on the yarn has an average radial coating thickness of about 50 microns to about 200 microns, or about 50 microns to about 150 microns, or about 50 microns to about 125 microns.

[0121] In one aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier, and the coating has a nominal average outer diameter of about 0.10 mm to about 0.50 mm, or about 0.10 mm to about 0.25 mm, or about 0.10 mm to about 0.20 mm. In one aspect, the core yarn is polyethylene terephthalate having a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier, and the coating has a nominal average outer diameter of about 0.10 mm to about 0.50 mm, or about 0.10 mm to about 0.25 mm, or about 0.10 mm to about 0.20 mm.

[0122] In other aspects, the coated yarn has a net total diameter (net total diameter) from about 0.2 millimeter to about 0.6 millimeter, or about 0.3 millimeter to about 0.5 millimeter, or about 0.4 millimeter to about 0.6 millimeter. In some respects, the lubricating oil including but not limited to mineral oil or silicone oil can be present on the yarn from about 0.5% to about 2% by weight, or from about 0.5% to about 1.5% by weight, or from about 0.5% to about 1% by weight. In some respects, the lubricating composition can be applied to the surface of the coated yarn before or during the process forming textiles. In some respects, when the thermoplastic composition is refluxed and resolidified in the presence of the lubricating composition, the thermoplastic composition and the lubricating composition are miscible. After reflux and resolidification, the composition of reflux and solidification can include the lubricating composition.

[0123] In one aspect, the core yarn has a percent elongation of about 8% to about 30%, about 10% to about 30%, about 15% to about 30%, about 20% to about 30%, about 10% to about 25%, or about 10% to about 20%. In one aspect, the core yarn has a tenacity of about 1 gram per denier to about 10 grams per denier, about 2 grams per denier to about 8 grams per denier, about 4 grams per denier to about 8 grams per denier, or about 2 grams per denier to about 6 grams per denier.

[0124] In one aspect, when thermoformed, the polymer composition of the first coating has a melting temperature from about 100 degrees Celsius to about 210 degrees Celsius, optionally from about 110 degrees Celsius to about 195 degrees Celsius, from about 120 degrees Celsius to about 180 degrees Celsius, or from about 120 degrees Celsius to about 170 degrees Celsius. In another aspect, the first polymer composition has a melting temperature greater than about 120 degrees Celsius and less than about 170 degrees Celsius, and optionally greater than about 130 degrees Celsius and less than about 160 degrees Celsius.

[0125] In further aspects, when the melt temperature is greater than 100 degrees Celsius, the integrity of the article formed from or incorporated into the first polymer composition is maintained if the article briefly encounters similar temperatures, such as during shipping or storage. In another aspect, when the melt temperature is greater than 100 degrees Celsius or greater than 120 degrees Celsius, the article formed from or incorporated into the first polymer composition can be steam treated without melting or uncontrollably fusing any polyester component incorporated into the article for purposes such as filling, zonal surfaces, or comfort features and stretch yarns for close fit and conforming features.

[0126] In one aspect, when the melting temperature is greater than 120 degrees Celsius, the material incorporated into the first polymer composition or the second polymer composition disclosed herein is less likely to soften and / or less likely to become sticky during use on a hot paved surface, a court surface, an artificial or natural football field or a similar playing surface, a runway or a field. In one aspect, the higher the melting temperature of the first polymer composition or the second polymer composition and the greater its melting enthalpy, the greater the ability of the footwear article or sports equipment article incorporated into the first polymer composition or the second polymer composition or constructed by the first polymer composition or the second polymer composition to withstand contact heating excursion, friction surface heating events or environmental heating excursion. In one aspect, such thermal excursion can be generated when the article contacts a hot ground surface, a court surface or a turf surface, or when the article contacts another surface such as the ground, another shoe, a ball or a similar surface from friction heating from friction or wear.

[0127] In another aspect, when the melt temperature is less than about 210 degrees Celsius, or less than about 200 degrees Celsius, or less than about 190 degrees Celsius, or less than about 180 degrees Celsius, or less than about 175 degrees Celsius, but greater than about 120 degrees Celsius, or greater than about 110 degrees Celsius, or greater than about 103 degrees Celsius, the polymer-coated yarn can be melted for the purpose of molding and / or thermoforming a given area of ​​a textile knitted therefrom so as to impart desired design features and aesthetic characteristics in a short period of time.

[0128] In one aspect, a melt temperature below 140 degrees Celsius prevents or reduces the risk of dye migration from polyester yarn incorporated into footwear or other articles. In another aspect, the migration of dye from package-dyed polyester yarn or silk is a diffusion-limited process, and short-term exposure to temperatures greater than 140 degrees Celsius, such as during thermoforming, does not extensively damage the appearance of the footwear or other article, does not discolor it, or otherwise render the appearance of the footwear or other article unacceptable. However, in another aspect, if the melt temperature of the polymer coating is greater than about 210 degrees Celsius, thermal damage and dye migration may occur.

[0129] In one aspect, a high melting enthalpy indicates that a longer heating time is required to ensure that the polymer is completely melted and will flow well. In another aspect, a low melting enthalpy requires less heating time to ensure complete melting and good flow.

[0130] In a further aspect, a high cooling exotherm indicates a rapid transition from melt to solid. In another aspect, a higher recrystallization temperature indicates that the polymer can solidify at a higher temperature. In one aspect, high temperature solidification facilitates thermoforming. In one aspect, recrystallization above 95 degrees Celsius promotes rapid solidification after thermoforming, reduces cycle time, reduces cooling requirements, and improves the stability of the shoe component during assembly and use.

[0131] In one aspect, the viscosity of the coating composition disclosed herein affects the properties and processing of the coating composition. In other aspects, high viscosity at low shear rates (e.g., less than 1 reciprocal second) indicates resistance to flow, displacement, and more solid behavior. In another aspect, low viscosity at higher shear rates (e.g., greater than 10 reciprocal seconds) is suitable for high-speed extrusion. In one aspect, as viscosity increases, the ability to fully flow and deform to coat the core yarn substrate becomes challenging. In another aspect, materials exhibiting a high shear thinning index (e.g., a viscosity at 10 reciprocal seconds or 100 reciprocal seconds is lower than the viscosity at 1 reciprocal second) may be challenging for extrusion, and if coated or extruded at too high a speed, melt fracture may occur.

[0132] In one aspect, the composition forming the first region has a durometer Shore A hardness of about 50 to about 90 Shore A, optionally from about 55 to about 85 Shore A, from about 60 to about 80 Shore A, from about 60 to about 70 Shore A, or from about 67 to about 77 Shore A.

[0133] In various aspects, the first polymer composition for covering the yarn has a Cold Sole Material Flexure Test result of about 120,000 to about 180,000, or about 140,000 to about 160,000, or about 130,000 to about 170,000 when tested on a thermoformed substrate of the first polymer composition for covering the yarn according to the Cold Sole Material Flexure Test as described below.

[0134] In one aspect, the polymer composition or coating of the first yarn or first region has two or more first properties provided above, or optionally three or more, four or more, five or more, six or more, seven or more, or all ten first properties.

[0135] In addition to the first property, when thermoforming, the first coating or polymer composition of the first yarn or first region has one or more second properties. In one aspect, when thermoforming, the first coating or polymer composition of the first yarn or first region has a glass transition temperature of less than 50 degrees Celsius, optionally less than 30 degrees Celsius, less than 0 degrees Celsius, less than -10 degrees Celsius, less than -20 degrees Celsius, or less than -30 degrees Celsius. In one aspect, when thermoforming, the first coating or polymer composition of the first yarn or first region has a stress at break greater than 7 MPa, optionally greater than 8 MPa, as determined using modulus, toughness, and elongation tests at 25 degrees Celsius. In one aspect, when thermoforming, the first coating or polymer composition of the first yarn or first region has a tensile stress greater than 2 MPa, optionally greater than 2.5 MPa, or greater than 3 MPa at 300% modulus, as determined using modulus, toughness, and elongation tests at 25 degrees Celsius. In one aspect, when thermoformed, the first coating or polymer composition of the first yarn or first region has an elongation at break greater than 400%, optionally greater than 450%, optionally greater than 500%, or greater than 550%, as determined using the Modulus, Tenacity, and Elongation Test at 25 degrees C. In another aspect, when thermoformed, the first coating or polymer composition of the first yarn or first region has two or more second properties, or optionally three or more second properties, or all four second properties.

[0136] In some aspects, film, fiber and yarn described herein can present the toughness greater than 1 gram / denier. In one aspect, film, fiber and yarn described herein can present the toughness from about 1 gram / denier to about 5 grams / denier. In one or more aspects, film, fiber and yarn described herein can present the toughness from about 1.5 grams / denier to about 4.5 grams / denier. In one aspect, film, fiber and yarn described herein can present the toughness from about 2 grams / denier to about 4.5 grams / denier. " toughness " as used herein refers to the property of fiber or yarn, and is determined using the corresponding test method and sampling procedure described below. Specifically, the toughness and elongation of yarn sample are determined according to the test method described in detail in EN ISO2062, wherein preload is set to 5 grams. Elongation is recorded at the maximum tensile force value applied before rupture. Toughness can be calculated as the ratio of the load required to rupture the sample to the linear density of the sample.

[0137] In some aspects, it is desirable to use yarns suitable for use on commercial knitting equipment. The free-standing shrinkage of yarn at 50 degrees Celsius is a property that can be predicted for a suitable yarn used on a commercial knitting machine. In some aspects, films, fibers, silks and yarns described herein can present a free shrinkage of less than 15% when heated from 20 degrees Celsius to 70 degrees Celsius. In various aspects, films, fibers and yarns described herein can present a free shrinkage of about 0% to about 60%, about 0% to about 30% or about 0% to about 15% when heated from 20 degrees Celsius to 70 degrees Celsius. As used herein, the term "free shrinkage" refers to the properties of yarns and the corresponding test method described below:

[0138] Yarn shrinkage test. The free shrinkage of yarn can be determined by the following method. Yarn sample is prepared according to the yarn sampling procedure described below, and is cut into a length of about 30 mm with minimum tension at about room temperature (e.g., 20 degrees Celsius). The cut sample is placed in an oven at 50 degrees Celsius or 70 degrees Celsius for 90 seconds. The sample is removed from the oven and measured. Using the oven-front measurement value and the oven-back measurement value of the sample, by dividing the oven-back measurement value by the oven-front measurement value, and multiplying by 100 to calculate the shrinkage percentage.

[0139] Yarn sampling procedure. Prior to testing, the yarn to be tested was stored at room temperature (20 degrees Celsius to 24 degrees Celsius) for 24 hours. The first 3 meters of material were discarded. The sample yarn was cut into a length of approximately 30 mm at minimal tension at approximately room temperature (e.g., 20 degrees Celsius).

[0140] In one or more aspects, the free shrinkage of yarn at 70 degrees Celsius can be a useful indicator of the ability of the yarn to be exposed to certain environmental conditions without any substantial changes to the physical structure of the yarn. In some aspects, the yarn comprising the low processing temperature polymer composition can present a free shrinkage from about 0% to about 60% when heated from 20 degrees Celsius to 70 degrees Celsius. In one or more aspects, the yarn comprising the low processing temperature polymer composition can present a free shrinkage from about 0% to about 30% when heated from 20 degrees Celsius to 70 degrees Celsius. In one aspect, the yarn comprising the low processing temperature polymer composition can present a free shrinkage from about 0% to about 20% when heated from 20 degrees Celsius to 70 degrees Celsius.

[0141] As discussed above, in some aspects, the first polymer composition and the second polymer composition as described herein have different properties. In various aspects, these different properties allow the coated fibers as described herein to melt and flow during the thermoforming process, and then cool and solidify into a structure different from the structure before the thermoforming process (e.g., thermoforming from yarn to a molten yarn component), and when the thermoforming process is performed at a temperature lower than the melting temperature of the uncoated fiber, the uncoated fiber cannot be deformed or melted during such a process and can maintain its structure (e.g., as a yarn). In such aspects, the molten yarn component formed by the coated fiber as described herein during the thermoforming process can be integrally connected with an unchanged structure (e.g., yarn or fiber), which can provide a three-dimensional structure and / or other properties for a specific part on a wearing article.

[0142] Exemplary Thermoplastic Elastomers In various fields, the polymer composition for the coating of the first yarn described herein comprises one or more thermoplastic elastomers. In aspect, " elastomer " is defined as having at 25 degrees Celsius the material of the elongation at break greater than 400% determined according to using ASTM D-412-98. In another aspect, elastomer is formed as substrate, wherein substrate has from 10 kgf to 35 kgf (kgf) or from about 10 kgf to about 25 kgf or from about 10 kgf to about 20 kgf or from about 15 kgf to about 35 kgf or from about 20 kgf to about 30 kgf of breaking strength. In another aspect, if adjusted for cross-sectional area, tensile strength or ultimate strength are greater than 70 kgf / cm2, or greater than 80 kgf / cm2. In another aspect, the elastomeric substrate has a strain at break of from 450% to 800%, or from 500% to 800%, or from 500% to 750%, or from 600% to 750%, or from 450% to 700%. In yet another aspect, the elastomeric substrate has a load at 100% strain of from 3 to 8 kgf / mm, or from about 3 to about 7 kgf / mm, from about 3.5 to about 6.5 kgf / mm, or from about 4 to about 5 kgf / mm. In one aspect, the elastomeric substrate has a toughness of from 850 kg·mm to 2200 kg·mm, or from about 850 kg·mm to about 2000 kg·mm, or from about 900 kg·mm to about 1750 kg·mm, or from about 1000 kg·mm to about 1500 kg·mm, or from about 1500 kg·mm to about 2000 kg·mm. In one aspect, the elastomeric substrate has a stiffness from about 35 to about 155, or from about 50 to about 150, or from about 50 to about 100, or from about 50 to about 75, or from about 60 to about 155, or from about 80 to about 150. In yet another aspect, the elastomeric substrate has a tear strength from about 35 to about 80, or from about 35 to about 75, or from about 40 to about 60, or from about 45 to about 50.

[0143] In aspects, exemplary thermoplastic elastomers include homopolymers and copolymers. The term "polymer" refers to a polymerized molecule with one or more monomeric substances, and includes homopolymers and copolymers. The term "copolymer" refers to a polymer with two or more monomeric substances, and includes terpolymers (i.e., copolymers with three monomeric substances). In certain aspects, the thermoplastic elastomer is a random copolymer. In one aspect, the thermoplastic elastomer is a block copolymer. For example, the thermoplastic elastomer can be a block copolymer having: a relatively hard repeating block (hard segment) of a polymer unit of the same chemical structure (segment) and a relatively soft repeating block (soft segment) of a polymer segment. In various aspects, in a block copolymer including a block copolymer with repeated hard segments and soft segments, physical crosslinking can be present in a block or between blocks, or in a block and between blocks. Specific examples of hard segments include isocyanate segments and polyamide segments. Specific examples of soft segments include polyether segments and polyester segments. As used herein, polymer segments can be polymer segments of a particular type, such as, for example, isocyanate segments, polyamide segments, polyether segments, polyester segments and similar segments. It should be understood that the chemical structure of the segment is derived from the described chemical structure. For example, an isocyanate segment is a unit of polymerization including an isocyanate functional group. When referring to a block of a polymer segment of a particular chemical structure, the block can include up to 10 mol% of segments of other chemical structures. For example, as used herein, a polyether segment is understood to include up to 10 mol% of a non-polyether segment.

[0144] In one aspect, the first polymer composition comprises a polymer component consisting of all polymers present in the polymer composition; optionally wherein the polymer component comprises two or more polymers, wherein the two or more polymers differ from each other in the chemical structure of the individual segments of each of the two or more polymers, or in the molecular weight of each of the two or more polymers, or both.

[0145] In various aspects, thermoplastic elastomer can include thermoplastic copolyester elastomer, thermoplastic polyether block amide elastomer, thermoplastic polyurethane elastomer, copolymer elastomer based on polyolefin, thermoplastic styrene copolymer elastomer, thermoplastic ionomer elastomer or any combination thereof one or more. In one aspect, the first polymer composition includes thermoplastic elastomer styrene copolymer. In other aspects, thermoplastic elastomer styrene copolymer can be styrene butadiene styrene (SBS) block copolymer, styrene ethylene / butylene styrene (SEBS) resin, styrene acrylonitrile (SAN) resin or any combination thereof. In one aspect, polymer composition includes thermoplastic elastomer polyester polyurethane, thermoplastic polyether polyurethane or any combination thereof. In some aspects, thermoplastic elastomer polyester polyurethane can be aromatic polyester, aliphatic composition or a combination thereof. It should be understood that other thermoplastic polymer materials not specifically described below are also intended to be used in coated fibers and / or uncoated fibers as described herein. In one aspect, the polymer composition comprising a thermoplastic elastomer has a melting temperature greater than about 110 degrees C and less than about 170 degrees C. In another aspect, the polymer composition comprising a thermoplastic elastomer has a melting temperature of about 110 degrees C to about 170 degrees C, about 115 degrees C to about 160 degrees C, about 120 degrees C to about 150 degrees C, about 125 degrees C to about 140 degrees C, about 110 degrees C to about 150 degrees C, or about 110 degrees C to about 125 degrees C.

[0146] In various aspects, the thermoplastic elastomer has a glass transition temperature (Tg) of less than 50 degrees Celsius when determined according to ASTM D3418-97 as described herein below. In some aspects, the thermoplastic elastomer has a glass transition temperature (Tg) of about -60 degrees Celsius to about 50 degrees Celsius, about -25 degrees Celsius to about 40 degrees Celsius, about -20 degrees Celsius to about 30 degrees Celsius, about -20 degrees Celsius to about 20 degrees Celsius, or about -10 degrees Celsius to about 10 degrees Celsius when determined according to ASTM D3418-97 as described herein below. In one aspect, the glass transition temperature of the thermoplastic elastomer is selected such that an article incorporates the covered yarn disclosed herein, wherein the covered yarn includes a coating material comprising a thermoplastic elastomer, the thermoplastic material, when incorporated into an article of footwear, is above its glass transition temperature (i.e., more rubbery and less brittle) during normal wear.

[0147] In one aspect, the thermoplastic elastomer comprises: (a) more than one first segment; (b) more than one second segment; and optionally, (c) more than one third segment. In various aspects, the thermoplastic elastomer is a block copolymer. In some aspects, the thermoplastic elastomer is a segmented copolymer. In other aspects, the thermoplastic elastomer is a random copolymer. In still other aspects, the thermoplastic elastomer is a condensation copolymer.

[0148] In further aspects, the thermoplastic elastomer has a weight average molecular weight of about 50,000 Daltons to about 1,000,000 Daltons; about 50,000 Daltons to about 500,000 Daltons; about 75,000 Daltons to about 300,000 Daltons; about 100,000 Daltons to about 200,000 Daltons.

[0149] In further aspects, the thermoplastic elastomer has a ratio of the first segment to the second segment from about 1:1 to about 1:2 based on the weight of each of the first segment and the second segment; or from about 1:1 to about 1:1.5 based on the weight of each of the first segment and the second segment.

[0150] In further aspects, the thermoplastic elastomer has a ratio of the first segment to the third segment from about 1:1 to about 1:5 based on the weight of each of the first segment and the third segment; from about 1:1 to about 1:3 based on the weight of each of the first segment and the third segment; from about 1:1 to about 1:2 based on the weight of each of the first segment and the third segment; from about 1:1 to about 1:3 based on the weight of each of the first segment and the third segment.

[0151] In further aspects, the thermoplastic elastomer has a first segment derived from a first component having a number average molecular weight of about 250 Daltons to about 6000 Daltons; about 400 Daltons to about 6,000 Daltons; about 350 Daltons to about 5,000 Daltons; or about 500 Daltons to about 3,000 Daltons.

[0152] In some aspects, the thermoplastic elastomer includes phase separated domains. For example, more than one first segment can be phase separated into domains that mainly contain the first segment. In addition, more than one second segment derived from segments with different chemical structures can be phase separated into domains that mainly contain the second segment. In some aspects, the first segment can include a hard segment and the second segment can include a soft segment. In other aspects, the thermoplastic elastomer can include phase separated domains that include more than one first copolyester unit.

[0153] In one aspect, prior to thermoforming, the polymer composition has a glass transition temperature of from about 20 degrees Celsius to about -60 degrees Celsius. In one aspect, prior to thermoforming, the polymer composition has a Taber abrasion resistance of from about 10 mg to about 40 mg as determined by ASTM D3389. In one aspect, prior to thermoforming, the polymer composition has a durometer hardness (Shore A) of from about 60 to about 90 as determined by ASTM D2240. In one aspect, prior to thermoforming, the polymer composition has a hardness of from about 0.80 g / cm2 as determined by ASTM D792. 3 to about 1.30 g / cm 3 In one aspect, before thermoforming, the polymer composition has a melt flow index of about 2 g / 10 min to about 50 g / 10 min at 160 degrees Celsius using a test weight of 2.16 kg. In one aspect, before thermoforming, the polymer composition has a melt flow rate greater than about 2 g / 10 min at 190 degrees Celsius or 200 degrees Celsius when using a test weight of 10 kg. In one aspect, before thermoforming, the polymer composition has a modulus of about 1 MPa to about 500 MPa.

[0154] Exemplary Thermoplastic Polyurethane Elastomers In certain aspects, the thermoplastic elastomer of the coating of the first yarn as in some aspects of this article is a thermoplastic polyurethane (TPU) elastomer. Thermoplastic polyurethane elastomer can be a thermoplastic block polyurethane copolymer. Thermoplastic polyurethane copolymer can be a copolymer comprising a hard segment and a soft segment, including a block of a hard segment and a block of a soft segment. The hard segment can include an isocyanate segment or be composed of an isocyanate segment. In the same aspect or in an optional aspect, the soft segment can include a combination of a polyether segment, or a polyester segment, or a combination of a polyether segment, or a polyester segment, or a polyether segment and a polyester segment. In one aspect, the polymer component of a thermoplastic material or a thermoplastic material can include an elastomeric thermoplastic polyurethane hard segment and a soft segment, or is substantially composed of an elastomeric thermoplastic polyurethane hard segment and a soft segment, and the elastomeric thermoplastic polyurethane hard segment and a soft segment are such as an elastomeric thermoplastic polyurethane having a repeating block of a hard segment and a repeating block of a soft segment.

[0155] In aspects, one or more of the thermoplastic polyurethane elastomers can be produced by polymerizing one or more isocyanates with one or more polyols to produce a copolymer chain having urethane bonds (-N(CO)O-), as shown below in Formula 1, wherein each of the isocyanates preferably includes two or more isocyanate (-NCO) groups per molecule, such as 2, 3 or 4 isocyanate groups per molecule (although monofunctional isocyanates may also optionally be included, for example as a chain terminating unit).

[0156]

[0157] (Formula 1).

[0158] In these aspects, each R1 and R2 is independently an aliphatic segment or an aromatic segment. Optionally, each R2 can be a hydrophilic segment.

[0159] Unless otherwise indicated, any functional group or compound described herein can be substituted or unsubstituted. "Substituted" group or compound, such as alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl, heteroaryl, alkoxy, ester, ether or carboxylate refers to alkyl group, alkenyl group, alkynyl group, cycloalkyl group, cycloalkenyl group, aryl group, heteroaryl group, alkoxy group, ester group, ether group or carboxylate group has at least one hydrogen group replaced by non-hydrogen group (i.e. substituent). The example of non-hydrogen group (or substituent) includes but is not limited to alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, ether, aryl, heteroaryl, heterocycloalkyl, hydroxyl, oxy (or oxo), alkoxy, ester, thioester, acyl, carboxyl, cyano, nitro, amino, amido, sulphur and halogen. When substituted alkyl group comprises more than one non-hydrogen group, substituent can be attached to the same carbon atom or two or more different carbon atoms.

[0160] In addition, the isocyanate can also be chain extended with one or more chain extenders to bridge two or more isocyanates. This can produce a polyurethane copolymer chain as shown in Formula 2 below, where R3 includes a chain extender. Like each R1 and R2, each R3 is independently an aliphatic segment or an aromatic segment.

[0161]

[0162] (Formula 2).

[0163] Each segment R1 or the first segment in Formula 1 and Formula 2 may independently include a linear or branched C 3-30The chain segments may be aliphatic, aromatic, or include a combination of aliphatic and aromatic moieties. The term "aliphatic" refers to a saturated or unsaturated organic molecule that does not include a ring system with delocalized π electrons. In contrast, the term "aromatic" refers to a ring system with delocalized π electrons that is conjugated, which exhibits greater stability than a hypothetical ring system with localized π electrons.

[0164] Each segment R2 may be present in an amount of 5 to 85% by weight, from 5 to 70% by weight, or from 10 to 50% by weight based on the total weight of the reactant monomers.

[0165] In the aliphatic aspect (from aliphatic isocyanates), each segment R1 may include a linear aliphatic group, a branched aliphatic group, an alicyclic group, or a combination thereof. For example, each segment R1 may include a linear or branched C 3-20 The alkylene segment (e.g., C 4-15 Alkylene or C 6-10 Alkylene), one or more C 3-8 Cycloalkylene segments (eg, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, or cyclooctyl), and combinations thereof.

[0166] Examples of suitable aliphatic diisocyanates for producing polyurethane copolymer chains include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), butylene diisocyanate (BDI), dicyclohexylmethane diisocyanate (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), diisocyanatomethylcyclohexane, diisocyanatomethyltricyclodecane, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4'-dicyclohexylmethane diisocyanate (H12MDI), diisocyanatododecane, lysine diisocyanate, and combinations thereof.

[0167] In the aromatic aspect (from aromatic isocyanates), each segment R1 may include one or more aromatic groups, such as phenyl, naphthyl, tetrahydronaphthyl, phenanthrenyl, biphenylene, indanyl, indenyl, anthracenyl and fluorenyl. Unless otherwise indicated, aromatic groups may be unsubstituted aromatic groups or substituted aromatic groups, and may also include heteroaromatic groups. "Heteroaromatic" refers to monocyclic or polycyclic (e.g., fused bicyclic and fused tricyclic) aromatic ring systems, in which one to four ring atoms are selected from oxygen, nitrogen or sulfur, and the remaining ring atoms are carbon, and wherein the ring system is connected to the rest of the molecule through any ring atoms. Examples of suitable heteroaryl groups include pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isoxazolyl, thiadiazolyl, oxadiazolyl, furanyl, quinolyl, isoquinolyl, benzoxazolyl, benzimidazolyl and benzothiazolyl.

[0168] Examples of suitable aromatic diisocyanates for producing polyurethane copolymer chains include toluene diisocyanate (TDI), TDI adducts with trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethyl xylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some aspects, the copolymer chain is substantially free of aromatic groups.

[0169] In a particular aspect, the polyurethane copolymer chains are produced from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. For example, the coated fibers of the present disclosure as described herein may include one or more polyurethane copolymer chains produced from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof.

[0170] In some aspects, according to the present disclosure, crosslinked polyurethane chains (e.g., partially crosslinked polyurethane copolymers retaining thermoplastic properties) or crosslinked polyurethane chains can be used. It is possible to use multifunctional isocyanates to produce crosslinked or crosslinkable polyurethane copolymer chains. Examples of suitable triisocyanates for producing polyurethane copolymer chains include TDI, HDI and IPDI adducts with trimethylolpropane (TMP), uretdione (i.e., diisocyanates), polymeric MDI and combinations thereof.

[0171] The segment R3 in Formula 2 may include a linear or branched C2-C10 segment based on the particular chain extender polyol used, and may be, for example, aliphatic, aromatic, or a polyether. Examples of suitable chain extender polyols for producing polyurethane copolymer chains include ethylene glycol, lower oligomers of ethylene glycol (e.g., diethylene glycol, triethylene glycol, and tetraethylene glycol), 1,2-propylene glycol, 1,3-propylene glycol, lower oligomers of propylene glycol (e.g., dipropylene glycol, tripropylene glycol, and tetrapropylene glycol), 1,4-butanediol, 2,3-butanediol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 1,4-cyclohexanedimethanol, 2-ethyl-1,6-hexanediol, 1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol, dihydroxyalkylated aromatic compounds (e.g., bis(2-hydroxyethyl) ethers of hydroquinone and resorcinol, xylene-α,α-diol, bis(2-hydroxyethyl) ether of xylene-α,α-diol, and combinations thereof.

[0172] The segment R2 in Formula 1 and Formula 2 may include a polyether group, a polyester group, a polycarbonate group, an aliphatic group, or an aromatic group. Each segment R2 may be present in an amount of 5% to 85% by weight, 5% to 70% by weight, or 10% to 50% by weight based on the total weight of the reactant monomers.

[0173] Optionally, in some examples, the thermoplastic polyurethane elastomer is a thermoplastic polyurethane with a relatively high degree of hydrophilicity. For example, the thermoplastic polyurethane may be a thermoplastic polyether polyurethane in which the segment R2 in Formula 1 and Formula 2 includes a polyether group, a polyester group, a polycarbonate group, an aliphatic group or an aromatic group, wherein the aliphatic group or the aromatic group is replaced by one or more side groups (i.e., relatively "hydrophilic" groups) with a relatively large degree of hydrophilicity. The relatively "hydrophilic" group may be selected from the group consisting of: hydroxyl, polyether, polyester, polylactone (e.g., polyvinyl pyrrolidone (PVP)), amino, carboxylate, sulfonate, phosphate, ammonium (e.g., tertiary ammonium and quaternary ammonium), zwitterionic groups (e.g., betaine, such as poly (carboxy betaine) (pCB) and ammonium phosphonate, such as phosphatidylcholine) and combinations thereof. In such an example, this relatively hydrophilic group or segment of R2 may form a part of the polyurethane backbone, or may be grafted to the polyurethane backbone as a side group. In some examples, the hydrophilic side groups or segments can be bonded to the aliphatic group or aromatic group through a linker.Each segment R2 can be present in an amount of 5% to 85% by weight, from 5% to 70% by weight, or from 10% to 50% by weight based on the total weight of the reactant monomers.

[0174] In some examples, at least one R2 segment of the thermoplastic polyurethane elastomer includes a polyether segment (i.e., a segment having one or more ether groups). Suitable polyethers include, but are not limited to, polyethylene oxide (PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF), polytetramethylene oxide (PTmO), and combinations thereof. As used herein, the term "alkyl" refers to a straight chain and branched saturated hydrocarbon group containing one to thirty carbon atoms, such as one to twenty carbon atoms or one to ten carbon atoms. The term C n It means that the alkyl group has "n" carbon atoms. For example, C4 alkyl refers to an alkyl group with 4 carbon atoms. 1-7 Alkyl refers to an alkyl group having a carbon number covering the entire range (i.e., 1 to 7 carbon atoms) and all subgroups (e.g., 1-6, 2-7, 1-5, 3-6, 1, 2, 3, 4, 5, 6 and 7 carbon atoms). The non-limiting examples of alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl (2-methylpropyl), tert-butyl (1,1-dimethylethyl), 3,3-dimethylpentyl and 2-ethylhexyl. Unless otherwise indicated, alkyl groups may be unsubstituted alkyl groups or substituted alkyl groups.

[0175] In some examples of thermoplastic polyurethane elastomers, at least one R2 segment includes a polyester segment. The polyester segment can be derived from the polyesterification of one or more diols (e.g., ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol, 1,5-diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, and combinations thereof) and one or more dicarboxylic acids (e.g., adipic acid, succinic acid, sebacic acid, suberic acid, methyl adipic acid, glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid, and citraconic acid, and combinations thereof). The polyester can also be derived from a polycarbonate prepolymer such as poly(hexamethylene carbonate) glycol, poly(propylene carbonate) glycol, poly(tetramethylene carbonate) glycol, and poly(nonanemethylene carbonate) glycol. Suitable polyesters can include, for example, polyethylene adipate (PEA), poly(1,4-butylene adipate), poly(tetramethylene adipate), poly(hexamethylene adipate), polycaprolactone, polyhexamethylene carbonate, poly(propylene carbonate), poly(tetramethylene carbonate), poly(nonamethylene carbonate), and combinations thereof.

[0176] In various aspects of the thermoplastic polyurethane elastomer, at least one R2 segment includes a polycarbonate segment. The polycarbonate segment can be derived from the reaction of one or more diols (e.g., ethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butylene glycol, 1,3-butylene glycol, 2-methylpentanediol, 1,5-diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanedimethanol, and combinations thereof) with ethylene carbonate.

[0177] In various examples of thermoplastic polyurethane elastomers, at least one R2 segment may include an aliphatic group substituted with one or more groups having a relatively greater degree of hydrophilicity, i.e., a relatively "hydrophilic" group. The one or more relatively hydrophilic groups may be selected from the group consisting of hydroxyl, polyether, polyester, polylactone (e.g., polyvinylpyrrolidone), amino, carboxylate, sulfonate, phosphate, ammonium (e.g., tertiary ammonium and quaternary ammonium), zwitterionic groups (e.g., betaines, such as poly(carboxybetaine) (pCB) and ammonium phosphonates, such as phosphatidylcholine), and combinations thereof. In some examples, the aliphatic group is straight chain and can include, for example, a C1-20 alkylene chain or a C1-20 alkenylene chain (e.g., methylene, ethylene, propylene, butylene, pentylene, hexylene, heptylene, octylene, nonylene, decylene, undecylene, dodecylene, tridecylene, vinylene, propenylene, butenylene, pentenylene, hexenylene, heptenylene, octenylene, nonenylene, decenylene, undecenylene, dodecenylene, tridecenylene). The term "alkylene" refers to a divalent hydrocarbon. The term C1-20 alkenylene chain includes, for example, methylene, ethylene, propylene, butylene, pentylene, hexylene, heptylene, octenylene, nonenylene, decenylene, undecenylene, dodecenylene, tridecenylene. n It means that the alkylene group has "n" carbon atoms. For example, C1-6 alkylene refers to an alkylene group having, for example, 1, 2, 3, 4, 5 or 6 carbon atoms. The term "alkenylene" refers to a divalent hydrocarbon having at least one double bond.

[0178] In some cases, at least one R2 segment comprises an aromatic group substituted with one or more relatively hydrophilic groups. The one or more hydrophilic groups can be selected from the group consisting of hydroxyl, polyether, polyester, polylactone (e.g., polyvinylpyrrolidone), amino, carboxylate, sulfonate, phosphate, ammonium (e.g., tertiary ammonium and quaternary ammonium), zwitterionic groups (e.g., betaines such as poly(carboxybetaine) (pCB) and ammonium phosphonate groups such as phosphatidylcholine), and combinations thereof. Suitable aromatic groups include, but are not limited to, phenyl, naphthyl, tetrahydronaphthyl, phenanthrenyl, biphenylene, indanyl, indenyl, anthracenyl, fluorenyl, pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl, tetrazolyl, oxazolyl, isoxazolyl, thiadiazolyl, oxadiazolyl, furanyl, quinolyl, isoquinolyl, benzoxazolyl, benzimidazolyl, and benzothiazolyl groups and combinations thereof.

[0179] In various aspects, aliphatic groups and aromatic groups can be replaced by one or more relatively hydrophilic and / or charged side groups. In some aspects, hydrophilic side groups include one or more (for example, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) hydroxyl groups. In various aspects, hydrophilic side groups include one or more (for example, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) amino groups. In some cases, hydrophilic side groups include one or more (for example, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) carboxylate groups. For example, aliphatic groups can include one or more polyacrylic acid groups. In some cases, hydrophilic side groups include one or more (for example, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) sulfonate groups. In some cases, the hydrophilic side groups include one or more (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10 or more) phosphate groups. In some instances, the hydrophilic side groups include one or more ammonium groups (e.g., tertiary ammonium and / or quaternary ammonium). In other instances, the hydrophilic side groups include one or more zwitterionic groups (e.g., betaines, such as poly (carboxybetaine) (pCB) and ammonium phosphonate groups such as phosphatidylcholine groups).

[0180] In some aspects, the R2 segment can include a charged group capable of binding a counterion to ionically crosslink the thermoplastic elastomer and form an ionomer. In these aspects, for example, R2 is an aliphatic or aromatic group having an amino side group, a carboxylate side group, a sulfonate side group, a phosphate side group, an ammonium side group, or a zwitterionic side group, or a combination thereof.

[0181] In various cases, when hydrophilic side groups are present, the "hydrophilic" side groups are at least one polyether group, such as two polyether groups. In other cases, the hydrophilic side groups are at least one polyester. In various cases, the hydrophilic side groups are polylactone groups (e.g., polyvinyl pyrrolidone). Each carbon atom in the hydrophilic side groups can be optionally replaced by, for example, C 1-6 Alkyl group substitution. In some of these aspects, the aliphatic and aromatic groups can be grafted polymer groups, where the pendant groups are homopolymer groups (eg, polyether groups, polyester groups, polyvinylpyrrolidone groups).

[0182] In some aspects, the hydrophilic side groups are polyether groups (eg, polyethylene oxide groups, polyethylene glycol groups), polyvinyl pyrrolidone groups, polyacrylic acid groups, or combinations thereof.

[0183] As described herein, thermoplastic polyurethane elastomers can be physically cross-linked by non-polar interactions or polar interactions between urethane or carbamate groups (hard segments) on polymers, for example. In these aspects, component R1 in formula 1 and components R1 and R3 in formula 2 form a polymer portion commonly referred to as a "hard segment", and component R2 forms a polymer portion commonly referred to as a "soft segment". In these aspects, the soft segment can be covalently bonded to the hard segment. In some instances, the thermoplastic polyurethane elastomer with physically cross-linked hard segments and soft segments can be a hydrophilic thermoplastic polyurethane elastomer (i.e., a thermoplastic polyurethane elastomer comprising a hydrophilic group as disclosed herein).

[0184] In one aspect, prior to thermoforming, the thermoplastic polyurethane elastomer is an aromatic polyester thermoplastic elastomer polyurethane or an aliphatic polyester thermoplastic elastomer polyurethane having the following properties: (1) a glass transition temperature from about 20 degrees Celsius to about -60 degrees Celsius; (2) a Taber abrasion resistance from about 10 mg to about 40 mg as determined by ASTM D3389; (3) a durometer hardness (Shore A) from about 60 to about 90 as determined by ASTM D2240; (4) a hardness from about 0.80 g / cm2 as determined by ASTM D792. 3 to about 1.30 g / cm 3 (5) a melt flow index of about 2 g / 10 minutes to about 50 g / 10 minutes at 160 degrees Celsius using a 2.16 kg test weight; (6) a melt flow rate greater than about 2 g / 10 minutes at 190 degrees Celsius or 200 degrees Celsius when a 10 kg test weight is used; and (7) a modulus of about 1 MPa to about 500 MPa.

[0185] Commercially available thermoplastic polyurethane elastomers with greater hydrophilicity suitable for use in the present invention include, but are not limited to, those sold under the trade names "TECOPHILIC", such as TG-500, TG-2000, SP-80A-150, SP-93A-100, SP-60D60 (Lubrizol, Countryside, IL), "ESTANE" (e.g., 58238, T470A; Lubrizol, Countryside, IL), and "ELASTOLLAN" (e.g., 9339, B70A; BASF).

[0186] In various aspects, the thermoplastic polyurethane elastomer can be partially covalently cross-linked, as previously described herein.

[0187] Exemplary Thermoplastic Styrene Copolymer Elastomers In some aspects, thermoplastic elastomer is a thermoplastic elastomer styrene copolymer. Examples of these copolymers include but are not limited to styrene butadiene styrene (SBS) block copolymers, styrene ethylene / butylene styrene (SEBS) resins, polyacetal resins (POM), styrene acrylonitrile resins (SAN) or its blends, alloys or compounds. Exemplary commercially available thermoplastic elastomer styrene copolymers include MONOPRENE IN5074, SP066070 and SP16975 (TeknorApex, Pawtucket, RI, USA), which are styrene ethylene / butylene styrene (SEBS) resins. In some aspects, blends, alloys and compounds should be melt compatible, or can be compatible with additives, oils or grafted chemical moieties to achieve miscibility.

[0188] In one aspect, the thermoplastic elastomeric styrene copolymer comprises at least one block as shown in Formula 3 below:

[0189] (Formula 3).

[0190] In another aspect, the thermoplastic elastomer styrene copolymer can be an SBS block copolymer comprising a first polystyrene block (block m of Formula 4), a polybutadiene block (block o of Formula 4), and a second polystyrene block (block p of Formula 4), wherein the SBS block copolymer has the general structure shown in Formula 4 below:

[0191] (Formula 4).

[0192] In another aspect, the thermoplastic elastomer styrene copolymer can be a SEBS block copolymer, which comprises a first polystyrene block (block x of Formula 5); a polyolefin block (block y of Formula 5), ​​wherein the polyolefin block includes alternating polyethylene blocks (block v of Formula 5) and polybutylene blocks (block w of Formula 4); and a second polystyrene block (block z of Formula 5), ​​as seen in Formula 5 below.

[0193]

[0194] (Formula 5).

[0195] In one aspect, SEBS polymer has a density from about 0.88 grams per cubic centimeter to about 0.92 grams per cubic centimeter. In other aspects, the density of SEBS polymer can be up to 15% to 25% less than crosslinked rubber, crosslinked polyurethane and thermoplastic polyurethane materials. In other aspects, the coating composition of less density provides weight saving and cost saving for the material of the same volume adopted, and realizes similar performance simultaneously.

[0196] Reference to "a" compound refers to one or more molecules of a compound and is not limited to a single molecule of the compound. Furthermore, one or more molecules may or may not be identical, as long as they fall under the class of the chemical compound. Thus, for example, "polyamide" is interpreted to include one or more polymer molecules of polyamide, where the polymer molecules may or may not be identical (e.g., different molecular weights and / or isomers).

[0197] The terms "at least one" element and "one or more" in an element are used interchangeably and have the same meaning including a single element and more than one element, and may also be indicated by the suffix "(s)" at the end of an element. For example, "at least one polyamide," "one or more polyamides," and "multiple polyamides" may be used interchangeably and have the same meaning.

[0198] Unless otherwise indicated, temperatures referred to herein are determined at standard atmosphere (ie, 1 ATM).

[0199] Property Analysis and Characterization Procedures Evaluation of the various properties and characteristics described herein was performed by various test procedures as described below.

[0200] Sample friction coefficient . The static coefficient of friction or dynamic coefficient of friction (COF) of a textile or substrate sample can be determined using test method ASTM D1894. In this method, the sample is cut to size and mounted on a sled, and a 100-gram weight plate is placed on the sled. During the test, the weighted sled is pulled across the test surface of the material being tested. For example, static and dynamic wet COF and dry COF can be determined by pulling the sled across a concrete surface to determine the COF of the sample and concrete. The coefficient of friction of the sample for the surface is captured by recording the normal force (100 grams plus the sled weight) and measuring the applied force required to drag the sled across the test surface. Then, the coefficient of friction (COF) is calculated from the ratio of the two forces. The dry COF is determined by testing a dry sample for a dry test surface, and the wet COF is determined by testing a sample wetted with water for a test surface wetted with room temperature water via soaking the sample in room temperature water for 10 minutes.

[0201] Textile-Ball Friction Coefficient Test . The static coefficient of friction and dynamic coefficient of friction (COF) of samples prepared using the component sampling procedure or textile sampling procedure described below relative to samples of panels from a "MERLIN" soccer ball (Nike Inc., Beaverton, OR, USA) can be determined using a modified version of the test method ASTM D1894 as described for sample coefficient of friction. In this method, the sample is cut to size and mounted on an acrylic substrate, and the ball material is cut to size and mounted on a sled. After the ball material has been mounted on the sled, the sled has a contact footprint of 3.9 inches by 1 inch and a weight of approximately 0.402 kilograms. During testing, the sample and ball material are positioned so that the outward-facing surface of the ball material contacts the surface of the sample, which surface is expected to form the outward-facing surface of the footwear article, and the sled is pulled across the sample. The dry sample and dry ball material are used to determine the static dry COF or the dynamic dry COF. To determine the static wet COF or the dynamic wet COF, the sample and the ball material are both soaked in room temperature water for 10 minutes shortly before testing. Each measurement was repeated at least 3 times, and the results of the runs were averaged.

[0202] Melting Temperature and Glass Transition Temperature Tests . Melting temperature and / or glass transition temperature of the sample prepared according to the material sampling procedure described below are determined using a commercially available differential scanning calorimeter ("DSC") according to ASTM D3418-97. In short, 10 mg-60 mg of sample is placed in an aluminum DSC pan, and then sealed with a tablet press. The DSC is configured to scan from -100 degrees Celsius to 225 degrees Celsius at a heating rate of 20 degrees Celsius / minute, keep at 225 degrees Celsius for 2 minutes, and then cool to 25 degrees Celsius at a rate of -20 degrees Celsius / minute. The DSC curve generated by the scan is then analyzed using standard techniques to determine the glass transition temperature and melting temperature. The melting enthalpy is calculated by integrating the melting endotherm and normalizing by the mass of the sample. The crystallization enthalpy after cooling is calculated by integrating the cooling endotherm and normalizing by the mass of the sample.

[0203] Deformation temperature test.According to the test method described in detail in the ASTM Tm D1525-09 standard test method for the Vicat softening temperature of plastics, the Vicat softening temperature of the sample of the material sampling procedure or the component sampling procedure article described below is preferably determined using load A and rate A. In short, the Vicat softening temperature is such a temperature at which a flat-ended needle penetrates the sample to a depth of 1 mm under a specific load. The temperature reflects the softening point expected when the material is used for high temperature applications. It is considered to be such a temperature at which the sample is penetrated to a depth of 1 mm by a flat-ended needle with a 1 square millimeter circular cross section or a square cross section. For the Vicat A test, a load of 10 Newtons (N) is used, while for the Vicat B test, the load is 50 Newtons. The test involves placing the test sample in a test device so that the penetrated needle stays on its surface at least 1 mm from the edge. According to the requirements of the Vicat A test or the Vicat B test, the load is applied to the sample. The sample is then lowered into an oil bath at 23 degrees Celsius. The bath is heated at a rate of 50 degrees Celsius or 120 degrees Celsius per hour until the needle penetrates 1 mm. The thickness of the test specimen must be between 3 mm and 6.5 mm, and the width and length must be at least 10 mm. No more than three layers may be stacked to achieve the minimum thickness.

[0204] Melt flow index test. According to the test method described in detail in the ASTM D1238-13 standard test method for the melt flow of thermoplastics by extrusion plastometer, the melt flow index of the sample prepared according to the material sampling procedure described below is determined using the procedure A described therein. In short, the melt flow index measures the rate at which thermoplastics are extruded through an orifice at a specified temperature and load. In the test method, about 7 grams of material are loaded into the barrel of a melt flow device, which has been heated to a temperature specified for the material. The weight specified for the material is applied to the plunger, and the molten material is forced through the die. The timed extrudate is collected and weighed. For a given applied load and applied temperature, the melt flow index value is calculated in g / 10 min. As described in ASTM D1238-13, the melt flow index can be determined at 160 degrees Celsius using a weight of 2.16 kg, or at 200 degrees Celsius using a weight of 10 kg.

[0205] Molten polymer viscosity testing. The test was performed using a 2 mm substrate or film prepared according to the substrate or film sampling procedure described below. A circular die was used to cut a 50 mm sample disc from a substrate or film. The test sample was mounted on a 50 mm diameter aluminum parallel plate on an ARES-G2 (displacement controlled) rheometer. The top plate was lowered so that the test sample was in contact with the two disc surfaces under a determined normal force load, and the stage was heated to 210 degrees Celsius. The sample was balanced until the melt continued for a determined residence time of several minutes, and an oscillatory shear frequency sweep was applied with a low strain amplitude to collect rate-related data. The ratio of the applied shear stress required to produce an oscillatory motion at a given shear frequency rate produces the measured viscosity value. Shear rate-related viscosity data can be collected from 0.1 reciprocal seconds to 1000 reciprocal seconds.

[0206] Substrate modulus testing. According to the test method described in detail in the ASTM D412-98 standard test method for vulcanized rubber and thermoplastic rubber and thermoplastic elastomer-stretching under the situation of following modification, determine the modulus of the sample prepared according to the substrate or film sampling procedure described below.Sample size is ASTM D412-98 Die C, and the sample thickness used is 2.0 millimeters plus or minus 0.5 millimeter.The type of fixture used is the pneumatic fixture with metal serrated fixture face (metalserrated grip face).The fixture distance used is 75 millimeters.The loading rate used is 500 millimeters / minute.Modulus (initial) is calculated by obtaining the slope of stress (MPa) relative to strain in the initial linear region.This test can also be used to determine other tensile properties such as breaking strength, breaking strain, load at 100% strain, toughness, rigidity, tear strength and similar properties.

[0207] Yarn denier and thickness testing. To determine the denier, a sample of the yarn is prepared according to the yarn sampling procedure described below. Yarn samples of known length are measured and their corresponding weights are converted to grams per 9000 meters of yarn. To determine the thickness of the coated yarn, the yarn is first cut with a razor and observed under a microscope, where the coating thickness is determined proportionally to the core yarn diameter.

[0208] Yarn modulus, tenacity and elongation testingThe modulus of the yarn is determined for samples prepared according to the yarn sampling procedure described above and tested according to the test method described in detail in EN ISO 2062 (Textiles-Yarns fromPackages)-Determination of Single-End Breaking Force and Elongation atBreak Using Constant Rate of Extension (CRE) Tester. The test method was modified as follows. Five samples were prepared, wherein the sample length was 600 mm. The equipment used was an Instron Universal Testing System. An Instron Pneumatic cord and Thread Grips or similar pneumatic grips were installed, wherein the grip distance was 250 mm. When using the Instron pneumatic cord and thread grips, the grip distance was set to 145+1 mm and the gauge length was set to 250+2 mm. The preload is set to 5 grams, and the loading rate used is 250 mm / min. Modulus (initial) is calculated by obtaining the slope of stress (MPa) relative to strain in the initial linear region. Record the maximum tensile force value. The toughness and elongation of the yarn sample are determined according to the test method described in detail in EN ISO 2062, wherein the preload is set to 5 grams. The maximum tensile force value applied before fracture is recorded at elongation. In some aspects, toughness is calculated as the ratio of the load required for sample fracture to the linear density of the sample.

[0209] Specific gravity test . Specific gravity (SG) is determined using volume displacement according to the test method detailed in ASTM D792. For example, a digital balance or Densicom tester (Qualitest, Plantation, Florida, USA) is used to measure the SG of a sample obtained using a substrate sampling procedure or a component sampling procedure. Each sample is weighed (g) and then immersed in a distilled water bath (at 22°C plus or minus 2°C). To avoid errors, remove bubbles on the surface of the sample, for example, by wiping isopropyl alcohol on the sample before immersing the sample in water or using a brush to remove bubbles on the surface of the sample after the sample is immersed. Record the weight of the sample in distilled water. Specific gravity is calculated using the following formula:

[0210]

[0211] Durometer Hardness Test The material hardness of a sample may be determined using the Shore A scale according to the test method detailed in ASTM D-2240 Durometer Hardness.

[0212] Yarn shrinkage test The free shrinkage of the yarn can be determined by the following method. The yarn sample is prepared according to the yarn sampling procedure described below and cut into a length of about 30 mm with minimal stretching at about room temperature (e.g., 20 degrees Celsius). The cut sample is placed in an oven at 50 degrees Celsius or 70 degrees Celsius for 90 seconds. The sample is removed from the oven and measured. Using the pre-oven measurement and post-oven measurement of the sample, the shrinkage percentage is calculated by dividing the post-oven measurement by the pre-oven measurement and multiplying by 100.

[0213] Stoll abrasion test. Abrasion resistance, including abrasion resistance simulating scratching of footwear uppers, can be measured using a Stoll abrasion test using samples prepared according to the component sampling procedure, substrate or film sampling procedure, or textile sampling procedure described below. The minimum number of samples for the Stoll abrasion test is 3. The samples used herein are hand-cut or die-cut into round objects with a diameter of 112 mm. The Stoll abrasion test is more fully described in ASTM D3886 and can be performed on an Atlas universal abrasion tester. In the Stoll abrasion test, an abrading medium is moved over a fixed, mounted test sample, and the visual appearance of the sample is monitored. The Stoll abrasion test is performed under pressure to simulate wear under normal use.

[0214] DIN abrasion test . Samples are prepared according to the component sampling procedure, substrate or film sampling procedure, or textile sampling procedure described below. Cylindrical samples with a diameter of 16 ± 0.2 mm and a minimum thickness of 6 mm cut using an ASTM standard drill are tested for abrasion loss. Abrasion loss is measured using method B of ASTM D 5963-97a on a Gotech GT-7012-D abrasion tester. The test is carried out at 22 degrees Celsius with a wear path of 40 meters. The No. 1 standard rubber used in the test has a density of 1.336 grams per cubic centimeter (g / cm3). The smaller the amount of abrasion loss, the better the wear resistance.

[0215] Water penetration test.The water penetration of the sample is determined as follows using a sample prepared according to the component sampling procedure, substrate or film sampling procedure or textile sampling procedure described below. The sample to be tested is mounted on a support base, wherein the surface is at a 45 degree angle to the horizontal plane. The support base includes a sample holder inner ring of 152 mm diameter. Before testing, the sample is allowed to balance in a laboratory environment for at least 2 hours. The test sample is cut into a circular object of 220 mm diameter. Thicker or harder materials such as leather or hard synthetic leather will have 3 notches cut in the outer edge of the sample. The sample can be cut or die-cut by hand. The test sample of the softer material is cut into the same size, wherein the length direction is marked on the test sample. The backing paper is prepared by white or off-white paper towels, coffee filters or similar thin absorbent paper. The backing paper is also cut into a circular object of 220 mm diameter. Each test sample prepares a backing paper, and the backing paper is not reused. The backing paper and the sample are placed in a sample fixture (fixture), and then the sample fixture is placed in a spray test device. The sample length direction should be parallel to the direction of water flow. The funnel is adjusted to a height of 6 inches (152.4 mm) between the spray nozzle and the test sample. The nozzle must be above the center of the test specimen. Add 250 ± 2 ml of distilled water to the funnel, which sprays water onto the test specimen. Within 10 seconds after the spray ends, the water repellency of the top surface is evaluated. After evaluating the top surface, the sample fixture is removed from the supporting base, and the backing paper is evaluated to determine whether water penetrates through the sample. Water penetration is reported after visual evaluation, and the sample is rated as "qualified (pass)" or "unqualified" according to the degree of wetness. If no adhesion or wetting of the top surface is observed, if slight random adhesion or wetting of the top surface is observed, or if wetting of the top surface is observed at the spray point, the sample is considered qualified. Further wetting beyond the spray point and / or including the rear surface indicates that the sample has not passed the water penetration test.

[0216] Textiles - Ball Impact Testing . Test samples of textiles are prepared according to the Component Sampling Procedure or the Textile Sampling Procedure described below. A 10 inch by 8 inch test sample of the textile is mounted on the outer surface of a metal cylinder having a 10 inch circumference. The test sample and cylinder are mounted on a robotic swing arm that swings at a rate of 50 miles per hour and impacts the equator of a stationary ball. The ball used is a Nike "MERLIN" soccer ball of specified size inflated to 0.80 bar. A high-speed camera is used to record the position of the ball immediately after impact. Using the position and rotation of the ball in space across multiple frames of images recorded by the high-speed camera, software is then used to calculate the velocity and rotation rate of the ball immediately after impact. Each measurement is repeated at least 3 times, and the results of the runs are averaged.

[0217] Upper - Ball Impact Test. The entire men's size 10.5 football boot or the upper of a men's size 10.5 football boot is mounted on the robot's swing arm and positioned so that the ball impacts the medial side of the boot's front upper, the laces, or near the laces (when the boot includes a lacing structure), and when the robot's swing arm swings at a rate of 50 miles per hour, the upper impacts the mid-equation of the ball. The ball used is a Nike "MERLIN" English soccer ball of a specified size inflated to 0.80 bar. A high-speed camera is used to record the position of the ball immediately after impact. Using the position and rotation of the ball in space across multiple frames of images recorded by the high-speed camera, the speed and rotation rate of the ball immediately after impact are then calculated using software. Each measurement is repeated at least 3 times, and the results of the runs are averaged.

[0218] Sampling Procedure Using the tests described above, various properties of the materials disclosed herein and articles formed therefrom can be characterized using samples prepared using the following sampling procedures: Material sampling procedures. The material sampling procedure can be used to obtain a pure sample of a polymer composition or polymer, or in some cases, to obtain a sample of a material used to form a polymer composition or polymer. The material is provided in a medium form such as a thin sheet, granules, powder, pellets and the like. If a source of a polymer material or polymer is not available in pure form, a sample can be cut from a component or element (such as a composite element or sole structure) containing the polymer material or polymer to isolate a sample of the material.

[0219] Substrate or membrane sampling procedures.Prepare a sample of a polymer composition or polymer. Then, a part of the polymer or polymer composition is molded into a film or substrate that is sized to assemble a test device. For example, when using a sole material flexure tester, by thermoforming the polymer composition or polymer in a mold, a substrate or film sample is sized to be assembled inside the sole material flexure tester used, and the sample has a size of about 15 centimeters (cm) × 2.5 centimeters (cm) and a thickness of about 1 millimeter (mm) to 4 millimeters (mm). For a substrate sample of a polymer, a sample can be prepared by: melting the polymer, loading the molten polymer into the mold, resolidifying the polymer into the shape of the mold, and removing the molded sample of the solidification from the mold. Alternatively, the sample of the polymer can be melted, and then extruded into a film, and the film is cut into a certain size. For a sample of a polymer composition, a sample can be prepared by: blending the components of the polymer composition, melting the thermoplastic components of the polymer composition, loading the molten polymer composition into the mold, resolidifying the polymer composition into the shape of the mold, and removing the molded sample of the solidification from the mold. Alternatively, the sample of polymer material can be prepared by mixing and melting the composition of polymer composition, and then the molten polymer composition can be extruded into film, and the film is cut into a certain size. For the film sample of polymer or polymer composition, the film is extruded into a mesh or sheet with a substantially constant film thickness (within ± 10% of average film thickness) for the film, and cooled to solidify the resulting mesh or sheet. Then cut a sample with a surface area of ​​4 square centimeters from the resulting mesh or sheet. Alternatively, if the source of the film material is not available in pure form, then the film can be cut from the substrate of footwear components, or the film can be cut from the backing substrate of the coextruded sheet or mesh, thereby separating the film. In either case, then cut a sample with a surface area of ​​4 square centimeters from the resulting separated film.

[0220] Component sampling procedures.The program can be used to obtain a sample of material from a part of an article of footwear, a part of an article of footwear, an article of clothing, an article of clothing, an article of sports equipment, or an article of sports equipment, including a sample of a polymer composition or a textile, or a part of a textile, such as a sample of a thermoforming network. A blade is used to cut a sample containing a material in a non-wet state (e.g., at 25 degrees Celsius and 20% relative humidity) from an article or a part. If the material is bonded to one or more other materials, the program can include separating other materials from the material to be tested. For example, in order to test the material on the surface facing the ground of the sole structure, the relative surface can be peeled, polished, scraped or otherwise cleaned to remove any adhesive, yarn, fiber, foam and the like attached to the material to be tested. The sample obtained includes the material, and can include any other material bonded to the material.

[0221] The sample is obtained at a location along the article or component that provides a substantially constant material thickness (within plus or minus 10% of the average material thickness) for the material as present on the article or component, such as, for an article of footwear, in the forefoot area, midfoot area, or heel area of ​​the ground-facing surface. For many of the test protocols described above, a 4 cm2 area is used. 2 ) surface area. The samples are cut to a certain size and shape (e.g., dog bone shaped samples) to fit into the test equipment. In the event that the material is not present on the article or part in any section having a 4 square centimeter surface area and / or the material thickness is not substantially constant for sections having a 4 square centimeter surface area, a sample size with a smaller cross-sectional surface area can be obtained and the measurement of the specific area adjusted accordingly.

[0222] Yarn sampling procedure. Prior to testing, the yarn to be tested was stored at room temperature (20 degrees Celsius to 24 degrees Celsius) for 24 hours. The first 3 meters of material were discarded. The sample yarn was cut into a length of approximately 30 mm at minimal tension at approximately room temperature (e.g., 20 degrees Celsius).

[0223] Textile Sampling Procedures. Prior to testing, the textile to be tested is stored at room temperature (20 degrees Celsius to 24 degrees Celsius) for 24 hours. At about room temperature (eg, 20 degrees Celsius) with minimal tension, the textile sample is cut to the size specified by the test method to be used.

[0224] Exemplary Aspects The following clauses represent example aspects of the concepts contemplated herein. Any of the following clauses may be combined in a multi-subordinate manner to be subordinate to one or more other clauses. In addition, any combination of subordinate clauses (clauses that are explicitly subordinate to previous clauses) may be combined while remaining within the scope of the various aspects contemplated herein. The following clauses are illustrative and non-restrictive in nature.

[0225] Item 1. A knitted component having a first surface and an opposing second surface, the first surface of the knitted component comprising: a first area having a first coefficient of friction, the first area comprising a first yarn having a core and a coating, the coating at least partially surrounding the core; and a second area having a second coefficient of friction different from the first coefficient of friction, the second area comprising a second yarn, wherein the first area forms an alternating pattern with the second area such that the first area occupies 40% to 80% of the total surface area of ​​the first surface.

[0226] Clause 2. The knitted component of Clause 1, wherein the coating comprises a thermoplastic elastomer.

[0227] Item 3. A knitted component according to any of items 1-2, wherein the first area of ​​the first area comprises a thermoformed network of interwoven yarns comprising a core and a coating, wherein the coating consolidates the thermoformed network of interwoven yarns by surrounding at least a portion of the core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns.

[0228] Clause 4. The knitted component of any of Clauses 1-3, wherein the first coefficient of friction is greater than the second coefficient of friction.

[0229] Clause 5. The knitted component of any of Clauses 1-4, wherein the first coefficient of friction and the second coefficient of friction are dynamic coefficients of friction.

[0230] Clause 6. The knitted component of any of Clauses 1-5, wherein the second yarn does not include a coating.

[0231] Clause 7. A knitted component according to any one of clauses 1 to 6, wherein the alternating pattern is a concentric pattern Clause 8. The knitted component of any of Clauses 1-7, wherein the first regions of the first regions and the second regions of the second regions are continuous in an alternating pattern, wherein a boundary between the first regions and the second regions is curvilinear.

[0232] Clause 9. The knitted component of any of Clauses 1-8, wherein the first regions of the first regions and the second regions of the second regions are continuous in an alternating pattern, wherein a boundary between the first regions and the second regions is linear.

[0233] Clause 10. The knitted component of any of Clauses 1-9, wherein the first region of the first region and the second region of the second region are continuous in an alternating pattern, wherein the first raised portion of the first surface extends continuously across the first region and the second region in the first direction.

[0234] Item 11. A knitted upper for an article of footwear having an outward-facing surface portion and an opposing inward-facing surface portion, the outward-facing surface comprising: a first area having a first coefficient of friction, the first area comprising a first yarn; and a second area having a second coefficient of friction different from the first coefficient of friction, the second area comprising a second yarn, wherein the first area and the second area form a first alternating pattern in a first zone of the outward-facing surface portion such that the first area accounts for 40% to 80% of the total surface area of ​​the outward-facing surface portion in the first zone.

[0235] Item 12. A knitted footwear article upper according to Item 11, wherein the first area and the second area form a second alternating pattern in a second zone of the outwardly facing surface portion such that the first area is 40% to 80% of the total surface area of ​​the outwardly facing surface portion in the second zone.

[0236] Clause 13. The knitted article of footwear upper of Clause 12, wherein the first area is on a medial portion of the knitted article of footwear upper and the second area is on a lateral portion of the knitted article of footwear upper.

[0237] Clause 14. A knitted article of footwear upper as described in any of Clauses 11-13, wherein the first alternating pattern is a concentric pattern.

[0238] Clause 15. A knitted article of footwear upper according to any of clauses 11-13, wherein the first alternating pattern comprises at least one of a curvilinear boundary between a first area in the first region and a second area in the second region or a linear boundary between a first area in the first region and a second area in the second region.

[0239] Clause 16. A knitted article of footwear upper according to any of clauses 12-15, wherein a first area of ​​the first areas comprises a thermoformed network of interwoven yarns each having a core, such that a thermoplastic elastomer consolidates the interwoven yarns by surrounding at least a portion of the core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns.

[0240] Clause 17. A knitted article of footwear upper according to any of clauses 11-16, wherein the first zone extends across at least a portion of a forefoot area of ​​the knitted article of footwear upper.

[0241] Clause 18. A knitted article of footwear upper as recited in any of clauses 11-16, wherein the first zone extends across at least a portion of a forefoot region of the knitted article of footwear upper and at least one of a medial side and a lateral side of the knitted article of footwear upper.

[0242] Item 19. A method of manufacturing a knitted component having a first surface and an opposing second surface, the method comprising: knitting a first yarn and a second yarn into a knitted component; and thermoforming the first surface of the knitted component, wherein the first surface of the knitted component comprises: a first region having a first coefficient of friction, the first region comprising a thermoformed network of interwoven yarns each having a core, such that a thermoplastic elastomer consolidates the interwoven yarns by surrounding at least a portion of each core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns, and a second region having a second coefficient of friction different from the first coefficient of friction, the second region comprising a second yarn, wherein the first region forms an alternating pattern with the second region such that the first region occupies 40% to 80% of the total surface area of ​​the first surface.

[0243] Clause 20. The method of Clause 19, wherein thermoforming the first surface further comprises molding the first surface with one or more raised portions of the first surface, the one or more raised portions extending across more than one first region and more than one second region.

[0244] The description of various aspects of the present disclosure is intended to be illustrative rather than restrictive. Without departing from its scope, alternative aspects will become apparent to those skilled in the art. Without departing from the scope of the present disclosure, the technician may develop alternative means to achieve the above improvements.

[0245] It should be understood that certain features and subcombinations are useful and may be employed without reference to other features and subcombinations and are contemplated to be within the scope of the claims.Not all steps listed in the various figures need to be performed in the particular order described.

[0246] Although specific elements and steps are discussed in conjunction with each other, it should be understood that any element and / or step provided herein is encompassed as being combinable with any other element and / or step, whether or not expressly specified, while still being within the scope provided herein. Since many possible aspects may be formed from the present disclosure without departing from the scope of the present disclosure, it should be understood that all contents stated herein or shown in the accompanying drawings are to be interpreted as illustrative rather than in a limiting sense.

Claims

1. A knitted component, comprising: A first region having a first coefficient of friction, the first region comprising a first yarn; and a second region having a second coefficient of friction different from the first coefficient of friction, the second region comprising a second yarn, wherein the first region and the second region form an alternating pattern.

2. A knitted component according to claim 1, wherein the first region comprises a thermoformed network of interwoven yarns, each having a core, wherein the thermoplastic elastomer consolidates the thermoformed network of interwoven yarns by surrounding at least a portion of the core and occupying at least a portion of the space between yarns in the thermoformed network of interwoven yarns.

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

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

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

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

7. The knitted component according to claim 1, wherein the first area and the second area are continuous in the alternating pattern, and wherein the boundary between the first area and the second area is linear.

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

9. The knitted component according to claim 1, wherein the second yarn has a higher melting temperature and / or deformation temperature than the first yarn.

10. A knitted component according to claim 9, wherein the melting temperature of the first yarn is at least 100 degrees Celsius, at least 130 degrees Celsius or at least 170 degrees Celsius, and the melting temperature and / or deformation temperature of the second yarn is at least 20 degrees Celsius higher than the melting temperature and / or deformation temperature of the first yarn.

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