Upper for article of footwear and method of making same

Abstract

The invention relates to an upper for an article of footwear and a method of making the same. The textile component comprises a yarn comprising a thermoplastic material. A blowing agent having at least activation conditions is included into the textile by being included in the yarn or impregnated in the textile after forming the unfoamed textile. When activation conditions of the blowing agent are triggered, the blowing agent introduces a plurality of cavities, i.e. Pores, into the thermoplastic material. The textile then includes a porous foam region of the textile, where the porous foam region includes a porous foam surrounding the core yarn. The textile may be incorporated into a variety of articles, such as articles of footwear, in its unfoamed or foamed state.

Description

[0001] This application is a divisional application of an application with an application date of November 12, 2020, application number 202080079593.9, and invention name “Upper for footwear and method for manufacturing the same”. Related Applications

[0002] This patent document claims the benefit of priority under 35 USC 119(e) to U.S. Provisional Patent Application No. 62 / 937,092, filed on November 18, 2019, U.S. Provisional Patent Application No. 62 / 939,110, filed on November 22, 2019, and U.S. Provisional Patent Application No. 62 / 937,117, filed on November 18, 2019. All of the foregoing patent applications are hereby incorporated by reference in their entireties. Technical Field

[0003] The present disclosure generally relates to textiles made from foamable yarns, methods of processing textiles from foamable yarns, textiles resulting from processing foamable yarns, textiles comprising processed foamed yarns, articles incorporating textiles comprising foamable yarns, and articles incorporating processed textiles comprising foamed yarns. background

[0004] Textiles have long been used to make a variety of clothing items, footwear items and other articles. The incorporation of textiles can increase desired texture (texture) or other characteristics, such as elasticity, strength, weight, durability, texture, breathability, cushioning and other properties. The manufacture of textiles can include any of many technologies, including knitting, crocheting, weaving, embedding (in-laying) and other. These different technologies can give textiles different properties, such as texture, density, pattern, weaving, drape (drape), rigidity, strength, elasticity and other properties. In addition, the multiple processes of incorporating yarn into textiles can promote the manufacture of textiles. The articles made with such textiles can be effectively manufactured with minimal material waste.

[0005] In addition, polymer foamed products have many advantages, including low raw material consumption, low density, excellent thermal and acoustic insulation, mechanical damping and shock absorption, low water vapor permeability, reduced moisture absorption, and others. These properties make foams useful in a variety of industries, including packaging, thermal / acoustic insulation, upholstery, footwear, and clothing. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Embodiments may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily to scale. In the drawings, like reference numerals represent corresponding parts throughout the different views.

[0007] Figure 1 : Cross-sectional rendering of a foamable textile before processing; Figure 2A-2F : Cross-sectional renderings of multiple examples of foamed textiles after processing with a first surface texture and a second surface texture; Figure 3A-3C : Cross-sectional renderings of multiple examples of multi-layered foamed textiles after processing with a first surface texture and a second surface texture; Figure 4 : A perspective view of a foamable textile before processing; Figure 5 : A perspective view of a foamed textile after being processed with a first surface texture and a second surface texture; Figure 6A-6C : A rendered cross-sectional view of an example of applying a mold to a foamable textile, foaming the textile in the mold, and the foamed textile having a first surface texture and a second surface texture; Figure 7A-7D : Rendered cross-sectional views of examples of applying a mold to a foamable textile, foaming the foamable textile, molding the textile, and the foamed textile having a first surface texture and a second surface texture; Figure 8 : Perspective views of exemplary foamed textiles after processing with various surface textures. Detailed Description

[0008] The subject matter of the present disclosure may also relate to the following aspects and others: I. Unprocessed textiles Textiles 100 including at least one thermoplastic yarn 110 are described herein. Generally, textiles can be defined as structures made of fibers, filaments or yarns characterized by a high ratio of flexibility, fineness and length to thickness. Textiles generally fall into two categories. The first category includes textiles directly produced by the web (web) of fibers, filaments and / or yarns to construct non-woven textiles, such as felts, by randomly interlocking fibers, filaments and / or yarns. The second category includes textiles formed by the mechanical operation of yarn (for example, by interweaving or mutually looping (interloop) one or more yarns). The example of textiles produced by mechanical operation includes braided textiles, knitted textiles, crocheted textiles, knitted textiles and tatted textiles (tatted textile).

[0009] Generally, yarn is the raw material used to form textiles. Generally, yarn is defined as a component with a considerable length and a relatively small cross-section formed by at least one filament or more than one fiber. Fiber has a relatively short length and generally utilizes a spinning process or a twisting process to produce a yarn with a suitable length and tenacity for use in textiles. General examples of fibers are cotton and wool. However, filaments have significantly longer lengths and can be used alone or can be combined with other filaments to produce yarns suitable for use in textiles. Filaments include naturally occurring materials, such as silk, or can be made of more than one synthetic material, such as glass, carbon or polymer materials, including rayon, nylon, polyester and polyacrylate. Yarn can be formed by a single filament, which is conventionally referred to as "monofilament strand" or "monofilament yarn", or by more than one individual filament such as twisting or entanglement that is grouped together. Yarn can also include individual filaments formed by different materials, or yarn can include filaments each formed by two or more different materials. Similar concepts also apply to yarns formed from fibers.Thus, yarns can have a variety of configurations that generally conform to the definitions provided above.

[0010] The yarn 110 includes at least one thermoplastic material, which includes at least one thermoplastic polymer. The thermoplastic material has a deformation temperature (the material softens at this point) and a melting point (the temperature at which the thermoplastic material transitions between a solid state and a liquid state). In some embodiments, the thermoplastic material also includes a foaming agent. In other words, when the thermoplastic material of the yarn 110 is in an unfoamed state, the yarn 110 is a "foamable" yarn, and the textile 100 including the "foamable" yarn is a "foamable" textile.

[0011] Thermoplastics are substances that soften and melt when heated and harden when cooled without undergoing a chemical transformation.The first thermoplastic material described herein may include a naturally occurring thermoplastic polymer material, a recycled thermoplastic material, a synthetic thermoplastic material, or some combination thereof.

[0012] Yarn 110 can be incorporated into a variety of textile structures by mechanically operating yarn 110 via a variety of means, including but not limited to knitting, braiding, crocheting, plaiting, weaving and winding and other means. Yarn 110 can be incorporated into the textile structure by embedding yarn 110 into the textile structure. For example, yarn can be embedded during braiding, knitting, crocheting, plaiting or weaving processes. The embedded yarn 110 can be held in place by one or more yarns of the structure of the textile formed by mechanical operation. In knitting and crocheting, embedding is included in the structure of the textile without forming a loop with the yarn and positioning the yarn. For example, in a double-needle flat knitting process, by positioning the yarn between the needle beds without forming a loop with the embedded yarn 110, the embedded yarn 110 can be incorporated into the knitted structure. In weaving, the embedded yarn 110 can form a part of the weft yarn. In one embodiment, yarn 110 can be simultaneously embedded and knitted, crocheted, braided, woven or woven into a textile structure, wherein yarn 110 is embedded in a first portion of the textile structure and knitted, crocheted, braided, woven or woven in a second portion of the textile structure. In another embodiment, yarn 110 is only embedded in the textile structure.

[0013] exist Figure 1-Figure 8 , element 120 is a general representation of a portion of a textile. The portion of the textile represented by 120 can be, but is not limited to, a knitted textile, a woven textile, a crocheted textile, a plaited textile, a woven textile, a wrapped textile, or some combination thereof.

[0014] As an example, the foamable textile 100 can be a knitted structure including a first knitted yarn and an embedded yarn 110, wherein the embedded yarn 110 is the yarn 110 described above. In one embodiment, the foamable textile 100 can be a knitted structure 120 of a first knitted yarn and an embedded yarn 130, wherein the embedded yarn 130 is the foamable yarn 110 described above. Alternatively, the foamable textile 100 can include a yarn including a porous foam in the first knitted yarn, the second knitted yarn, or together with the embedded yarn 130. Alternatively, the first knitted yarn 120 can include the foamable yarn 110. In a second embodiment, the foamable textile 100 can be a woven textile including a first weft yarn and a second warp yarn, wherein at least a portion of the warp yarns include the foamable yarn 110.

[0015] In some embodiments, the first thermoplastic material may include any of a variety of synthetic thermoplastic polymers, including homopolymers or copolymers or a combination of homopolymers and copolymers. For example, the first thermoplastic material may include: a thermoplastic polyurethane, including a thermoplastic polyurethane consisting essentially of polyurethane bonds; and a thermoplastic polyurethane copolymer, such as a polyether-polyurethane or a polyester-polyurethane. The first thermoplastic material may include a thermoplastic polyolefin. The thermoplastic polyolefin may include a thermoplastic polyethylene homopolymer or copolymer, such as an ethylene-vinyl acetate copolymer or an ethylene-vinyl alcohol copolymer or a polyethylene-polyamide block copolymer. The thermoplastic polyolefin may include a thermoplastic polypropylene homopolymer or copolymer. The first thermoplastic material may include a thermoplastic polyester homopolymer or copolymer, such as, as already mentioned polyester-polyurethane copolymers. The first thermoplastic material may include a thermoplastic polyether homopolymer or copolymer, such as, as already mentioned polyether-polyurethane copolymers. The first thermoplastic material may include a thermoplastic polyamide homopolymer, such as nylon 6, nylon 11 or nylon 6,6, or a polyamide copolymer, such as the polyethylene-polyamide block copolymer mentioned previously. The first thermoplastic material may include any combination of thermoplastic polymers disclosed above, including two or three or four of the thermoplastic polymers. The first thermoplastic material may be described as including a thermoplastic polymer component consisting of all thermoplastic polymers present in the first thermoplastic material. The first thermoplastic material may include a thermoplastic polymer component from about 5 weight percent to about 100 weight percent based on the gross weight of the first thermoplastic material. Alternatively, the thermoplastic polymer component may account for from about 15 weight percent to about 100 weight percent, from about 30 weight percent to about 100 weight percent, from about 50 weight percent to about 100 weight percent, or from about 70 weight percent to about 100 weight percent of the first thermoplastic material.

[0016] In addition, in other embodiments, the first thermoplastic material comprises a thermosetting thermoplastic material. As described herein, a thermosetting material is a material that is initially thermoplastic, but solidifies and becomes a thermosetting material when exposed to specific conditions (e.g., specific types and levels of heat or light or other types of actinic radiation), which trigger chemical reactions such as cross-linking reactions in the material. Thermosetting materials should be understood to be uncured, and therefore, are thermoplastic before curing. When curing, thermosetting materials undergo chemical changes and become thermosetting materials. Examples of actinic radiation that can trigger curing can include microwave radiation, radiowave radiation, electron beam radiation, gamma beam radiation, infrared radiation, ultraviolet light, visible light, or combinations thereof, and other conditions.

[0017] In some embodiments, the first thermoplastic material also includes a crosslinking agent. As understood in the art, a crosslinking agent is a chemical product that chemically forms a bond between two hydrocarbon chains. The reaction can be exothermic or endothermic, depending on the crosslinking agent used. The concentration of the crosslinking agent present in the first thermoplastic material can be enough to partially crosslink the first thermoplastic material, or can be enough to completely crosslink the first thermoplastic material. In an example, when the first thermoplastic material is a thermosetting thermoplastic material, the thermosetting thermoplastic material can include a concentration of a crosslinking agent that is enough to completely crosslink the thermosetting thermoplastic material. Those skilled in the art will be able to select any number of suitable crosslinking agents that are compatible with thermoplastic polymers and allow the first thermoplastic material to be crosslinked under desired processing conditions, and the processing conditions include temperature, pressure, UV light exposure and similar conditions.

[0018] In some cases, suitable cross-linking agents include homobifunctional cross-linking agents. Homobifunctional agents consist of identical reactive groups at both ends of a spacer arm. Examples of homobifunctional cross-linking agents include: di(tert-butylperoxyisopropyl)benzene, dimethyl pimelimidate dihydrochloride, 3,3'-dithiodipropionic acid di(N-hydroxysuccinimide ester), suberate bis(3-sulfo-N-hydroxysuccinimide ester) sodium salt, and others.

[0019] In other cases, suitable crosslinking agents include heterobifunctional crosslinking agents. Heterobifunctional crosslinking agents have two different reactive groups, allowing the crosslinking reaction to be carried out in a controlled two-step reaction. This can reduce the prevalence of dimers and oligomers during crosslinking. Examples of heterobifunctional crosslinking agents include: S-acetylthioglycolic acid N-hydroxysuccinimide ester, 5-azido-2-nitrobenzoic acid N-hydroxysuccinimide ester, 4-azidophenacyl bromide, bromoacetic acid N-hydroxysuccinimide ester, N-(3-dimethylaminopropyl)-N'-ethylcarbodiimide hydrochloride, iodoacetic acid N-hydroxysuccinimide ester, and others.

[0020] In other embodiments, the first thermoplastic material includes a blowing agent. As understood in the art, a blowing agent is a substance that decomposes or vaporizes at an activation temperature to produce a certain amount of gas or vapor. Therefore, they can be classified as chemical blowing agents or physical blowing agents. Chemical blowing agents are compounds that can release gas at their activation temperature. Typically, this released gas does not chemically react with the thermoplastic polymer used as the polymer matrix. The process of releasing gas from the blowing agent is usually exothermic; however, certain compounds that decompose by thermal dissociation, such as bicarbonates, release gas in a reversible and endothermic reaction. Chemical blowing agents can also be subcategorized into inorganic blowing agents and organic blowing agents. Inorganic blowing agents are mainly used in rubber technology, but can be used in plastic applications to produce additional crosslinking during the foaming process.

[0021] Physical blowing agents are compounds that can change phase to gas when temperature, pressure, or temperature and pressure are changed. At a given pressure, the temperature at which a physical blowing agent changes to gas is the activation temperature. Physical blowing agents include low boiling hydrocarbons or inert gases, liquids, and supercritical fluids.

[0022] The choice of blowing agent can affect the quality, density, uniformity and cost of the foamed product. As discussed below, the characteristic property of these compounds is their activation temperature, which determines their practical use as blowing agents for a given thermoplastic material and for its processing conditions. In order for the yarn 110 to form a stable foam, the first thermoplastic material must be deformable or molten at the activation temperature of the blowing agent. To this end, the deformation temperature of the thermoplastic material can be the same as the activation temperature of the blowing agent, or it can be lower than the activation temperature of the blowing agent.

[0023] In some embodiments, the deformation temperature of the thermoplastic material is at least 10 degrees Celsius below the activation temperature of the blowing agent. In some embodiments, the deformation temperature of the thermoplastic material is at least 20 degrees Celsius below the activation temperature of the blowing agent. In other embodiments, the first thermoplastic material has a softening temperature or melting temperature from about 50 degrees Celsius to about 145 degrees Celsius.

[0024] In some embodiments, the chemical blowing agent has an activation temperature that is at least 5 degrees C. above the melting temperature of the first thermoplastic material. In other embodiments, the activation temperature of the blowing agent is at least 10 degrees C. above the melting temperature of the first thermoplastic material. In additional embodiments, the activation temperature of the blowing agent is at least 20 degrees above the melting temperature of the first thermoplastic material.

[0025] Other properties that may be considered when selecting a chemical blowing agent include the following: affinity with the thermoplastic polymer, maximum production of gas; activation temperature of the blowing agent to release gas, rate of gas evolution, toxicity, corrosivity, odor of decomposition products, effect of decomposition products on color and other physicochemical properties of the thermoplastic polymer, cost, availability, stability against decomposition during storage, and others.

[0026] In some embodiments, the blowing agent comprises a chemical blowing agent. In some embodiments, the chemical blowing agent comprises sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, calcium azide, azodicarbonamide, hydrazocarbonamide, benzenesulfonylhydrazide, dinitrosopentamethylenetetramine, toluenesulfonylhydrazide, p,p'-oxybis(benzenesulfonylhydrazide), azobisisobutyronitrile, barium azodicarboxylate, or any combination thereof.

[0027] In some embodiments, the blowing agent comprises a physical blowing agent. In addition to partially halogenated fluorochlorocarbons (fluorochlorohydrocarbons), hydrocarbons (e.g., isobutylene and pentane) and inert liquids, gases or supercritical fluids, such as carbon dioxide or nitrogen or a combination thereof, can be used as physical blowing agents. Inert liquids, gases and supercritical fluids provide many advantages, including low environmentally harmful output, low gas consumption, increased foam volume per weight of blowing agent used, high cost effectiveness, non-flammable, non-toxic, chemically inert, leaving minimal or no residue in the polymer foam after processing. In addition, carbon dioxide has the advantage of having a higher solubility in many thermoplastic polymers than other inert compounds such as nitrogen.

[0028] In some embodiments, the blowing agent is present in the first thermoplastic material in an amount that effectively makes the first thermoplastic material foam into a porous foam 210 structure when the yarn 110 is processed. The amount of the blowing agent can be measured as the concentration of the blowing agent by weight in the first thermoplastic material. When the activation blowing agent causes the volume of the first thermoplastic material to increase by at least 10%, the amount of the blowing agent is considered to be effective. In an example, the first thermoplastic material can include a blowing agent from about 1% to about 10% by weight, or from about 1% to about 5% by weight, or from about 1% to about 3% by weight based on the gross weight of the first thermoplastic material. In another example, the first thermoplastic material includes a concentration of a blowing agent of at least 100% by volume, or 100% to 900% by volume, or 200% to 500% by volume, or 300% to 400% by volume that is enough to expand the first thermoplastic material based on the initial volume of the first thermoplastic material before foaming.

[0029] In some embodiments, more than one foaming agent can be used. The combination of foaming agents can include at least two chemical foaming agents, at least two physical foaming agents or a combination of physical foaming agents and chemical foaming agents. Each foaming agent has an activation temperature at a given processing pressure. These activation temperatures can be roughly the same, or can be different. By using foaming agents with different activation temperatures, processing yarn 110 into porous foam 310 structure can be carried out within a larger temperature operating window. In addition, by controlling the temperature to activate the first foaming agent and then increasing the temperature of yarn 110 to activate the second foaming agent, a variety of different desired foam structures can be obtained. In some embodiments, two foaming agents can have an activation temperature that differs at least about 5 degrees Celsius. In some embodiments, two foaming agents can have an activation temperature that differs at least about 10 degrees Celsius. In some embodiments, two foaming agents can have an activation temperature that differs at least about 20 degrees Celsius.

[0030] A wide range of additives can also be used. Catalysts accelerate the reaction, or in some cases, reduce the initiation temperature of the reaction. As discussed above, a foaming agent that forms bubbles in a polymer or polymeric mixture produces foam. A surfactant can be added to control the size of the bubbles. In addition to a foaming agent and an optional cross-linking agent, other additives that may be present in the first thermoplastic material include chain extenders, fillers, flame retardants, coloring materials (such as dyes or pigments), ultraviolet light absorbers, antioxidants, lubricants, plasticizers, emulsifiers, rheology modifiers, fragrances, deodorants, halogen scavengers or any combination thereof, depending on the application. In an example, other additives are present in the first thermoplastic material in a concentration of from about 0.1 weight percent to about 20 weight percent, or from about 0.2 weight percent to about 10 weight percent, or from about 0.5 weight percent to about 5 weight percent based on the gross weight of the first thermoplastic material.

[0031] The molecular structure, amount and reaction temperature of each component determine the characteristics and subsequent uses of yarn 110 after processing. Therefore, each formulation can be designed with appropriate ingredients to obtain the desired properties of the final material. As an example, different foaming agents may require additional additives to maintain thermal properties. Finally, after yarn 110 is processed, the density of the foam is determined by the number and size of the holes, which are at least partially affected by the amount of foaming that occurs during processing. By mixing different combinations of starting materials, the reaction rate and total cure rate during processing can be controlled.

[0032] In some embodiments, yarn 110 can be a single filament consisting essentially of a first thermoplastic material. In a second embodiment, yarn 110 includes a core including a core material coated with a coating. In some embodiments, the coating includes a first thermoplastic material. The core can include any of a variety of natural polymer fibers or filaments, regenerated fibers or filaments, synthetic polymer fibers or filaments, metals, or some combination thereof, to obtain the desired properties of yarn 110. The fiber or filament can be plant-derived or animal-derived. Plant-derived fibers can include cotton, flax, industrial hemp (hemp) or jute. Animal-derived fibers or filaments can include spider silk, silk, sheep wool or alpaca wool. Regenerated materials are produced by dissolving cellulose materials in a solvent and spinning the solution into fibers or filaments, such as by viscose method (viscose method). Examples of regenerated fibers or filaments can include rayon or modal (modal) and others. In some embodiments, the core material is a thermoplastic core material, that is, a polymer material with a deformation temperature at which the core material softens and a melting temperature at which the core material melts. In other embodiments, the core material is a thermosetting core material, i.e., a core material without deformation temperature or melting temperature, or a thermoformable core material, i.e., a core material with deformation temperature but without melting temperature. In addition, the core can be a single single filament strand or multifilament strand (multifilament strand), including a plurality of single filament strands or multifilament strands. In the case where the core is a multifilament strand, the individual filaments of the multifilaments can be aligned, twisted together, knotted, braided, or similarly. For example, yarn 110 can include a polyethylene terephthalate (PET) core that is twisted or entangled with multifilaments. In addition, each strand of the multifilament core itself can be a single filament strand or multifilament strand. In the case where the strand of the multifilament core itself is a multifilament comprising a plurality of sub-strands (sub-strand), the sub-strands can be aligned, twisted together, entangled, knotted, braided or similarly interconnected. Additionally, in some embodiments, the sub-strands can be coated in the first thermoplastic material such that the first thermoplastic material surrounds the sub-strands themselves before the sub-strands are incorporated into the core.

[0033] The presence of the core in the yarn 110 provides advantages, such as providing the yarn 110 with tensile strength and / or stretch resistance, which is not provided by the first thermoplastic material and therefore would not exist if the first thermoplastic coating composition is used alone. The core can provide a structure that enables the yarn to remain in place during and after the foaming process. In addition, when the yarn 110 is combined with a non-foamable or unfoamed yarn in the textile 100, the presence of the core can provide additional strength for the textile 100. In an example, when the yarn 110 is included in the textile in a manner that allows the yarn 110 to have little, if any, freedom of movement (e.g., when it is embedded rather than interlocked), the presence of the core can be used to increase the locking of the portion of the textile that includes the yarn 110.

[0034] In some embodiments, the core has a percent elongation of less than about 30 percent or less than about 25 percent. For example, the core can have a percent elongation from about 0.5 percent to about 30 percent or from about 5 percent to about 25 percent.

[0035] In other embodiments, the core has a breaking strength of from about 0.5 kgf / cm2 to about 10 kgf / cm2. The core may have a breaking strength of at least 1.5 kgf / cm2, such as from about 1.5 kgf / cm2 to about 10 kgf / cm2, or from about 1.5 kgf / cm2 to about 4.0 kgf / cm2, or from about 2.5 kgf / cm2 to about 4 kgf / cm2.

[0036] Another measure of the force required to break a yarn is tenacity. As used herein, "tenacity" is understood to refer to the amount of force (expressed in units of weight, e.g., pounds, grams, centinewtons, or other units) required to break a yarn (i.e., the breaking force or breaking point of the yarn) divided by the linear mass density of the yarn, expressed, for example, in (unstrained) denier, decitex, or some other weight measure per unit length. The amount of force required to break a yarn (the "breaking force" of the yarn) is measured by stretching a sample of the yarn subjecting the sample to a known amount of force until it breaks, e.g., by inserting each end of the sample of the yarn into a fixture on the measuring arm of an extensometer, subjecting the sample to the stretching force, and measuring the force required to break the sample using a strain gauge load cell. Suitable testing systems can be obtained from Instron (Norwood, MA, USA). Yarn tenacity and yarn breaking force are distinct from the burst strength or bursting strength of a textile, which is a measure of the maximum force that can be applied to a surface of a textile before the surface breaks.

[0037] Generally, in order to make yarn withstand the force applied in industrial knitting machines, the minimum toughness required is about 1.5 grams per denier (g / D). Most of the synthetic polymer filament yarns formed by commodity polymer materials generally have a toughness in the range of about 1.5 g / D to about 4 g / D. For example, the polyester filament yarn that can be used to manufacture the knitting upper for footwear articles has a toughness in the range of about 2.5 g / D to about 4 g / D. The filament yarn formed by commodity synthetic polymer materials that is considered to have high toughness generally has a toughness in the range of about 5 g / D to about 10 g / D. For example, the commercially available package dyed polyethylene terephthalate filament yarn from National Spinning (Washington, NC, USA) has a toughness of about 6 g / D, and the commercially available solution dyed polyethylene terephthalate filament yarn from Far Eastern New Century (China, Taiwan, Taipei) has a toughness of about 7 g / D. Filament yarns formed from high performance synthetic polymer materials typically have a tenacity of about 11 g / D or greater. For example, filament yarns formed from aramid typically have a tenacity of about 20 g / D, and filament yarns formed from ultra-high molecular weight polyethylene (UHMWPE) having a tenacity greater than 30 g / D are available from Dyneema (Stanley, NC, USA) and Spectra (Honeywell-Spectra, Colonial Heights, VA, USA).

[0038] In one embodiment, the core has a tenacity of at least 5 grams per denier (g / D). The core can have a tenacity of from about 1.5 g / D to about 4 g / D, or from about 2.5 g / D to about 4 g / D, or from about 5 g / D to about 35 g / D, or from about 5 g / D to about 10 g / D.

[0039] The linear mass density of the yarn 110 and the core can be expressed in (unstrained) denier. In one embodiment, the yarn has a linear mass density from about 100 denier (D) to 300,000 D, or from about 500 D to 200,000 D, or from about 1,000 D to 10,000 D. Similarly, the core can have a linear mass density from about 60 D to 70,000 D, from about 100 D to 1,000 D, or from about 150 D to 700 D.

[0040] In some embodiments, the core comprises at least one long filament, and the at least one long filament is at least partially surrounded by the first thermoplastic material. In other embodiments, the at least one long filament is substantially surrounded by the first thermoplastic material so that the first thermoplastic material covers at least 75% of the surface area of ​​the at least one long filament.

[0041] In various embodiments, the yarn 110 includes a core including a core material and a coating of a first thermoplastic material including a blowing agent, and is coated with a coating of a second thermoplastic material including a second thermoplastic polymer and a second blowing agent, wherein the second coating forms an outer layer of the yarn 110. In this embodiment, the blowing agent or the thermoplastic polymer or the first thermoplastic material and the second thermoplastic material can be the same or different, or can have the same or different concentrations. In addition, the first thermoplastic material and the second thermoplastic material can have the same or different additives.

[0042] In some embodiments, the first thermoplastic material and the second thermoplastic material 500 may include the same blowing agent and the same thermoplastic polymer, but in different amounts. For example, the first thermoplastic material may include a thermoplastic polyurethane with a heat-activated chemical blowing agent, but such that the concentration of the heat-activated chemical blowing agent in the first thermoplastic material is at least twice the concentration of the heat-activated chemical blowing agent in the second material. When processed, such a structure may produce coaxially aligned foam regions with different density and hardness properties, or, under certain processing conditions, may produce a yarn in which the coaxial foam regions have a density gradient or hardness gradient along the cross-sectional radius.

[0043] Similarly, by varying the concentrations of various additives such as, but not limited to, colorants, crosslinkers, stabilizers, emulsifiers, binders or other additives in different coaxial coatings before and after being foamed, it is possible to have any number of different coaxial regions having different properties, or radial gradients having different properties, such as color density, foam density, hardness, viscosity, melting temperature, and other properties.

[0044] In other embodiments, the yarn 110 may include a first yarn strand, the first yarn strand including a thermoplastic material further including a foaming agent and a thermoplastic polymer; and may be combined with a second yarn strand. The second yarn strand may include a thermoplastic material or may not include a thermoplastic material. The first yarn strand and the second yarn strand may be combined to form a multi-strand yarn 620 by twisting, winding, braiding, knotting, aligning, fusing, softening or other acceptable manners of the yarn material. In other embodiments, the yarn 110 may include a first yarn strand including a core and a coating of a thermoplastic material including a foaming agent and a thermoplastic polymer.

[0045] The yarn 110 can have any one of a variety of cross-sectional shapes or sizes, which is determined by the requirements of the final application of the yarn 110. In some embodiments, as further described above, the yarn 110 includes a core and a coating coaxial with the core. At any given cross section of the yarn 110, the core has a cross-sectional area, and the coating has a cross-sectional area. The average coating cross-sectional area is equal to the volume of the coating divided by the length of the yarn 110. For any given cross section of the yarn 110, the coating has an average thickness, which is the average distance measured from the inner surface of the coating to the outer surface of the coating, and the average distance is measured according to the outer surface orthogonal to the coating. In some embodiments, the diameter of the core is less than the average thickness of the coating. For example, the core can have a cross-sectional diameter, and the surrounding coating has an average thickness, so that the cross-sectional diameter of the core is less than the average thickness of the coating before the yarn 110 is foamed, or less than at least 1 / 2, or less than at least 2 / 3. In other embodiments, the diameter of the core is greater than the average thickness of the coating. In such examples, the core may have a cross-sectional diameter and the surrounding coating may have an average thickness such that the cross-sectional diameter of the core is at least 2 times, or at least 3 times, or at least 5 times the average thickness of the coating.

[0046] In some embodiments, the coating has an average thickness from about 0.3 mm to about 5.0 mm. In yet other embodiments, the coating has an average thickness less than about 0.3 mm. In yet other embodiments, the coating has an average thickness greater than about 5.0 mm. In yet other embodiments, the coating has a thickness from about 0.4 mm to about 3.0 mm or from about 0.5 mm to about 2 mm. In some embodiments, the coating has a variable thickness, and the variable thickness is in the range of from 0.1 mm to about 6.0 mm.

[0047] In some embodiments, yarn 110 includes a core yarn, which includes a core material having a layer of a first thermoplastic material that substantially surrounds the core layer and defines the outer surface of yarn 110. In one such embodiment, the first thermoplastic material of yarn 110 includes at least 30 weight percent of a thermoplastic polymer component, wherein the thermoplastic polymer component includes at least one thermoplastic polyurethane, or at least one thermoplastic polyolefin, or at least one thermoplastic polyamide, or any combination thereof. The thermoplastic polymer component of the first thermoplastic material may include at least one thermoplastic polyurethane or be substantially composed of at least one thermoplastic polyurethane, such as a polyester polyurethane copolymer. The thermoplastic polymer component may include at least one polyolefin or be substantially composed of at least one polyolefin, such as an ethylene-vinyl acetate copolymer. The thermoplastic polymer component may include at least one polyamide or be substantially composed of at least one polyamide, such as a polyethylene polyamide block copolymer. In one such embodiment, the first thermoplastic material also includes a heat-activated chemical foaming agent and a heat-activated crosslinking agent. In one such embodiment, the core yarn is a multi-filament yarn, such as an air-entangled multi-filament yarn, and has a breaking strength greater than 1.5 kilograms of force per square centimeter. The core material of the core yarn can include at least one thermoplastic polyester, such as thermoplastic polyethylene terephthalate, or at least one thermoplastic polyamide homopolymer. In one such embodiment, the deformation temperature of the core material is at least 20 degrees Celsius, or at least 40 degrees Celsius, or at least 60 degrees Celsius higher than the melting temperature of the first thermoplastic material, the activation temperature of the foaming agent activated by heat, and the activation temperature of the cross-linking agent activated by heat. In one such embodiment, the yarn 110 including the unfoamed thermoplastic material has a breaking strength greater than 1.5 kilograms of force per square centimeter, an elongation less than 20 percent. In one such embodiment, the thickness of the coating of the first thermoplastic material is in the range of from about 0.4 millimeters to about 3 millimeters, and the volume expansion is from about 2 times to about 6 times when foaming.

[0048] II. Methods of processing textile products Described herein is a method of processing the foamable textile 100 described above to form a foamed textile 200 comprising any yarn described above, wherein the yarn 110 is a strand comprising at least one thermoplastic material comprising at least one thermoplastic polymer and a blowing agent.

[0049] The textile incorporating any yarn can be processed to produce one or more regions of porous foam 210 in the foamed textile 200. Porous foam is an expanded material with a porous structure due to the introduction of bubbles during manufacturing, i.e., a plurality of cavities defined by the foamed material. Open-cell foam is a porous foam in which most of the pores are not completely closed by the foamed material. Closed-cell foam is a porous foam in which most of the pores are completely closed by the foamed material. Once foamed, the porous foam region 220 of the foamed textile 200 has properties different from the portion 230 of the textile without porous foam 210, including the portion of the yarn 110 that has not yet been foamed. For example, the foamed region 220 can impart increased texturing, cushioning, wear resistance, strength, lockout, or any combination of these properties to the textile.

[0050] In embodiments where the foamable yarn 110 includes a blowing agent, a first method of foaming a region of the foamable textile 100 includes the steps of softening the thermoplastic material, activating the blowing agent of the thermoplastic material of the yarn 110 to expand the softened thermoplastic material into a porous foam 210, and curing the porous foam 210 to form one or more regions of porous foam 210 in the “foamed” textile 200. In some embodiments, the step of activating the blowing agent includes exposing a portion of the foamable textile 100 including the unprocessed yarn 110 to a heat source, including but not limited to a heated solid surface, a heated fluid, actinic radiation (such as microwave radiation, radio wave radiation, electron beam radiation, gamma beam radiation, infrared radiation, ultraviolet light, visible light), or some combination thereof.

[0051] In the embodiment that the foamable yarn 110 does not include a foaming agent, the step of impregnating the foamable textile 200 with a foaming agent can be performed before the step of foaming the foaming agent. In some such embodiments, impregnating the foamable textile 100 with a foaming agent can be achieved by a variety of means, including softening the thermoplastic material of the foamable yarn 110 and introducing the foaming agent into the foamable yarn. The step of softening the yarn can include raising the temperature of the foamable yarn 110 to a softening temperature higher than the thermoplastic material. Raising the temperature of the thermoplastic yarn can be achieved by a variety of means, including but not limited to exposing the yarn 110 to a heated solid surface, a heated fluid, actinic radiation (such as microwave radiation, radio wave radiation, electron beam radiation, gamma beam radiation, infrared radiation, ultraviolet light, visible light) or some combination thereof.

[0052] In some embodiments, the blowing agent to be injected into the textile 100 is a physical blowing agent. In some embodiments, the blowing agent includes a physical blowing agent. In addition to fluorocarbons, including fully or partially halogenated fluorocarbons, such as fully or partially chlorinated fluorocarbons; hydrocarbons (e.g., isobutylene and pentane); and inert liquids, gases or supercritical fluids, such as carbon dioxide or nitrogen or a combination thereof, can be used as physical blowing agents. Inert liquids, gases and supercritical fluids provide many advantages, including low environmentally harmful output, low gas consumption, increased foam volume per weight of blowing agent used, high cost effectiveness, non-flammable, non-toxic, chemically inert, leaving minimal or no residue in the polymer foam after processing. In addition, carbon dioxide has the advantage of having a higher solubility in many thermoplastic polymers than other inert compounds such as nitrogen. In some embodiments, the physical blowing agent may include carbon dioxide, wherein the carbon dioxide is present in an amount of about 1% to about 3% or about 1% to about 5% by weight based on the total weight of the thermoplastic material. Alternatively, the physical blowing agent may include nitrogen, wherein the nitrogen is present in an amount of about 1% to about 3% or about 1% to about 5% by weight based on the total weight of the thermoplastic material.

[0053] The step of impregnating the physical blowing agent into the thermoplastic material may also include dissolving or suspending the physical blowing agent in the thermoplastic material. Impregnation may also include the steps of softening the thermoplastic material of the yarn, impregnating the softened thermoplastic material, and resolidifying the injected thermoplastic material of the yarn 110 before the steps of softening the thermoplastic material and foaming the porous foam 210. Impregnation may include forming a single-phase solution of the physical blowing agent in the first thermoplastic material, and solidifying the single-phase solution under conditions effective to keep the physical blowing agent in solution when solidified.

[0054] The molecular structure, amount and reaction temperature of each component determine the characteristics and subsequent use of the foam. Therefore, each formulation can be designed by the selection of multiple components to obtain a porous foam with multiple properties. For example, the concentration and type of the blowing agent and / or surfactant used can affect the cell size, expansion rate, hardness and / or density of the porous foam. Similarly, the concentration and type of the thermoplastic polymer included in the thermoplastic material can affect the hardness and / or density of the porous foam.

[0055] The blowing agent used in the foaming step will determine, in part, the temperature and pressure ranges used for processing. Suitable blowing agents may include chemical blowing agents, physical blowing agents, or some combination thereof.

[0056] In some embodiments, the step of activating the chemical foaming agent comprises raising the temperature of the thermoplastic material to about the activation temperature of the foaming agent or higher than the activation temperature of the foaming agent. The step of raising the temperature can include exposing the yarn 110 or textile 100 to a heated solid surface, a heated fluid, a form of actinic radiation or a combination thereof. When the foaming agent is activated, when the thermoplastic material is at a temperature at which it is soft and deformable or fully melted, the generation of gas will cause the thermoplastic material to foam. After the thermoplastic material is expanded into porous foam 210, the porous foam is solidified.

[0057] In some embodiments, the step of activating the chemical blowing agent includes raising the temperature of the thermoplastic material to about or above the activation temperature. When the blowing agent is activated, when the thermoplastic composition is at a temperature at which it is soft and deformable or fully melted, the generation of gas will cause the thermoplastic composition to foam. After foaming the thermoplastic composition, some embodiments of the method include curing the porous foam 210.

[0058] In some embodiments, the blowing agent is present in the first thermoplastic material in an amount that effectively makes the first thermoplastic material foam into a porous foam 210 structure when the yarn 110 is processed. The amount of the blowing agent can be measured as the concentration by weight of the blowing agent in the thermoplastic material. When the activated blowing agent causes the volume of the thermoplastic material to increase by at least 10%, the amount of the blowing agent is considered to be effective. In an example, the thermoplastic material can include a blowing agent from about 1% to about 10% by weight, or from about 1% to about 5% by weight, or from about 1% to about 3% by weight based on the gross weight of the thermoplastic material. In another example, the thermoplastic material includes a concentration of a blowing agent that is enough to expand the thermoplastic material based on the initial volume of the thermoplastic material before foaming, at least 100% by volume, or 100% to 900% by volume, or 200% to 500% by volume, or 300% to 400% by volume.

[0059] In some embodiments of the method, the step of curing the cellular foam comprises reducing the temperature of the foamed thermoplastic material to a temperature below its deformation temperature.

[0060] In other embodiments of the method, the step of solidifying the porous foam includes crosslinking the thermoplastic material to the point where the composition becomes a thermosetting material. In the embodiment using a crosslinking agent, the crosslinking agent can be initiated during the processing conditions for processing textiles, and has an initiation temperature within the processing conditions for textiles. For example, the crosslinking agent can be a heat-activated crosslinking agent with an initiation temperature of a heat-activated crosslinking agent, and the initiation temperature of the heat-activated crosslinking agent can be close to the initiation temperature of the foaming agent, so that foaming and crosslinking occur simultaneously or almost simultaneously. In this way, when the foaming agent is activated in the thermoplastic material, the thermoplastic material can remain soft enough to form a porous structure, but shows enough melt strength (melt strength) to maintain the porous structure without self-collapse, and solidifies into a solid porous foam with sufficient hardness.

[0061] If the thermoplastic material includes a thermally activated blowing agent, the activation temperature of the blowing agent should be at about or above the melting temperature of the thermoplastic material before processing. As an example, if the thermoplastic material has a melting temperature of about 90 degrees Celsius and the blowing agent has an activation temperature of about 120 degrees Celsius or higher, the thermoplastic material will be in a molten state before the blowing agent begins to release gas to produce a porous form structure. In such a case, the textile or yarn can be processed at about 120 degrees Celsius or higher, including being processed at about 145 degrees Celsius.

[0062] In other embodiments, thermoplastic material also comprises other additives.Except blowing agent and optional cross-linking agent, other additives that may be present in thermoplastic material also comprise chain extender, filler, flame retardant, coloring material (such as dye or pigment), ultraviolet light absorber, antioxidant, lubricant, plasticizer, emulsifier, rheology modifier, fragrance, deodorant, halogen scavenger or its any combination, this depends on application.Catalyst accelerates reaction, or in some cases, reduces the initiation temperature of reaction.As discussed above, the blowing agent that forms bubble in polymer or polymeric mixture produces foam.Surfactant can be added to control the size of bubble.In an example, other additives are present in thermoplastic material with the concentration from about 0.1 weight percent to about 20 weight percent or from about 0.2 weight percent to about 10 weight percent or from about 0.5 weight percent to about 5 weight percent based on the gross weight of thermoplastic material.

[0063] As described above, if the thermoplastic material includes a thermally activated blowing agent, the activation temperature of the blowing agent should be at or above the melting temperature of the thermoplastic material. As an example, if the thermoplastic material has a melting temperature of about 90 degrees Celsius and the blowing agent has an activation temperature of about 120 degrees Celsius or higher, the thermoplastic material will be in a molten state before the blowing agent begins to release gas to produce a porous form structure. In such a case, the textile or yarn can be processed at or above about 120 degrees Celsius or higher, including being processed at or above about 145 degrees Celsius.

[0064] In some embodiments, the method of solidifying the partially processed thermoplastic material into a foamed textile 200 further includes adhering the foamed textile 200 to a surrounding portion of the textile. This step may include reducing the temperature of the foamed textile 200.

[0065] In some embodiments, during the foaming step, the material 110 can expand from about 10% to 2000% by volume, or from about 100% to about 1000%. During foaming, the material 110 can expand from about 200% to about 700% by volume, or from about 300% to about 500% by volume.

[0066] In other embodiments, the method of processing the foamable textile 100 or yarn 110 further comprises the step of molding the textile or yarn. The step of applying the mold 600 to the textile 100 can be performed before, during, or after the foaming of the thermoplastic material. Figures 6A-7D In some embodiments, the step includes applying a mold to the textile. In some cases, the mold can be a compression mold 600 having a first mold surface 610 and a second mold surface 620, such as Figures 6A-7D , or a slump mold having only one molding surface. Although the mold can be at ambient temperature, in other embodiments, the step of molding the textile or yarn can also include heating the mold 600.

[0067] The step of heating can comprise that mould 600 is exposed to the solid surface of heating, the fluid of heating, electricity, actinic radiation or its combination.The temperature of the mould 600 for processing textile 100 or yarn 110 will depend on the characteristic of the expectation of porous foam 210 and blowing agent, processing pressure and thermoplastic polymer and change.A possible scope is between about 60 degrees Celsius and 250 degrees Celsius.It is a kind of mode that allows textile to maintain the shape of moulding during general use, wear and tear, washing, drying, cleaning and storage by moulding foamable textile 100 at a temperature higher than the used temperature of textile 200 of foaming at least 20 degrees Celsius.This other step of heating mould 600 can be carried out after foamable textile 100 or yarn 110 are applied to mould 600 or before foamable textile 100 or yarn 110 are applied to mould 600.

[0068] Additionally, for the case where the textile is applied to the compression mold 600, the step of molding the textile may include applying additional pressure to the mold, i.e., a pressure in excess of atmospheric pressure. Applying pressure to the mold may shape the material 110, a portion of the textile, and / or limit foaming of the material 110, a portion of the textile, producing a shaped foam and / or a denser foam. The amount of pressure applied will vary depending on the desired properties of the porous foam as well as the blowing agent, processing temperature, and thermoplastic polymer.

[0069] In some embodiments, the step of molding includes applying a mold 600 to a foamable textile 100, such as Fig. 6A As seen in, activated foaming agents such as Figure 6B As seen in the figure, at least a portion of the foamable textile 100 is foamed. In some of these embodiments, the step of molding further includes removing the yarn 110 or textile 200 from the mold, such as Figure 6C In some such embodiments, the step of reducing the temperature of the first thermoplastic material is performed before, after, or during removal of foamed textile 200 from mold 600.

[0070] In other embodiments, as by Figure 7A-7C As illustrated, the blowing agent in the foamable textile is activated to begin foaming the thermoplastic material, and then the mold 600 is applied to the foamed textile while the thermoplastic material is thermo-moldable. In some of these embodiments, the step of molding further includes removing the yarn 110 or textile from the mold, such as Fig.7D In some such embodiments, the step of reducing the temperature of the first thermoplastic material is performed after removing the foamed textile 200 from the mold.

[0071] In some embodiments, the step of applying the mold 600 to the heat moldable foamed textile 200 or the foamable textile 100 results in at least one surface texture feature positioned to protrude from the surface of the textile, i.e., protruding or extending from the textile and / or adjacent foamed area. In other embodiments, the step of applying the mold 600 to the heat moldable foamed textile 200 or the foamable textile 100 results in at least one foamed area positioned flush with the surface of the textile. In still other embodiments, the step of applying the mold 600 to the heat moldable foamed textile 200 or the foamable textile 100 results in at least one foamed area in which the porous foam does not extend beyond the surface of the textile. In still other embodiments, the step of applying the mold 600 to the heat moldable foamed textile 200 or the foamable textile 100 results in an area 700 with increased rigidity, wherein the foamed textile 200 maintains a non-planar form after curing. In any such embodiments, the foamable yarns 110 may be enmeshed with at least some of the porous foam 210 .

[0072] III. Processed Textiles Described herein is a foamed textile 200 that includes a porous foam 210. The porous foam 210 can be open-cell or closed-cell and can be the reaction product of foaming at least a portion of a first yarn, wherein the first yarn is a strand that includes at least one thermoplastic material that includes at least one thermoplastic polymer and a blowing agent.

[0073] The textiles incorporated into the foaming of yarn can show some advantageous properties of textiles based on fiber, such as easy manufacture, minimum waste, flexibility of design, change of elasticity and thickness, easy customization and similar advantageous properties. The textiles incorporated into the foaming of porous foam can show some advantageous properties of foam, such as increased hardness, water resistance, moldability, rigidity, cushioning, sound damping, mechanical damping and other properties. In addition, the textiles incorporated into the foaming of yarn can show other advantageous properties, such as maintaining a fixed distance between textile fibers, strands and yarns, i.e. effectively locking textiles into specific forms. This may be additionally advantageous in the case where the spacing of textile fibers, strands, yarns or the like has an impact on the properties of materials, the properties of the materials such as but not limited to conductivity or resistance, elasticity, strength, shear strength, tear resistance or abrasion resistance.

[0074] In some embodiments, the porous foam 210 is a thermoplastic porous foam. For example, the thermoplastic porous foam may include a thermoplastic material that is a reaction product of a thermoplastic material containing a chemical blowing agent, wherein the reacted thermoplastic material contains a reacted chemical blowing agent. In other embodiments, the porous foam 210 may include a thermosetting material that is a cross-linked reaction product of a thermoplastic material containing a blowing agent and a cross-linking agent.

[0075] In some embodiments, the porous material may include a thermoplastic material. In other embodiments, the porous foam 210 may include a thermoset material. In still other embodiments, the porous foam 210 may include a thermoformable material.

[0076] The foamed textile 200 also includes a first surface with a first surface texture and a second surface with a second surface texture, and at least one intermeshing region (intermeshingregion) 220 interconnected by the foam 210 and the unfoamed textile 120. The first surface texture and the second surface texture may be similar or may not be similar. For example, the first surface may include a foamed region, wherein the foamed region has a larger height (i.e., positioned to protrude the surrounding textile), and the second surface may be substantially flat. The intermeshing region 220 may have a separate yarn 110 or fiber passed through, which produces an internal structure in the foam 210. In some embodiments, the internal structure may serve as a substructure of the porous foam 210, which imparts a variety of properties, such as tensile or stretch resistance, stiffness, etc. In some embodiments, the structure may be reticular. In other embodiments, the separate yarn 110 may be arranged substantially parallel to each other. In yet other embodiments, the yarn 110 may form a series of loops passing through the porous foam 210. In any such embodiment, the yarn 110 passing through the porous foam 210 can impart specific qualities to the porous foam, including but not limited to elasticity, durability, strength, hardness, abrasion resistance, conductivity, and other qualities. In addition, the foamed textile incorporating the yarn can exhibit other advantageous properties, such as maintaining a fixed distance between textile fibers, strands, and yarns, i.e., effectively locking the textile into a specific form. This may be additionally advantageous in situations where the spacing of the textile fibers, strands, yarns, or the like has an effect on the properties of the material, such as, but not limited to, conductivity or resistance, elasticity, strength, shear strength, tear resistance, or abrasion resistance.

[0077] In some embodiments, and as Figure 2B , Figure 2C and Figure 2E, the first surface texture includes areas of continuous foam surface with little or no visible yarn 110 or unfoamed textile 120. As stated above, in Figure 1-Figure 8 In the embodiment of the present invention, element 120 is a general representation of a part of a textile. The part of the textile represented by 120 can be but not limited to knitted textiles, braided textiles, crocheted textiles, plaited textiles, woven textiles, winding textiles or some combination thereof. The first surface can be bumpy, with a relatively thicker smaller sub-region of the depth of the foam and a relatively thinner smaller sub-region of the foam. The sub-regions of these relatively thick and relatively thin foams can be regularly spaced or randomly distributed on the first surface. In other embodiments, the thickness of the foam can be roughly uniform so that the first surface texture is substantially smooth.

[0078] The smoothness of a surface can be measured by contact methods or non-contact methods. Contact methods include, for example, dragging a measurement stylus across the surface with a profilometer. Non-contact methods include: interferometry, confocal microscopy, focus variation, structured light, capacitance, electron microscopy, atomic force microscopy, and photogrammetry.

[0079] In other embodiments, Figure 5 As exemplified in , the foamed regions 220 may be discrete at the surface, creating a ridged texture or a dotted texture. In yet other embodiments, for example, Figure 8 In the embodiment illustrated in , the foamed textile 200 can have a variety of foamed areas 220, which produce a variety of surface features. These can include abstract designs, symbols or other descriptions, decorative textures, or functional textures.

[0080] In other embodiments, Figure 2A , Figure 2D and Figure 2F , the first surface texture includes regions of discontinuous foam surface, wherein sub-regions of foam are distributed between sub-regions of exposed unfoamed textile 120. These sub-regions may be regularly spaced to create a pattern, or randomly distributed on the first surface.

[0081] In some embodiments, the porous foam 210 extends beyond the surface of the unfoamed textile 120 through a gap or pore in the unfoamed textile. In the embodiment where the unfoamed textile 120 is a knitted textile, the gap or pore can be the space between the first knit stitch and the second knit stitch. Alternatively, in the case where the unfoamed textile is a woven textile, the gap or pore can be the space between the first strand and the second strand of the woven textile. In other embodiments, the porous foam 210 extends beyond the surface of the unfoamed textile 120 through more than one gap or pore in the unfoamed textile.

[0082] In other embodiments, Figure 2B , Figure 2E and Figure 2F , the foamed textile 200 may include a foamed region 220 in which the porous foam 210 does not extend beyond the surface of the unfoamed textile 120. In some embodiments, such foamed regions 220 may remain below the surface of the unfoamed textile 120. In other embodiments, such foamed regions 220 may be positioned flush with the surface of the foamed textile 120, such that the unfoamed textile 120 is encapsulated in the porous foam 210, or such that the unfoamed textile 120 is not completely encapsulated in the porous foam 210.

[0083] exist Figure 3A-3C In some embodiments illustrated in , the foamed textile 200 may include more than one textile layer 300, 310, 320. Any of the textile layers 300, 310, 320 may include a foamed region 220. The layers 300, 310, 320 may be layered or interconnected to form a variety of foamed regions 220 and unfoamed regions 230, which results in a variety of surface textures, some of which are described above, and intermeshing layers of foam 210 and unfoamed textile 120. Figure 3B In some embodiments, the first textile layer 300 may have a foamed area 220 including a first porous foam material 330, and the second textile layer 310 may have a foamed area 220 including a second porous foam material 340. In some embodiments, the first foam material 330 and the second foam material 340 may include the same thermoplastic material. In some embodiments, the first foam material 330 and the second foam material 340 may include different thermoplastic materials. In other embodiments, the first foam material 330 and the second foam material 340 may have different densities or different porous structures. In still other embodiments, the third textile layer 310 may include a third porous foam material 350.

[0084] In some embodiments, the first foam material and the second foam material can form a gradient zone in which the first foam material 330 transitions to the second foam material 340. In other multi-layer embodiments, the first foam material may not be in physical contact with the second foam material 340. In still other embodiments, the first foam material 330 may abut the second foam material 340 without forming a gradient zone.

[0085] In some embodiments, the porous foam 210 has a hardness ranging from about 20 Asker C to 70 Asker C, or from about 30 Asker C to about 60 Asker C, or from about 40 Asker C to about 50 Asker C. However, depending on the desired properties of the porous foam 210, the hardness may be greater than 70 Asker C, or less than 20 Asker C. For example, if the foamed yarn is intended to provide cushioning, a softer foam may be desired. If the foamed yarn is intended to provide wear resistance or act as a sacrificial layer, a harder foam may be desired.

[0086] IV. Articles including textiles Described herein are articles incorporating the foamed textile 200 or yarn 110 described above, comprising a porous foam 210, wherein the porous foam 200 can be open-cell or closed-cell and can be a reaction product of foaming at least a portion of a first yarn, wherein the yarn 110 is a strand comprising at least one thermoplastic material comprising at least one thermoplastic polymer and a blowing agent.

[0087] Such an article may include an article of footwear or a portion of such an article (such as an upper, sole, collar, tongue, heel or other), an article of apparel or a portion of such an article, an article of sports equipment or a portion of such an article. The article may include a foamable textile 100 or a foamed textile 200, wherein the foamed textile 200 has an unfoamed area 230, a foamed area 220, or some combination of the two. In addition, such an article may include a grip element of the article, a cushioning element of the article, a sound damping element of the article, and a vibration damping element of the article.

[0088] V. Methods of making articles Methods of making articles incorporating the foamed textile 200 or yarn described above, including the porous foam 210, are described herein.

[0089] A first method of manufacturing an article includes the steps of attaching a first component to a second component, wherein the first component includes textile 100 or 200 as described above.

[0090] For purposes of this disclosure, "consisting essentially of" permits the inclusion of unlisted components provided that they do not substantially affect the essential properties or characteristics of the disclosure. For example, the essential properties or characteristics may be determined using standard tests known to those of ordinary skill in the art, such as standard tests for physical properties. Depending on the property, a change of at least 1%, or at least 2%, or at least 5%, of a property may be considered a substantial effect. Alternatively or additionally, the presence of at least 1 weight percent, or at least 2 weight percent, or at least 5 weight percent of an impurity or other material may be considered to substantially alter the composition. These are examples and should not be considered a limited list of properties or methods to which this term may apply.

[0091] Although various embodiments have been described, it will be apparent to those of ordinary skill in the art that more embodiments and implementations are possible. Therefore, the embodiments described herein are examples, rather than the only possible embodiments and implementations.

[0092] The subject matter of the present disclosure may also relate to the following aspects: A first aspect relates to a textile product comprising a first yarn comprising: a first thermoplastic material comprising a blowing agent and at least one thermoplastic polymer.

[0093] A second aspect relates to the textile product of the first aspect, wherein the blowing agent is a chemical blowing agent.

[0094] The third aspect relates to the textile product of the first aspect, wherein the blowing agent is a physical blowing agent.

[0095] The fourth aspect relates to the textile of the first to third aspects, wherein the textile is selected from a knitted textile, a knitted textile, a crocheted textile, a plaited textile, a woven textile or a non-woven textile.

[0096] The fifth aspect relates to the textile product of the fourth aspect, wherein the textile product is a non-woven textile product.

[0097] A sixth aspect relates to the textile of the fourth aspect, wherein the textile further comprises a second yarn, and the first yarn and the second yarn are in contact with each other.

[0098] A seventh aspect relates to the textile of the fourth aspect, wherein the first yarn is embedded in the textile.

[0099] An eighth aspect relates to the textile of the seventh aspect, wherein the textile is a knitted textile and the first yarn is embedded in the knitted textile.

[0100] A ninth aspect relates to the textile product of the sixth aspect, wherein the first yarn and the second yarn are interlooped with each other.

[0101] A tenth aspect relates to the textile product of the ninth aspect, wherein the second yarn does not include the first thermoplastic material.

[0102] An eleventh aspect relates to the textile product of the tenth aspect, wherein the second yarn is interlooped with at least one loop of the first yarn to form a second knitted course adjacent to the first knitted course.

[0103] A twelfth aspect relates to the textile product of the eleventh aspect, further comprising a third yarn embedded between at least the first loop and the second loop of the knitted component.

[0104] A thirteenth aspect relates to the textile product of the ninth aspect, wherein the first yarn forms more than one crocheted stiches.

[0105] A fourteenth aspect relates to the textile product of the thirteenth aspect, wherein the second yarn is interconnected with the first yarn, which forms a second crochet course.

[0106] A fifteenth aspect relates to the textile product of the fourteenth aspect, further comprising a third yarn embedded between the first and second courses.

[0107] A sixteenth aspect relates to the textile product of any preceding aspect, further comprising first more than one yarns oriented along a first direction, forming a warp comprising more than one warp yarn.

[0108] A seventeenth aspect relates to the textile product of the sixteenth aspect, further comprising a second one or more yarns oriented in a second direction unique to the first direction, forming a weft comprising more than one weft yarn.

[0109] An eighteenth aspect relates to the textile product of the seventeenth aspect, wherein the warp threads and the weft threads are interwoven.

[0110] A nineteenth aspect relates to the textile product of the sixth aspect, further comprising a third yarn, wherein the first yarn, the second yarn, and the third yarn are braided.

[0111] A twentieth aspect relates to the textile product of any preceding aspect, wherein the thermoplastic material comprises thermoplastic ethylene vinyl acetate and a heat-activated chemical blowing agent, and a heat-activated cross-linking agent.

[0112] A twenty-first aspect relates to a textile comprising: a porous foam, wherein the porous foam is the reaction product of foaming at least a portion of a first yarn, the first yarn comprising a first thermoplastic material, the first thermoplastic material comprising one or more thermoplastic polymers, optionally wherein the first thermoplastic material comprises a blowing agent.

[0113] A twenty-second aspect relates to a textile comprising: a first yarn comprising a core and a porous foam surrounding the core.

[0114] A twenty-third aspect relates to the textile product of aspect twenty-second, wherein the porous foam is attached to the core.

[0115] A twenty-fourth aspect relates to the textile product of aspect twenty-third, wherein the porous foam substantially surrounds the core.

[0116] A twenty-fifth aspect relates to the textile product of aspect twenty-third, wherein the porous foam partially surrounds the core.

[0117] A twenty-sixth aspect relates to the textile of any one of aspects twenty-third to twenty-fifth, comprising a second yarn interconnected with the first yarn.

[0118] A twenty-seventh aspect relates to the textile product of aspect twenty-sixth, wherein the second yarn is interlooped with the first yarn.

[0119] A twenty-eighth aspect relates to the textile of aspect twenty-sixth or aspect twenty-seventh, wherein the second yarn is not surrounded by foam.

[0120] A twenty-ninth aspect relates to the textile of aspect twenty-eight, wherein the second yarn is exposed on the first surface of the textile.

[0121] A thirtieth aspect relates to the textile of any one of aspects 20 to 29, wherein the first yarn comprises a core, and the core comprises a core material at least partially surrounded by a sheath material.

[0122] A thirty-first aspect relates to the textile product of aspect 30, wherein the sheath material comprises a thermoplastic material further comprising a blowing agent.

[0123] The thirty-second aspect relates to the textile product of the thirty-first aspect, wherein the blowing agent is a physical blowing agent.

[0124] Aspect thirty-third relates to the textile of aspect thirty-first, wherein the foaming agent is a chemical foaming agent, wherein the porous foam comprises a second material, the second material comprises a reacted form of the chemical foaming agent, and the second material is a foamed product of the first thermoplastic material, the first thermoplastic material comprises one or more polymers and a chemical foaming agent, optionally wherein the chemical foaming agent is a heat-activated chemical foaming agent.

[0125] The thirty-fourth aspect relates to the textile product of the thirty-first aspect, wherein the thermoplastic material comprises thermoplastic ethylene vinyl acetate and a heat-activated chemical foaming agent, and a heat-activated cross-linking agent.

[0126] A thirty-fifth aspect relates to the textile of any one of aspects twenty-first to thirty-fourth, wherein the porous foam is an open-cell porous foam.

[0127] A thirty-sixth aspect relates to the textile of any one of aspects 21 to 35, wherein the porous foam is a closed-cell porous foam.

[0128] A thirty-seventh aspect relates to the textile of any one of aspects twenty-first to thirty-sixth, wherein the second material is a thermoplastic material.

[0129] A thirty-eighth aspect relates to the textile of any one of aspects 21 to 37, wherein the second material is a thermoset material.

[0130] A thirty-ninth aspect relates to a textile of any one of aspects 33 to 38, wherein the second material is a cross-linked product of the first thermoplastic material comprising the one or more polymers, and wherein the first thermoplastic material comprises a cross-linking agent, optionally wherein the cross-linking agent is a heat-activated cross-linking agent.

[0131] The 40th aspect relates to the textile of any one of aspects 21 to 39, wherein the textile is selected from a knitted textile, a woven textile, a crocheted textile, a plaited textile or a non-woven textile.

[0132] A forty-first aspect relates to the textile of any one of aspects 21 to 40, wherein the porous foam has a hardness of from about 30 to about 60 as measured on an Asker C durometer.

[0133] A forty-second aspect relates to the textile of any one of aspects twenty-first to forty-first, wherein the porous foam has a hardness of from about 40 to about 50 as measured on an Asker C durometer.

[0134] A forty-third aspect relates to the textile of any one of aspects twenty-first to forty-second, wherein the textile has a first surface having a first texture and a second surface having a second texture.

[0135] A forty-fourth aspect relates to the textile of the forty-third aspect, wherein the porous foam defines a foamed region on the first surface of the textile.

[0136] A forty-fifth aspect relates to the textile product of the forty-fourth aspect, wherein the foamed region is positioned flush with the first surface.

[0137] A forty-sixth aspect relates to the textile product of the forty-fourth aspect, wherein the foamed region is positioned to protrude from the first surface.

[0138] The forty-seventh aspect relates to the textile of the forty-first aspect, wherein the foamed area has a maximum height measured as the maximum distance from the first surface to the second surface of the foamed area, and the maximum height is at least about 5 mm greater than the minimum height measured as the minimum distance from the first surface to the second surface.

[0139] A forty-eighth aspect relates to the textile of any one of aspects 45 to 47, wherein the textile comprises more than one foamed region.

[0140] A forty-ninth aspect relates to the textile of the forty-eighth aspect, wherein at least three of the foamed regions are regularly spaced or periodically arranged relative to each other.

[0141] A fiftieth aspect relates to the textile of the forty-eighth aspect, wherein the more than one foamed regions are randomly dispersed throughout the first surface of the textile.

[0142] A fifty-first aspect relates to the textile of the forty-fifth aspect or the forty-sixth aspect, wherein the foamed area has a shape, and the shape is a representative shape.

[0143] Aspect 52 relates to a textile of any one of aspects 43 to 51, wherein the textile further comprises a first textile layer and a second textile layer, the first textile layer comprising a first front layer surface and a first back layer surface, and the second textile layer comprising a second front layer surface and a second back layer surface.

[0144] A fifty-third aspect relates to the textile of aspect fifty-second, wherein the first back layer surface is in contact with at least a portion of the second front layer surface, which defines an interior portion of the textile layer.

[0145] A fifty-fourth aspect relates to the textile product of the fifty-third aspect, wherein the first front surface comprises the foamed region.

[0146] A fifty-fifth aspect relates to the textile of the fifty-third or fifty-fourth aspect, wherein the first backing surface comprises the foamed area.

[0147] A fifty-sixth aspect relates to the textile of any one of aspects fifty-third to fifty-fifth, wherein the second front surface comprises the foamed area.

[0148] A fifty-seventh aspect relates to the textile of any one of aspects fifty-third to fifty-six, wherein the first backing surface comprises the foamed area.

[0149] Aspect fifty-eight relates to the textile of aspect fifty-three, wherein the first back layer includes a first foamed area comprising a first foamed material, and the second front layer includes a second foamed area comprising a second foamed material, so that the first foamed material is in contact with the second foamed material within the interior portion of the textile layer.

[0150] A fifty-ninth aspect relates to the textile product of the fifty-eighth aspect, wherein the first foamed material and the second foamed material form a blended region, in which the first foamed material is mixed with the second foamed material.

[0151] The sixtieth aspect relates to the textile product of the fifty-ninth aspect, wherein the blended regions are defined by a concentration gradient of the first foamed material.

[0152] The sixty-first aspect relates to the textile of any one of aspects fifty-third to sixty, wherein the textile further comprises a third textile layer, the third textile layer comprising a third front surface and a third back surface, such that the third front surface contacts at least a portion of the second back surface.

[0153] The sixty-second aspect relates to the textile of the sixty-first aspect, wherein the third textile layer further comprises the foamed area.

[0154] The sixty-third aspect relates to a method for processing a textile, the method comprising the following steps: increasing the temperature of the textile, the textile comprising a first yarn, the first yarn comprising a first thermoplastic material, the first thermoplastic material comprising a blowing agent and one or more thermoplastic polymers, the first yarn optionally comprising a core, wherein increasing the temperature comprises increasing the temperature of at least a portion of the yarn to a temperature at or above the softening temperature of the first thermoplastic material; activating the blowing agent thereby foaming at least a portion of the first thermoplastic material of the first yarn into a porous foam; and curing the porous foam to form a foamed area in the textile.

[0155] The sixty-fourth aspect relates to a method for processing a textile, the method comprising the following steps: impregnating a first thermoplastic material with a blowing agent, the first thermoplastic material comprising one or more thermoplastic polymers, the first thermoplastic material forming at least a portion of a first yarn, the first yarn optionally comprising a core formed by a core material; raising the temperature of at least a portion of the textile comprising the first yarn to a temperature at or above the softening temperature of the first thermoplastic material; activating the blowing agent thereby foaming at least a portion of the first thermoplastic material of the first yarn into a porous foam, and curing the porous foam to form a foamed area in the textile.

[0156] The sixty-fifth aspect relates to the method of the sixty-third aspect, wherein the blowing agent is a chemical blowing agent, optionally, wherein the chemical blowing agent is a heat-activated blowing agent.

[0157] The sixty-sixth aspect relates to the method of the sixty-fifth aspect, wherein the chemical foaming agent is selected from sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, calcium azide, azodicarbonamide, hydrazonoformamide, benzenesulfonylhydrazide, dinitrosopentamethylenetetramine, toluenesulfonylhydrazide, p,p'-oxybis(benzenesulfonylhydrazide), azobisisobutyronitrile, barium azodicarboxylate or any combination thereof.

[0158] The sixty-seventh aspect relates to the method of the sixty-third aspect or the sixty-fourth aspect, wherein the blowing agent is a physical blowing agent.

[0159] The sixty-eighth aspect relates to the method of the sixty-seventh aspect, wherein the physical blowing agent is selected from fluorocarbons; hydrocarbons; inert gases; inert liquids; supercritical fluids; or any combination thereof.

[0160] The sixty-ninth aspect relates to the method of the sixty-eighth aspect, wherein the physical foaming agent is selected from an inert liquid, an inert gas or a supercritical fluid.

[0161] The seventieth aspect relates to the method of the sixty-ninth aspect, wherein the inert liquid, the inert gas or the supercritical fluid comprises nitrogen.

[0162] The seventy-first aspect relates to the method of the sixty-ninth aspect, wherein the inert liquid, the inert gas or the supercritical fluid comprises carbon dioxide.

[0163] The seventy-second aspect relates to the method of the seventy-first aspect, wherein, prior to foaming, the first thermoplastic material comprises the physical blowing agent in an amount of about 1% to about 5% by weight based on the total weight of the thermoplastic material.

[0164] The seventy-third aspect relates to the method of the seventy-first aspect, wherein, prior to foaming, the first thermoplastic material comprises the physical blowing agent in an amount of about 1% to about 3% by weight based on the total weight of the thermoplastic material.

[0165] The seventy-fourth aspect relates to the method of the sixty-fourth aspect, wherein impregnating the first thermoplastic material comprises injecting the first thermoplastic material with the physical blowing agent.

[0166] The seventy-fifth aspect relates to the method of the seventy-fourth aspect, wherein injecting the physical blowing agent comprises dissolving the blowing agent in the first thermoplastic material.

[0167] The seventy-sixth aspect relates to the method of the seventy-fourth aspect or the seventy-fifth aspect, further comprising the step of softening the first thermoplastic material before or during the impregnation step, and re-softening the first thermoplastic material during the temperature increase step.

[0168] The seventy-seventh aspect relates to the method of the seventy-sixth aspect, wherein the injecting comprises adding the physical blowing agent to a molten first thermoplastic material to form a single-phase solution of the physical blowing agent in at least one of the first thermoplastic materials, and solidifying the single-phase solution under conditions effective to maintain the physical blowing agent in solution when solidifying.

[0169] The seventy-eighth aspect relates to the method of the seventy-fourth aspect, wherein the injecting comprises injecting the solid first thermoplastic material with the physical blowing agent to form an injected solid first thermoplastic material.

[0170] The seventy-ninth aspect relates to the method of any one of aspects sixty-third to seventy-eight, wherein the first yarn is present in at least a portion of a textile, optionally wherein the textile comprises a second yarn.

[0171] The eightieth aspect relates to the method of any one of aspects sixty-third to seventy-ninth aspects, wherein the step of curing further comprises adhering the porous foam to a surrounding portion of the textile to form the foamed area.

[0172] An eighty-first aspect relates to the method of any one of aspects sixty-third to eighty, wherein the step of curing the porous foam comprises reducing the temperature of the porous foam.

[0173] The eighty-second aspect relates to the method of the eighty-first aspect, wherein reducing the temperature comprises cooling the porous foam at ambient temperature.

[0174] The eighty-third aspect relates to the method of the eighty-first aspect, wherein the step of reducing the temperature further comprises quenching the porous foam with a liquid.

[0175] The eighty-fourth aspect relates to the method of the eighty-third aspect, wherein quenching the porous foam comprises spraying the textile with a liquid.

[0176] The eighty-fifth aspect relates to the method of the eighty-third aspect, wherein quenching the porous foam comprises placing the textile in contact with the liquid in a bath.

[0177] The eighty-sixth aspect relates to the method of the eighty-third aspect, wherein quenching the porous foam comprises pouring the liquid onto the textile.

[0178] The eighty-seventh aspect relates to the method of the eighty-first aspect, wherein the step of reducing the temperature further comprises exposing the porous foam to a gas.

[0179] The eighty-eighth aspect relates to the method of the eighty-first aspect, wherein the step of reducing the temperature further comprises placing at least the portion of the textile including the porous foam in contact with a surface.

[0180] The eighty-ninth aspect relates to the method of any one of aspects sixty-third to eighty-eight, wherein the step of increasing the temperature of the first yarn comprises exposing the textile to a heat source.

[0181] The ninetieth aspect relates to the method of the eighty-ninth aspect, wherein the heat source is a convective heat source.

[0182] The ninety-first aspect relates to the method of the eighty-ninth aspect, wherein the heat source is a direct heat source.

[0183] The ninety-second aspect relates to the method of the eighty-ninth aspect, wherein the heat source is an indirect heat source.

[0184] The ninety-third aspect relates to the method of the eighty-ninth aspect, wherein the heat source is an oven.

[0185] The ninety-fourth aspect relates to the method of the ninety-first aspect, wherein the direct heat source is a liquid, optionally, wherein the direct heat source is a liquid bath.

[0186] The ninety-fifth aspect concerns the method of the ninety-first aspect, wherein the direct heat source is a surface.

[0187] The ninety-sixth aspect relates to the method of the ninety-first aspect, wherein the direct heat source is a surface.

[0188] A ninety-seventh aspect relates to the method of any one of aspects sixty-third to ninety-sixth aspects, wherein the step of foaming the first thermoplastic material comprises exposing the first yarn to actinic radiation.

[0189] The ninety-eighth aspect relates to the method of the ninety-seventh aspect, wherein the actinic radiation is selected from microwave radiation, radio wave radiation, electron beam radiation, gamma beam radiation, infrared radiation, ultraviolet light, visible light, or a combination thereof.

[0190] The ninety-ninth aspect relates to the method of any one of aspects sixty-third to ninety-eighth, further comprising the step of molding the textile.

[0191] The one hundredth aspect relates to the method of the ninety-ninth aspect, wherein molding the textile comprises applying a mold to the textile.

[0192] The one-hundredth aspect relates to the method of the one-hundredth aspect, wherein the mold is a slump-type mold.

[0193] Aspect 102 relates to the method of aspect 100, wherein the mold is a compression mold.

[0194] The one-hundred-and-third aspect relates to the method of aspects one-hundred to one-hundred, further comprising the step of increasing the temperature of the mold.

[0195] The one-hundred and fourth aspects relate to the method of the one-hundred and third aspects, wherein a step of increasing the temperature of the mold is performed after applying the mold to the textile.

[0196] The one-hundred and fifth aspect relates to the method of the one-hundred and third aspect, wherein a step of increasing the temperature of the mold is performed before applying the mold to the textile.

[0197] The one-hundred and sixth aspect relates to the method of aspects one-hundred to one-hundred and fifth aspects, further comprising the step of removing the textile from the mold after the step of curing the porous foam.

[0198] Aspect 107 relates to the method of aspect 106, wherein the step of reducing the temperature of the first thermoplastic material is performed before or during the step of removing the textile from the mold.

[0199] Aspect 108 relates to the method of aspect 106, wherein the step of reducing the temperature of the first thermoplastic material is performed after removing the textile from the mold.

[0200] Aspect 109 relates to the method of any one of aspects 63 to 108, further comprising the step of injecting a physical foaming agent into the first thermoplastic material, wherein the injection is performed before the steps of softening the first thermoplastic material, foaming the first thermoplastic material, and curing the porous foam.

[0201] The 110th aspect relates to a textile made by the method of any one of aspects 63 to 109.

[0202] A one-hundred-eleventh aspect relates to an article comprising: a textile comprising a first yarn, the first yarn comprising a first thermoplastic material, the first thermoplastic material comprising a blowing agent and one or more thermoplastic polymers, optionally wherein the first yarn comprises a core, the core comprising a core material.

[0203] A one-hundred-twelfth aspect relates to an article comprising: a first yarn comprising a first thermoplastic material, wherein the first thermoplastic material comprises a blowing agent and one or more thermoplastic polymers.

[0204] A one-hundred-thirteenth aspect relates to an article comprising: a textile comprising a porous foam, wherein the porous foam is the reaction product of foaming at least a portion of a first yarn, the first yarn comprising a first thermoplastic material, the first thermoplastic material comprising a blowing agent and one or more thermoplastic polymers, optionally wherein the first yarn comprises a core, the core comprising a core material.

[0205] The fourteenth aspect relates to the article of the thirteenth aspect, wherein the textile is a textile according to any one of the first aspect to the sixty-first aspect.

[0206] The fifteenth aspect relates to the article of the fourteenth aspect, wherein the porous foam has a hardness of from about 30 to about 60 as measured on an Asker C durometer.

[0207] A sixteenth aspect relates to the article of aspect one hundred and fourteen, wherein the porous foam has a hardness of from about 40 to about 50 measured on an Asker C durometer.

[0208] Aspect 117 relates to the article of any one of aspects 111 to 116, wherein the article is an article of footwear.

[0209] Aspect 118 relates to the article of any one of aspects 111 to 116, wherein the article is an article of clothing.

[0210] Aspect 119 relates to the article of any one of aspects 111 to 116, wherein the article is an article of sports equipment.

[0211] Aspect 120 relates to the article of any one of aspects 111 to 116, wherein the textile is a handle element of the article.

[0212] The one-hundred and twenty-first aspect relates to the article of any one of aspects one-hundred and eleven to one-hundred and sixteen, wherein the textile is a cushioning element of the article.

[0213] Aspect 122 relates to the article of any one of aspects 111 to 116, wherein the textile is a sound damping element of the article.

[0214] Aspect 123 relates to the article of any one of aspects 111 to 116, wherein the textile is a vibration damping element of the article.

[0215] Aspect 124 relates to a method of manufacturing an article, the method comprising: attaching a first component to a second component, wherein the first component comprises the textile according to any one of aspects 63 to 82.

[0216] Aspect 125 relates to the method of aspect 124, wherein the first component is an upper for an article of footwear and the second component is a sole structure for an article of footwear.

[0217] A one-hundred and twenty-sixth aspect relates to an upper for an article of footwear, the upper comprising: a textile comprising a first yarn, the first yarn comprising a core yarn and a first thermoplastic material, the first thermoplastic material forming an unfoamed coating at least partially surrounding the core yarn; wherein the core yarn comprises more than one fiber or filament, each of the more than one fiber or filament comprising a core material; and wherein the first thermoplastic material comprises at least one first thermoplastic polymer, the first thermoplastic polymer being selected from thermoplastic polyurethanes, thermoplastic polyolefins, thermoplastic polyesters, thermoplastic polyethers, thermoplastic polyamides, or any combination thereof; and a chemical foaming agent, wherein the chemical foaming agent is present in the first thermoplastic material in an amount effective to foam the unfoamed coating of the first thermoplastic material into a porous foam.

[0218] A one-hundred and twenty-seventh aspect relates to the upper for the article of footwear of the one-hundred and twenty-sixth aspect, wherein the textile is a knitted textile and the knitted textile further includes a second yarn.

[0219] A one-hundred and twenty-eighth aspect relates to the upper of aspect one-hundred and twenty-seventh aspect, wherein the first yarn is embedded between rows of the second yarn in the knitted textile.

[0220] A one-hundred and twenty-ninth aspect relates to the upper of the one-hundred and twenty-seventh aspect, wherein the second yarn is interlooped with at least one loop of the first yarn.

[0221] Aspect 130 relates to the upper of any one of aspects 126 to 129, wherein the first thermoplastic material comprises the thermoplastic polyolefin, and the thermoplastic polyolefin comprises a thermoplastic ethylene-vinyl acetate copolymer, wherein the chemical foaming agent is a heat-activated chemical foaming agent, wherein the first thermoplastic material further comprises a heat-activated cross-linking agent, and wherein the core material comprises a thermoplastic polyester.

[0222] The one hundred and thirty-first aspect relates to an upper for an article of footwear, the upper comprising: a textile comprising a porous foam at least partially surrounding a core yarn and attached to the core yarn; wherein the core yarn comprises more than one fiber or filament, each of the more than one fiber or filament comprises a core material; and wherein the porous foam is the product of processing an unfoamed coating at least partially surrounding the core yarn so that the unfoamed coating expands into the porous foam; wherein the porous foam comprises a first polymer material, the first polymer material comprising at least one first polymer selected from polyurethane, polyolefin, polyether, polyamide or any combination thereof; and a degradation product of a chemical foaming agent.

[0223] Aspect 132 relates to the upper of aspect 131, wherein the unfoamed coating comprises a first thermoplastic material, the first thermoplastic material comprising: at least one first thermoplastic polymer, the first thermoplastic polymer being selected from thermoplastic polyurethane, thermoplastic polyolefin, thermoplastic polyester, thermoplastic polyether, thermoplastic polyamide or any combination thereof; and a chemical foaming agent, wherein the chemical foaming agent is present in the first thermoplastic material in an amount effective to foam the unfoamed coating of the first thermoplastic material into the porous foam.

[0224] Aspect 133 relates to the upper of aspect 132, wherein the first polymer material is a cross-linked polymer material.

[0225] Aspect 134 relates to the upper of aspect 133, wherein the unfoamed coating comprises a first thermoplastic material, the first thermoplastic material comprising: at least one first thermoplastic polymer, the first thermoplastic polymer being selected from thermoplastic polyurethane, thermoplastic polyolefin, thermoplastic polyester, thermoplastic polyether, thermoplastic polyamide or any combination thereof; a cross-linking agent; and a chemical foaming agent, wherein the chemical foaming agent is present in the first thermoplastic material in an amount effective to foam the unfoamed coating of the first thermoplastic material into the porous foam.

[0226] A one-hundred and thirty-fifth aspect relates to the upper of any one of aspects one-hundred and thirty-second to one-hundred and thirty-fourth, wherein the porous foam has a hardness of from about 30 to about 60 as measured by an Asker C durometer.

[0227] Aspect 136 relates to the upper of any one of aspects 132 to 135, wherein the textile further comprises a second yarn, and the second yarn is exposed on the first surface of the textile.

[0228] Aspect 137 relates to the upper of any one of aspects 132 to 136, wherein the porous foam defines a foamed area on the first surface of the textile.

[0229] Aspect 138 relates to the upper of aspect 137, wherein the textile comprises more than one foamed area, and at least three of the more than one foamed areas are regularly spaced or periodically arranged relative to each other.

[0230] Aspect 139 relates to the upper of aspect 137, wherein the textile comprises more than one foamed region, and the more than one foamed region are randomly dispersed throughout the first surface of the textile.

[0231] The one-hundred-and-forty aspect relates to the upper of the one-hundred-and-thirty-seventh aspect, wherein the foamed area has a shape, and the shape is a representative shape.

[0232] The one hundred and forty-first aspect relates to a method for processing an upper for an article of footwear, the method comprising the following steps: expanding at least a portion of an unfoamed coating of the yarn present in the textile into a porous foam by raising the temperature of the yarn to a first processing temperature, thereby forming a foamed area in the textile portion of the upper; after expanding the unfoamed coating into the porous foam, lowering the temperature of the porous foam to a second processing temperature, at which the porous foam adheres to a core yarn, to a surrounding portion of the textile, and solidifies while maintaining the porous structure of the porous foam, thereby forming the foamed area in the textile portion; wherein the yarn comprises a core yarn and the unfoamed coating formed therein The invention relates to a first thermoplastic material having a coating thereon, the first thermoplastic material at least partially surrounding the core yarn, the core yarn comprising more than one fiber or filament, and each of the more than one fiber or filament comprising the core material; wherein the first thermoplastic material comprises at least one first thermoplastic polymer, the first thermoplastic polymer being selected from thermoplastic polyurethanes, thermoplastic polyolefins, thermoplastic polyesters, thermoplastic polyethers, thermoplastic polyamides or any combination thereof, the first thermoplastic material further comprising a blowing agent, and the blowing agent is present in the first thermoplastic material in an amount effective to expand the unfoamed coating of the first thermoplastic material into a porous foam; and wherein the first processing temperature is a temperature at or above the softening temperature of the first thermoplastic material.

[0233] A one-hundred and forty-second aspect relates to the method of the one-hundred and forty-first aspect, wherein the porous foam is a cross-linked foam, and the first thermoplastic material further comprises a cross-linking agent.

[0234] The one-hundred and forty-third aspect relates to the method of the one-hundred and forty-first aspect or the one-hundred and forty-second aspect, wherein the core material is a second thermoplastic material and the first processing temperature is a temperature at least 20 degrees Celsius below the softening temperature of the second thermoplastic material.

[0235] Aspect 144 relates to the method of any one of aspects 141 to 143, wherein the blowing agent is a heat-activated blowing agent and the first processing temperature is a temperature at or above the activation temperature of the heat-activated blowing agent, and optionally, when the porous foam is a cross-linked foam and the first thermoplastic material further includes a heat-activated cross-linking agent, the first processing temperature is a temperature at or above the activation temperature of the heat-activated cross-linking agent.

[0236] The one-hundred and forty-fifth aspect relates to an upper for an article of footwear made by the method of any one of aspects one-hundred and forty-fourth aspect.

Claims

1. An upper for an article of footwear, comprising: a textile product comprising a first yarn including a core yarn and a first thermoplastic material, the first thermoplastic material forming an unfoamed coating at least partially surrounding the core yarn; wherein the core yarn comprises more than one fiber or filament, each of the more than one fiber or filament comprising a core material; and The first thermoplastic material comprises: at least one first thermoplastic polymer, the first thermoplastic polymer is selected from thermoplastic polyurethane, thermoplastic polyolefin, thermoplastic polyester, thermoplastic polyether, thermoplastic polyamide or any combination thereof; and a chemical blowing agent, wherein the chemical blowing agent is present in the first thermoplastic material in an amount effective to foam the unfoamed coating of the first thermoplastic material into a cellular foam.

2. An upper for an article of footwear according to any one of claims 1, wherein the textile is a knitted textile and the knitted textile further comprises a second yarn.

3. An upper for an article of footwear according to claim 2, wherein the first yarn is embedded between rows of the second yarn in the knitted textile.

4. The upper for an article of footwear according to claim 2, wherein the second yarn is interlooped with at least one loop of the first yarn.

5. An upper for an article of footwear according to any one of claims 1-4, wherein the first thermoplastic material comprises the thermoplastic polyolefin, and the thermoplastic polyolefin comprises a thermoplastic ethylene-vinyl acetate copolymer, wherein the chemical blowing agent is a heat-activated chemical blowing agent, wherein the first thermoplastic material further comprises a heat-activated cross-linking agent, and wherein the core material comprises a thermoplastic polyester.

6. An upper for an article of footwear, comprising: a textile comprising a porous foam at least partially surrounding a core yarn and attached to the core yarn; wherein the core yarn comprises more than one fiber or filament, each of the more than one fiber or filament comprising a core material; and wherein the porous foam is the product of processing an unfoamed coating at least partially surrounding the core yarn to expand the unfoamed coating into the porous foam; The porous foam comprises: a first polymer material, the first polymer material comprising at least one first polymer selected from polyurethane, polyolefin, polyether, polyamide or any combination thereof; and a degradation product of a chemical blowing agent.

7. The upper for an article of footwear according to claim 6, wherein the unfoamed coating comprises a first thermoplastic material, the first thermoplastic material comprising: at least one first thermoplastic polymer selected from the group consisting of thermoplastic polyurethanes, thermoplastic polyolefins, thermoplastic polyesters, thermoplastic polyethers, thermoplastic polyamides, or any combination thereof; and a chemical blowing agent, wherein the chemical blowing agent is present in the first thermoplastic material in an amount effective to foam the unfoamed coating of the first thermoplastic material into the cellular foam.

8. An upper for an article of footwear according to claim 7, wherein the first polymer material is a cross-linked polymer material.

9. The upper for an article of footwear according to claim 8, wherein the unfoamed coating comprises a first thermoplastic material, the first thermoplastic material comprising: at least one first thermoplastic polymer selected from the group consisting of thermoplastic polyurethane, thermoplastic polyolefin, thermoplastic polyester, thermoplastic polyether, thermoplastic polyamide, or any combination thereof; a cross-linking agent; and a chemical blowing agent, wherein the chemical blowing agent is present in the first thermoplastic material in an amount effective to foam the unfoamed coating of the first thermoplastic material into the cellular foam.

10. An upper for an article of footwear according to any one of claims 7 to 9, wherein the porous foam has a hardness of from about 30 to about 60 as measured by an Asker C durometer.

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