Textile and article and process for manufacturing textile and article

Abstract

The invention relates to a textile and an article and a process for manufacturing the textile and the article. Wearable articles having one or more textiles comprising a low processing temperature polymer composition and a high processing temperature polymer composition, and methods of making the wearable articles, are disclosed. The low processing temperature polymer composition and the high processing temperature polymer composition may be selectively incorporated into a textile to provide an article with one or more structural properties and / or other advantageous properties. The textile may be thermoformed to impart such structural characteristics and / or other advantageous characteristics to the wearable article. This abstract is intended as a browsing tool for purposes of retrieval in the particular art and is not intended to limit the present disclosure.

Description

[0001] This application is a divisional application of the application filed on November 9, 2017, with application number 202111413049.6 and the invention title "Textiles and Articles and Processes for Manufacturing Textiles and Articles".

[0002] The application filed on November 9, 2017, with application number 202111413049.6 and entitled "Textiles and Articles and a Process for Manufacturing Textiles and Articles", is a divisional application of the application filed on November 9, 2017, with application number 201780082865.9 and entitled "Textiles and Articles and a Process for Manufacturing Textiles and Articles".

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

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

[0005] This disclosure relates to articles, such as clothing articles, footwear articles, and sports equipment articles. More specifically, this disclosure relates to articles comprising one or more materials, including low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. This disclosure also relates to methods of manufacturing articles using materials comprising low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. background

[0007] Traditionally, certain wearable items, such as footwear, are manufactured by cutting individual pieces of material and then joining them together. The pieces can be joined by sewing and / or using adhesives. However, cutting and joining multiple pieces of material is a wasteful, labor-intensive, and error-prone process, where such errors lead to increased waste as well as increased manufacturing time and energy. Attached Figure Description

[0008] Other aspects of this disclosure will be readily understood when viewed in conjunction with the accompanying drawings and after reviewing the detailed description described below.

[0009] Figure 1A These are top and side perspective views of footwear articles according to aspects of the present invention, mainly illustrating the locations of three different textile zones.

[0010] Figure 1B According to aspects of the present invention Figure 1ABottom and side perspective views of footwear items.

[0011] Figure 1C According to aspects of the present invention Figure 1A The top and side perspective views of alternative aspects of footwear items primarily illustrate the location of three distinct textile sections.

[0012] Figure 2A This is a side view of a garment article according to an aspect of the present invention, mainly illustrating the elbow patch;

[0013] Figure 2B According to aspects of the present invention Figure 2A A close-up view of the elbow patch on the clothing item, mainly illustrating three different textile areas.

[0014] Figure 3 This is a schematic plan view of a textile having three types of textile zones according to an aspect of the present invention.

[0015] Figures 4A-4E Depicting aspects according to the invention Figure 3 Exemplary cross-sections of various types of textile areas.

[0016] Figure 5A-5J The aspects of the invention described can exist Figures 4A-4E Exemplary knitted structures in various segments of an exemplary cross-section depicted in the figure.

[0017] Figure 6 This is a schematic representation of courses of loops of two interconnected loops having different types of yarns and depicting an interlaced interface, according to an aspect of the invention.

[0018] Figure 7A This is a schematic representation of three interconnected rows of coils according to an aspect of the invention, wherein the middle row of coils is formed of yarns different from those of the outer rows of coils.

[0019] Figure 7B It is according to an aspect of the invention after exposure to the thermoforming process. Figure 7A A schematic representation of the rows of interconnected coils, showing that the middle row of coils transforms into a molten yarn component after thermoforming, but the rows of the two outer coils do not transform into molten yarn components.

[0020] Figure 8 According to aspects of the present invention Figure 7BA schematic representation of the cross-section of the molten yarn component, and showing a portion of the yarn from one of the rows of coils from the outside encapsulated within the molten yarn component.

[0021] Figure 9A According to aspects of the present invention Figure 7A A schematic representation of a cross-section of a portion of the interconnected rows, showing one coil in the middle row of coils and one coil in the upper row of coils.

[0022] Figure 9B According to aspects of the present invention Figure 7A The interconnected rows have been exposed after the thermoforming process. Figure 9A A schematic representation of the cross-section shows how the yarn loops in the middle row deform but still maintain the general yarn structure.

[0023] Figure 10A This is a schematic representation of three interconnected rows of yarn of a type according to an aspect of the invention, wherein the anchoring yarn is in a float stitch and a tuck stitch.

[0024] Figure 10B According to aspects of the present invention Figure 10A A schematic representation of interconnected rows, and shows that after thermoforming, one type of yarn forming the interconnected rows has been transformed into a molten yarn component, wherein the anchoring yarn still exists as yarn.

[0025] Figure 10C According to aspects of the present invention Figure 10B A schematic representation of the cross-section of the molten yarn component, showing that the anchoring yarn is encapsulated within the molten yarn component.

[0026] Figure 11A According to aspects of the present invention Figure 3 A schematic representation of a portion of the textile area of ​​a textile, and showing areas with different types of fibers.

[0027] Figure 11B It is according to an aspect of the invention after exposure to the thermoforming process. Figure 11A The diagram illustrates a portion of the material and shows how one type of fiber has been transformed into a non-fiber material, in which fibers of another material are embedded within the non-fiber material.

[0028] Figure 11C According to aspects of the present invention Figure 11B The cross-section of the non-fibrous material shows two other fibers encapsulated within the non-fibrous material.

[0029] Figure 12 This is a schematic side view of footwear articles comprising textile materials according to an aspect of the invention, and shows a chassis, heel counter, and sock liner for incorporation into the footwear articles.

[0030] Figure 13 According to aspects of the present invention Figure 12 A cross-section of a footwear item having a sole plate, a heel stabilizer, and an insole positioned inside the footwear item.

[0031] Figure 14 This is a schematic side view of a footwear article comprising textile material according to an aspect of the invention, showing the addition of ground-engaging cleats to the ground-facing outsole area of ​​the footwear article.

[0032] Figure 15 These are top and side perspective views according to an aspect of the invention, showing an upper for footwear articles placed on a last.

[0033] Figure 16 It is from the present invention on the shoe last Figure 15 The top and side perspective views of the shoe upper show at least the portion of the upper that wraps around the bottom of the last.

[0034] Figure 17 It is from the aspects of the present invention Figure 16 The cross-section of the upper on the shoe last shows the contact between the shoe last and the inner surface of the upper.

[0035] Figure 18 It is from the present invention. Figure 16 The top and side perspective views of the upper on the shoe last show the protective sheath surrounding the upper.

[0036] Figure 19 It is from the present invention. Figure 18 The cross-section of the shoe upper covered by the protective cover shows the outer surface of the shoe upper in contact with the protective cover.

[0037] Figure 20A It is from the present invention. Figure 16 The side view of the upper on the shoe last shows a vacuum bag with the upper placed inside.

[0038] Figure 20B According to aspects of the present invention Figure 20AA side view of the shoe upper inside a vacuum bag, showing the vacuum bag pressing the outer surface of the shoe upper.

[0039] Figure 21 This is a schematic representation of a thermoforming system having a heating zone and a cooling zone according to an aspect of the present invention.

[0040] Figure 22 This is a flowchart of an exemplary process for manufacturing an upper for a shoe according to an aspect of the present invention.

[0041] Figure 23 This is a flowchart of another exemplary process for manufacturing an upper for a shoe according to an aspect of the present invention.

[0042] Figure 24 This is a flowchart of an exemplary process for manufacturing a knitted upper for footwear articles according to an aspect of the present invention.

[0043] Figure 25 This is a flowchart of an exemplary process for forming knitted articles according to aspects of the present invention.

[0044] Figure 26 This is a flowchart of an exemplary process for manufacturing an upper for footwear articles according to aspects of the present invention.

[0045] Figure 27 This is a flowchart of an exemplary process for manufacturing an outsole for footwear articles according to an aspect of the present invention. Detailed description

[0047] This disclosure relates to textiles or combinations of textiles with other materials (e.g., molded parts, films, second textiles, yarns, or fibers), wherein one or more of the textiles or other materials comprise a low-processing-temperature polymer composition, and one or more of the textiles or other materials comprise a high-processing-temperature polymer composition. In some aspects, a single textile comprises both a low-processing-temperature polymer composition and a high-processing-temperature polymer composition. This disclosure also relates to methods of thermoforming a single textile or a textile combined with one or more other materials on a molding surface to reshape the textile, to attach one or more other materials to the textile using re-flowed polymeric material, or performing both operations. The thermoforming process involves placing at least a portion of the textile on the molding surface and, while the textile remains in contact with the molding surface, raising the temperature of the entire textile to a first temperature, and then lowering the temperature of the entire textile to a second temperature. The first temperature is a temperature above the melting point of the low-processing-temperature polymer composition but below at least one of the following of the high-processing-temperature polymer composition: 1) a creep relaxation temperature T. cr;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs Therefore, using the disclosed process, portions of textiles and / or one or more materials comprising a low-processing-temperature polymer composition will melt, reflow, and then be solidified into a new shape or configuration, while portions formed from a high-processing-temperature polymer composition will retain their original shape or configuration. Forming first fibers and / or yarns from the low-processing-temperature polymer composition and using these fibers and / or yarns to construct textiles, such as woven textiles, knitted textiles, non-woven textiles, braided textiles, etc., is a particularly efficient and effective way to incorporate low-processing-temperature polymer compositions into these thermoforming processes. For example, the use of the disclosed textiles and process makes it possible to produce thermoformed articles including an integrally formed area using only a single textile and only a single thermoforming process, the thermoformed articles having properties ranging from conventional textiles to solid molding polymer materials. It has been found that producing well-functioning yarns and / or fibers while also producing final articles with desirable properties in the disclosed process requires the use of a balanced low-processing-temperature polymer composition with the properties disclosed herein. Examples of polymers that can provide this balance of properties in low-processing-temperature polymer compositions are also disclosed. In specific embodiments, low-processing-temperature polymer compositions suitable for manufacturing yarns for use in commercial weaving or knitting equipment are also disclosed.

[0048] In various aspects, this disclosure relates to a textile comprising: a first yarn or first fiber comprising a low-processing-temperature polymer composition, the low-processing-temperature polymer composition comprising one or more first thermoplastic polymers; and a second yarn or second fiber comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m creep relaxation temperature T cr .

[0049] In one aspect, this disclosure relates to a textile comprising: a first yarn or first fiber comprising a low-processing-temperature polymer composition, the low-processing-temperature polymer composition comprising one or more first thermoplastic polymers; and a second yarn or second fiber comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m Heat distortion temperature T hd .

[0050] In one aspect, this disclosure relates to a textile comprising: a first yarn or first fiber comprising a low-processing-temperature polymer composition, the low-processing-temperature polymer composition comprising one or more first thermoplastic polymers; and a second yarn or second fiber comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m Vicat softening temperature T vs .

[0051] In one aspect, this disclosure relates to a textile comprising: a first yarn or first fiber comprising a low-processing-temperature polymer composition, the low-processing-temperature polymer composition comprising one or more first thermoplastic polymers, wherein the low-processing-temperature polymer composition exhibits a melting temperature T of 135°C or less. m ; and a second yarn or second fiber comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition containing one or more second thermoplastic polymers, wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs .

[0052] In one aspect, this disclosure relates to a process for manufacturing articles, the process comprising: providing the disclosed textile; and combining the textile with one or more other components to form footwear articles, clothing articles, or sports equipment articles.

[0053] In one aspect, this disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and re-cured product of a first element selected from a first forming component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m creep relaxation temperature T cr .

[0054] In one aspect, this disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and re-cured product of a first element selected from a first forming component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Heat distortion temperature T hd .

[0055] In one aspect, this disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and re-cured product of a first element selected from a first forming component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m Vicat softening temperature T vs .

[0056] In one aspect, this disclosure relates to an article comprising: a first reflow material; and a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and re-cured product of a first element selected from a first forming component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature Thd ; or 3) Vicat softening temperature T vs .

[0057] In each respect, the melted and re-cured product is a melted and re-cured element selected from the first forming component, the first film, the first yarn, the first fiber, the first textile or any combination thereof, and the melted and re-cured element is a component of the second element.

[0058] In one aspect, this disclosure relates to a process for manufacturing articles, the process comprising: providing the disclosed articles; and combining the articles with one or more other materials to form footwear articles, clothing articles, or sports equipment articles.

[0059] In one aspect, this disclosure relates to a process for manufacturing articles, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber; and receiving a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers, wherein the second element comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs ; Place at least a portion of the first element and at least a portion of the second element on the molding surface; while at least a portion of the first element and at least a portion of the second element are on the molding surface, raise the temperature of the entire article to above the melting temperature T of the polymer composition at the low processing temperature. m And below the creep relaxation temperature T of the high-processing-temperature polymer composition. cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs At least one of the following temperatures; and after raising the temperature of the entire article, while holding at least a portion of the article on the molding surface, lowering the temperature of the entire article to below the melting temperature T of the low-processing polymer composition. m The temperature is such that the object is formed.

[0060] In one aspect, this disclosure relates to a combined upper and outsole for footwear articles, the combined upper and outsole comprising: a first reflow material; and a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflow material is a melted and re-cured product of a first element selected from a first forming component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature polymer composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymer composition exhibits a melting temperature T greater than that of the low processing temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs The combined upper and outsole include a medial midsole region, a lateral midsole region, and a ground-facing outsole region, and at least a portion of the first return material is present on the ground-facing outsole region.

[0061] In one aspect, this disclosure relates to a process for manufacturing a combined upper and outsole for footwear articles, the process comprising: receiving a first element selected from a first forming component, a first film, a first textile, a first yarn, and a first fiber; receiving a second element selected from a second forming component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers, wherein the second element comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs At least a portion of the first element and at least a portion of the second element are placed on the molding surface; while at least a portion of the first element and at least a portion of the second element are on the molding surface, the temperature of the entire first element and the entire second element is raised to a temperature higher than the melting temperature T of the polymer composition at the low processing temperature. m And below the creep relaxation temperature T of the high-processing-temperature polymer composition. cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature Tvs The temperature of at least one of the components; and after raising the temperature of the entire first article and the entire second article, while holding at least a portion of the first article and at least a portion of the second article on the molding surface, lowering the temperature of the entire first component and the entire second component to below the melting temperature T of the low-processing-temperature polymer composition. m The temperature is such that the object is formed.

[0062] This disclosure relates to materials and processes for manufacturing textiles, sports equipment articles, and wearable articles (including footwear and apparel). It should be understood that this disclosure contemplates a variety of sports equipment articles, including backpacks, gear bags, hats, protective gear, and the like. It should be understood that this disclosure contemplates a variety of wearable articles, including knitted articles. A non-limiting list of wearable articles contemplated by this disclosure includes footwear, shirts, trousers, socks, jackets or other outerwear, protective equipment, hats, and underwear such as bras. In some aspects, wearable articles are footwear articles. "Footwear article" is used to refer to articles intended for wearing on human feet; for example, in some aspects, footwear articles can be shoes. In some aspects, the disclosed materials and processes can be used to manufacture components used in wearable articles such as footwear articles. Exemplary components of wearable articles include, but are not limited to, uppers for footwear articles.

[0063] Exemplary footwear articles are athletic or sporting footwear, including but not limited to running shoes, basketball shoes, soccer shoes, baseball shoes, American football shoes, tennis shoes, rugby shoes, cross-training shoes, walking shoes, hiking boots, golf shoes, rubber-soled athletic shoes, and the like. Alternatively, footwear articles may be non-athletic footwear, including but not limited to dress shoes, loafers, casual shoes, sandals, and boots, including work boots. Shoes may or may not cover the wearer's entire foot. For example, shoes may be sandals or other items that expose most of the foot being worn. Therefore, those skilled in the art will understand that the materials and processes disclosed herein are suitable for a wide variety of footwear types or styles other than the specific types or styles discussed in the following materials and depicted in the accompanying drawings.

[0064] The disclosed textiles and articles may include yarns, fibers, or combinations of yarns and fibers comprising a low-processing-temperature polymer composition (described below) and yarns, fibers, or combinations of yarns and fibers comprising a high-processing-temperature polymer composition (also described below). The disclosed textiles and articles include at least two yarns that balance many of the material properties described herein. Furthermore, the yarns and fibers used in the disclosed materials and processes will be selected based on a variety of factors, including the type of footwear to be manufactured, such as whether it is athletic or non-athletic footwear, and the typical use of the footwear. For example, when considering the type of yarns and fibers used in athletic footwear, the type of sport used in the athletic footwear and / or the conditions under which the athletic footwear will be worn (e.g., indoors or outdoors) may be considered.

[0065] The disclosed articles may include molded parts, films, fibers, yarns, or combinations thereof comprising low-processing-temperature polymer compositions (described below) and high-processing-temperature polymer compositions (also described below). The disclosed articles comprise at least two polymer compositions that balance many of the material properties described herein. Furthermore, the compositions and processes used to form these articles will be selected based on a variety of factors, including the type of article to be manufactured and its typical application.

[0066] In various aspects, the disclosed molded parts, films, textiles, and articles comprise two different polymer compositions, wherein one polymer composition can be melted or deformed in a thermoforming process within a first temperature range (referred to herein as a low-processing-temperature polymer composition), while the other polymer composition retains its shape within the first temperature range (referred to herein as a high-processing-temperature polymer composition). It should be understood that reference to "polymer composition" is intended to mean a composition comprising at least one polymer. Optionally, additional components such as pigments, dyes, fillers, processing aids, and the like may be present in the polymer composition. The low-processing-temperature polymer composition comprises one or more first thermoplastic polymers. The high-processing-temperature polymer composition comprises one or more second polymers. In some embodiments, the high-processing-temperature polymer composition is a thermoplastic composition and comprises one or more second thermoplastic polymers. The polymer compositions of this disclosure can be used to form molded parts, films, and / or fibers. Molded parts and / or films can be incorporated into articles as described herein. Fibers can be used to form yarns and textiles as described herein, and these yarns and textiles can also be incorporated into articles as described herein. In another aspect, the disclosed textiles and articles include a first film, fiber, or yarn comprising a low-processing-temperature polymer composition and a second film, fiber, or yarn comprising a high-processing-temperature polymer composition.

[0067] As mentioned above, the articles described herein may include materials such as molded parts, films, fibers, yarns, and / or textiles, wherein the articles are formed at least in part from low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. In some embodiments, the material is formed at least in part from low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. As used herein, "low-processing-temperature polymer composition" and "high-processing-temperature polymer composition" refer to the relative creep relaxation temperature (T0) of each of these compositions. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) and / or melting temperature (T m The relative term for creep relaxation temperature (T) of a low-processing-temperature polymer composition. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) and melting temperature (T m This is also understood to be below the decomposition temperature of the high-processing-temperature polymer composition. These parameters are described in further detail below. It should be understood that other properties and parameters may differ between low-processing-temperature and high-processing-temperature polymer compositions, as discussed in detail below. In various aspects, the low-processing-temperature polymer composition and / or the high-processing-temperature polymer composition, or both, may be present in molded parts, films, textiles, yarns, or fibers.

[0068] In all aspects, when both the low-processing-temperature polymer composition and the high-processing-temperature polymer composition are thermoplastic compositions, the melting temperature (T) of the low-processing-temperature polymer composition is... m The polymer composition has at least one of the following properties below the high processing temperature: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m In other words, for example, low-processing-temperature polymer compositions exhibit a lower creep relaxation temperature (T0) than high-processing-temperature polymer compositions. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) or melting temperature (T) m The melting temperature (T) of one or more of the following temperatures m ).

[0069] In another aspect, the melting temperature (T) of low-processing-temperature polymer compositions m The creep relaxation temperature (T) of polymer compositions below the high processing temperaturecr In another aspect, the melting temperature (T) of low-processing-temperature polymer compositions. m The Vicat softening temperature (T) of polymer compositions below the high processing temperature vs In another aspect, the melting temperature (T) of low-processing-temperature polymer compositions. m The heat distortion temperature (T) of polymer compositions below the high processing temperature hd In even other respects, the melting temperature (T) of low-processing-temperature polymer compositions. m The melting temperature of polymer compositions below the high processing temperature (T) m ).

[0070] In all aspects, the melting temperature (T) of high-processing-temperature polymer compositions m The polymer composition has at least one of the following properties that are greater than the low processing temperature: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m In other words, for example, high-processing-temperature polymer compositions exhibit a higher creep relaxation temperature (T0) than low-processing-temperature polymer compositions. cr Vicat softening temperature (T) vs ), heat distortion temperature (T) hd ) or melting temperature (T) m The melting temperature (T) of one or more of the following temperatures m ).

[0071] In another aspect, the melting temperature (T) of high-processing-temperature polymer compositions m The creep relaxation temperature of the polymer composition is greater than the low processing temperature (T). cr In another aspect, the melting temperature (T) of high-processing-temperature polymer compositions. m The Vicat softening temperature (T) of the polymer composition is greater than that of the low-processing-temperature polymer composition. vs In another aspect, the melting temperature (T) of high-processing-temperature polymer compositions... m The heat distortion temperature (T) of the polymer composition at the low processing temperature is greater than that of the low processing temperature polymer composition. hd In even other respects, the melting temperature (T) of high-processing-temperature polymer compositions. m The melting temperature of the polymer composition is greater than that of the low-processing-temperature polymer composition (T). m ).

[0072] In various respects, low-processing-temperature polymer compositions and high-processing-temperature polymer compositions may be selectively incorporated into textiles or articles to provide one or more structural properties and / or other advantageous properties. In various respects, such textiles may be thermoformed to impart such structural properties and / or other advantageous properties. Thermoforming may be carried out at temperatures below at least one of the following properties of the high-processing-temperature polymer composition: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m Thermoforming can be performed at creep relaxation temperatures (T0) of polymer compositions below the high processing temperature. cr Thermoforming can be performed within a temperature range below the Vicat softening temperature (T0) of the polymer composition at its high processing temperature. vs Thermoforming can be performed within a temperature range below the high processing temperature of the polymer composition (T). hd Thermoforming can be performed within a temperature range below the melting temperature (T0) of the polymer composition, which is lower than the high processing temperature. m It is carried out within the temperature range of ).

[0073] In various aspects, low-processing-temperature polymer compositions can be used to form fibers. As used herein, "fiber" is understood to include filaments. Similarly, in various aspects, high-processing-temperature polymer compositions can be used to form fibers. In various aspects, the fiber can be a bicomponent fiber comprising a first portion formed of a low-processing-temperature polymer composition and a second portion formed of a high-processing-temperature polymer composition. For example, the low-processing-temperature polymer composition and the high-processing-temperature polymer composition can be co-extruded to form a bicomponent fiber. The fiber can be extruded from the low-processing-temperature polymer composition and subsequently coated with the high-processing-temperature polymer composition. Alternatively, the fiber can be extruded from the high-processing-temperature polymer composition and subsequently coated with the low-processing-temperature polymer composition. In another aspect, the fiber can be a multicomponent fiber comprising three or more polymer compositions, said three or more polymer compositions including one or more low-processing-temperature polymer compositions and one or more high-processing-temperature polymer compositions.

[0074] In various aspects, the disclosed fibers can be used to prepare yarns. Yarns can be formed using short fibers or continuous fibers. The yarns of this disclosure comprise at least one of a low-processing-temperature polymer composition and a high-processing-temperature polymer composition. Embodiments of this disclosure include both low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. For example, a yarn may comprise one or more of the disclosed fibers, said fibers comprising a low-processing-temperature polymer composition, a mixture of two or more low-processing-temperature polymer compositions, a high-processing-temperature polymer composition, a mixture of two or more high-processing-temperature polymer compositions, or a mixture of one or more low-processing-temperature polymer compositions and one or more high-processing-temperature polymer compositions. Substantially all or most of the fibers of the yarn may be formed from a low-processing-temperature polymer composition. Alternatively, substantially all or most of the fibers of the yarn may be formed from a high-processing-temperature polymer composition. Yarns may comprise fibers formed from low-processing-temperature polymer compositions or fibers formed from high-processing-temperature polymer compositions, or both types of fibers. Yarns may comprise fibers formed from low-processing-temperature polymer compositions, wherein the yarn is coated with a high-processing-temperature polymer composition. Alternatively, the yarn may comprise fibers formed from a high-processing-temperature polymer composition, wherein the yarn is coated with a low-processing-temperature polymer composition.

[0075] In various aspects, the aforementioned fibers or yarns can be used to prepare textiles. Textiles may include one or more of the disclosed fibers or yarns. In various aspects, the textiles may be woven textiles comprising one or more of the disclosed yarns. In another aspect, the textiles may be knitted textiles comprising one or more of the disclosed yarns. In yet another aspect, the textiles may be nonwoven textiles comprising one or more of the disclosed fibers.

[0076] In various aspects, low-processing-temperature polymer compositions or high-processing-temperature polymer compositions, or both, can be used to prepare molded parts. The molded parts can be molded parts manufactured by injection molding, compression molding, blow molding, rotational molding, or other molding techniques known to those skilled in the art. In some aspects, the molded part can comprise a mixture of two or more low-processing-temperature polymer compositions. In alternative aspects, the molded part can comprise a mixture of two or more high-processing-temperature polymer compositions. In other aspects, the molded part can comprise one or more low-processing-temperature polymer compositions and one or more high-processing-temperature polymer compositions. For example, the molded part can comprise two or more portions, wherein a first portion is formed of a low-processing-temperature polymer composition and a second portion is formed of a high-processing-temperature polymer composition. The two or more portions can be formed using a double-shot molding process.

[0077] In various aspects, both low-processing-temperature polymer compositions and high-processing-temperature polymer compositions can be used to manufacture membranes. In some aspects, the membrane may comprise one or more low-processing-temperature polymer compositions. Alternatively, in some aspects, the membrane may comprise one or more high-processing-temperature polymer compositions. In other aspects, the membrane may comprise one or more low-processing-temperature polymer compositions and one or more high-processing-temperature polymer compositions. In various aspects, the membrane may be a multilayer membrane comprising one or more of the disclosed membranes, for example, a bilayer membrane comprising a first layer comprising a low-processing-temperature polymer composition and a second layer comprising a high-processing-temperature polymer composition. Multilayer membranes can be formed by co-extrusion or lamination.

[0078] In the traditional formation of articles, including wearable items, the transition from a first functional area to a second functional area can be achieved through a change in the material that imparts functionality. This transition from a first material with a first functional description to a second material with a different functional description can introduce constraints into the final article. For example, in the case of shoes, the transition from the sole to the upper occurs near the bite line. This transition can be described as a hard-to-soft transition because the sole typically has a relatively rigid response to foot movement, and the upper has a relatively generally non-rigid response to foot movement. Other such hard-to-soft transitions can exist in other locations on the shoe, depending on the design and construction methods used. At this transition, the wearer of the shoe may experience discomfort because the portion of the foot on one side of the transition is allowed to move in a different way than the portion of the foot on the other side of the transition (e.g., more freely). This abrupt change in the allowable degrees of freedom of movement of the wearer's foot (e.g., a hard-to-soft transition) can affect the perceived performance and feel of the shoe. To limit the effects of a hard-to-soft transition, manufacturers may insert multiple layers of material or otherwise mechanically manipulate the transition area to mask the change. Each of these changes could introduce complexity, additional processing steps, and / or materials, which could further affect the shoe's efficiency, cost, and weight.

[0079] Therefore, the aspects contemplated herein allow for integrally formed article portions having a transition from a first functional region to a second functional region, said transition being engineered into and during the formation of said region. For example, manipulation of materials and techniques, such as knitting stitches, can be implemented to allow a gradient from the first functional region to the second functional region. Returning this to the hard-to-soft transition of a shoe, it is contemplated that the first functional region of the shoe (e.g., the sole region) can be formed (e.g., knitted) with a first type of material (e.g., a low-processing-temperature polymer composition described below), and the second functional region of the shoe (e.g., the upper portion) can be formed (e.g., knitted) with a different material (e.g., a high-processing-temperature polymer composition described below). Alternatively or additionally, the sole region of the shoe can be knitted with a first type of stitch, and the upper portion of the shoe can be knitted with a second type of stitch. Furthermore, in this embodiment, the transition from a first functional area (e.g., the sole area) to a second functional area (e.g., the upper area) may include one or more transition zones, wherein knitting techniques (e.g., stitch selection, layer manipulation) and / or materials are blended in a defined manner to integrally form a more natural transition from the first functional area to the second functional area during the manufacturing of the area. In an exemplary aspect, this integral transition between functional areas can positively influence the wearer's perceived performance and / or feel of the shoe.

[0080] In one aspect, a textile is provided comprising a first plurality of fibers comprising a low-processing-temperature polymer composition. The textile also includes a second plurality of fibers comprising a high-processing-temperature polymer composition. The first and second plurality of fibers can be deposited to form separate regions of the textile. For example, the first plurality of fibers can form a first surface of the textile, and the second plurality of fibers can form a second surface of the textile opposite to the first surface. Alternatively or additionally, the first plurality of fibers can form an inner portion of the first surface of the textile, and the second plurality of fibers can form an outer portion of the first surface of the textile. The first and second plurality of fibers can be laid in a first, second, and third region, the second region being positioned between the first and third regions, wherein the first region includes the second plurality of fibers with increased concentration compared to the second region, and wherein the third region includes the first plurality of fibers with increased concentration compared to the second region. In a particular embodiment, the textile is a nonwoven textile. In some embodiments, the textile is a component of an article of the present disclosure, such as clothing articles, footwear articles, or sports equipment articles. In a particular embodiment, the textile is a component of the upper of a footwear article. Textile components may constitute at least 75 wt% of the upper for footwear articles.

[0081] In one aspect, a textile is provided comprising a first yarn comprising a low-processing-temperature polymer composition. The textile also includes a second yarn comprising a high-processing-temperature polymer composition. The first and second yarns can be used to form separate regions of the textile. The first and second yarns can be included in a first, second, and third region, the second region being positioned between the first and third regions, wherein the first region includes a second yarn with increased concentration compared to the second region, and wherein the third region includes a first yarn with increased concentration compared to the second region. In some embodiments, the textile is a component of an article of this disclosure, such as clothing articles, footwear articles, or sports equipment articles. In a particular embodiment, the textile is a component of the upper of a footwear article. The textile component may constitute at least 75 wt% of the upper for the footwear article.

[0082] In one aspect, a woven textile is provided, the woven textile comprising a first yarn comprising a low-processing-temperature polymer composition. The woven textile article also includes a second yarn comprising a high-processing-temperature polymer composition. The first and second yarns can be used to form separate regions of the woven textile article. For example, the first yarn can form substantially all or a portion of the warp yarns of the weave of the woven textile article, and the second yarn can form substantially all or a portion of the weft yarns of the weave of the woven textile article, or vice versa. The first and second yarns can form a first region, a second region, and a third region, the second region being located between the first and third regions, wherein the first region includes a second yarn with increased concentration compared to the second region, and wherein the third region includes a first yarn with increased concentration compared to the second region. In some embodiments, the woven textile is a component of an article of the present disclosure, such as a clothing article, footwear article, or sports equipment article. In a particular embodiment, the woven textile is a component of the upper of a footwear article. The woven textile component can constitute at least 75 wt% of the upper for a footwear article.

[0083] In one aspect, a knitted textile is provided, the knitted textile comprising a first yarn comprising a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The knitted textile also includes a second yarn comprising a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The first and second yarns at least partially form a plurality of interconnected rows in at least one knitted layer of the knitted textile having at least a first region, a second region, and a third region, the second region being positioned between the first and third regions, wherein the first region comprises a second yarn with increased concentration compared to the second region, and wherein the third region comprises a first yarn with increased concentration compared to the second region. In some embodiments, the knitted textile is a component of an article of the present disclosure, such as a garment article, footwear article, or sports equipment article. In a particular embodiment, the knitted textile is a component of the upper of a footwear article. The knitted textile component may constitute at least 75 wt% of the upper for a footwear article.

[0084] Knitted textiles can be formed by knitting processes such as flat knitting or circular knitting. In some aspects, knitted textiles can be knitted articles with a substantially seamless construction. In other aspects, knitted textiles can be knitted articles formed from a single-piece knitted construction. As used herein, a knitted article is defined as being formed from a “single-piece knitted construction” when it is formed into a one-piece element by a knitting process. That is, the knitting process substantially forms the various features and structures of the knitted article without requiring a large number of additional manufacturing steps or processes. Although parts of the knitted article may be joined together after the knitting process (e.g., the edges of the knitted article are joined together, as at seams), the knitted article remains formed from a single-piece knitted construction because it is formed as a one-piece knitted element. In various aspects, the knitted article may also include other elements that can be added after the knitting process (e.g., tongues, struts, laces, heel stabilizers, logos, trademarks, labels).

[0085] Knitted textiles can incorporate various types and combinations of stitches and yarns. Regarding stitches, knitted textiles can have one type of stitch in one area and another type of stitch in another area. Depending on the type and combination of stitches used, areas of a knitted textile can have, for example, plain knit structures, mesh knit structures, or rib knit structures. Different types of stitches can affect the physical properties of knitted textiles, including aesthetics, stretch, thickness, breathability, and abrasion resistance. In other words, different types of stitches can impart different properties to different areas of a knitted textile. Regarding yarns, knitted textiles can have one type of yarn in one area and another type of yarn in another area; for example, yarn containing a low-processing-temperature polymer composition in one area and yarn containing a high-processing-temperature polymer composition in another area. Depending on various design criteria, knitted textiles can incorporate yarns with, for example, different deniers, materials (e.g., cotton, spandex, polyester, rayon, wool, and nylon), and degrees of twist. Different types of yarn can affect the physical properties of knitted textiles, including aesthetics, stretch, thickness, breathability, and abrasion resistance. In other words, different types of yarn can impart different properties to different areas of a knitted textile. By combining various types and combinations of stitches and yarns, each area of ​​a knitted item can possess specific properties, which, when used in footwear, apparel, or sports equipment, enhance the comfort, durability, and performance of the knitted textile as needed.

[0086] Knitted textiles can be produced using a variety of suitable processes. For example, flat knitting can be used to manufacture knitted textiles. While flat knitting provides a suitable process for forming knitted textiles, other knitting processes can also be used, such as wide tube circular knitting, narrow tube circular knit jacquard, single knit circular knit jacquard, double knit circular knitting, warp knit tricot, warp knit raschel, and double-needle bar raschel. In various aspects, knitted textiles can undergo post-processing steps, such as removing portions of the knitted textile, adding components to the knitted textile, or creating a fleece texture. In other aspects, knitted textiles can include various knitted structures and / or different knitted sublayers.

[0087] In some respects, the entire knitted garment can be seamless. Seamless knitted garments can be provided, for example, through circular knitting. Circular knitting allows for the provision of three-dimensional pre-formed garments without the need for sewing up at designated locations. Therefore, unwanted seams in knitted garments can be avoided, and three-dimensional pre-formed knitted garments can have the particularly good fit of a seamless structure, as well as the other aforementioned benefits.

[0088] However, it should be noted that textiles and textile articles, including knitted articles, can utilize the present disclosure in the manufacture of composite elements. In some aspects, the composite element may include a first textile and a second textile or film or forming component prepared as disclosed herein. That is, the composite element includes a first textile region and a second region selected from a region including a second textile, a region including a film, a region including a forming component, or a combination thereof.

[0089] In one aspect, a textile comprising a first plurality of fibers is provided, the first plurality of fibers comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The textile may be a non-woven textile. The textile may be a textile article. The textile article may be a component of a sports equipment article. The textile article may be a component of a clothing article. The textile article may be a component of a footwear article. The textile article may be an upper portion of a footwear article.

[0090] In various aspects, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition in the first plurality of fibers (T0). m At least one of the following: (1) creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m ).

[0091] In another aspect, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first plurality of fibers (T0). m The creep relaxation temperature (T) cr ).

[0092] In another aspect, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first plurality of fibers (T0). m The heat distortion temperature (T) hd ).

[0093] In another aspect, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first plurality of fibers (T0). m Vicat softening temperature (T) vs ).

[0094] In another aspect, the textile includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first plurality of fibers (T0). m The melting temperature (T) m ).

[0095] In another aspect, the textile includes a first yarn comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The textile can be a knitted textile. The textile can be a woven textile. The textile can be a textile article. A textile article can be an upper portion of a footwear article.

[0096] In various aspects, the textile includes a second yarn comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m At least one of the following: (1) creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m ).

[0097] In another aspect, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m The creep relaxation temperature (T) cr ).

[0098] In another aspect, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m The heat distortion temperature (T) hd ).

[0099] In another aspect, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m Vicat softening temperature (T) vs ).

[0100] In another aspect, the textile includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m The melting temperature (T) m ).

[0101] In some aspects, a textile article is provided comprising a molten fiber component that has been thermoformed from a first state as a first plurality of fibers to a second state as a molten fiber component (i.e., a component formed of a plurality of fibers, wherein at least a portion of the plurality of fibers has been at least partially melted and re-cured into a new structure different from their fiber structure). The first plurality of fibers comprises a low-processing-temperature polymer composition. It should be understood that the molten fiber component may include structures such as partially melted first plurality of fibers, substantially fully melted first plurality of fibers, and mixtures thereof. The textile article may also include a second plurality of fibers comprising a high-processing-temperature polymer composition. Optionally, the molten fiber component and the second plurality of fibers at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region comprises a second plurality of fibers with a higher concentration than the second region, and the third region comprises molten fiber components with a higher concentration than the second region. In some embodiments, this structure may form the outer surface of the article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

[0102] In one aspect, the textile article includes a first plurality of fibers comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The textile article may be a component of clothing articles. The textile article may be a non-woven textile article. The textile article may be a component of sports equipment articles. The textile article may be a component of footwear articles. The textile article may be an upper portion of footwear articles.

[0103] In various respects, textile articles include a second plurality of fibers comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition in the first plurality of fibers (T0). m At least one of the following: (1) creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The first plurality of fibers transitions from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0104] In another aspect, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first plurality of fibers. m The creep relaxation temperature (T) crThe first plurality of fibers transitions from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0105] In another aspect, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first plurality of fibers. m The heat distortion temperature (T) hd The first plurality of fibers transitions from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0106] In another aspect, the textile article includes a second plurality of fibers comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first plurality of fibers. m Vicat softening temperature (T) vs The first plurality of fibers transitions from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0107] In another aspect, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first plurality of fibers. m The melting temperature (T) m The first plurality of fibers transitions from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0108] In some aspects, a textile article is provided comprising a molten yarn component that has been thermoformed from a first state as a first yarn to a second state as a molten yarn component (i.e., a component formed from yarn that has been at least partially melted and re-solidified into a new configuration different from its yarn configuration). The first yarn comprises a low-processing-temperature polymer composition. It should be understood that the molten yarn component may include structures such as partially melted first yarn, substantially completely melted first yarn, and mixtures thereof. Knitted articles may also include a second yarn comprising a high-processing-temperature polymer composition. Optionally, the molten yarn component and the second yarn at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region comprises a second yarn with a higher concentration than the second region, and the third region comprises a molten yarn component with a higher concentration than the second region. In some embodiments, this structure may form the outer surface of the article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

[0109] In one aspect, the textile article includes a first yarn comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The textile article may be a knitted article. The textile article may be a woven article. The textile article may be a component of a garment article. The textile article may be a component of a footwear article. The textile article may be an upper portion of a footwear article. The textile article may be a knitted upper portion of a footwear article.

[0110] In various respects, textile articles include a second yarn comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m At least one of the following: (1) creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0111] In another aspect, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m The creep relaxation temperature (T) cr The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0112] In another aspect, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m The heat distortion temperature (T) hd The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0113] In another aspect, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m Vicat softening temperature (T) vs The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0114] In another aspect, the textile article includes a second yarn comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition in the first yarn (T0). m The melting temperature (T) m The first yarn changes from a first state as a first yarn to a second state as a molten yarn component.

[0115] In some aspects, a textile article is a knitted article comprising a plurality of interconnected rows. Each of the plurality of interconnected rows comprises a first yarn and a second yarn. The first yarn comprises a low-processing-temperature polymer composition. The second yarn comprises a high-processing-temperature polymer composition. The knitted article also includes at least one knitted layer comprising at least a first zone, a second zone, and a third zone, wherein the second zone is positioned between the first zone and the third zone. Each of the plurality of interconnected rows extends through the first zone, the second zone, and the third zone, wherein the third zone has a first yarn with increased concentration compared to the second zone. In some embodiments, this structure may form the outer surface of the article, wherein the first zone, the second zone, and the third zone each form a portion of the outer surface. Furthermore, the knitted article includes an anchoring yarn extending through at least a portion of the third zone. The anchoring yarn comprises a high-processing-temperature polymer composition, such as, for example, fibers formed from a high-processing-temperature polymer composition. The anchoring yarn exhibits an elongation rate less than that of the first yarn.

[0116] In addition to textiles and articles including textiles, this disclosure also relates to articles comprising molten film components that are thermoformed from a first state as a film to a second state as a molten film (i.e., a film comprising a low-processing-temperature polymer material, wherein at least a portion of the low-processing-temperature polymer material of the film has been melted on a substrate and re-cured to a new structure different from its film structure). The article may also comprise a high-processing-temperature polymer composition. Optionally, the molten film component and the high-processing-temperature polymer composition at least partially form a structure having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region comprises a higher concentration of the high-processing-temperature polymer composition compared to the second region, and the third region comprises a higher concentration of the molten film component compared to the second region. In some embodiments, this structure may form the outer surface of the article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

[0117] In one aspect, the article includes a molten film component comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The article may be a component of clothing articles. The article may be a component of sports equipment articles. The article may be a component of footwear articles. The article may be an upper portion for footwear articles.

[0118] In various respects, articles include a second element (e.g., a molding component, film, textile, fiber, yarn) comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition of the melting film component (T0). m At least one of the following: (1) creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The molten film component changes from a first state as a film to a second state as a molten film component.

[0119] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition of the melting film component (T0). m The creep relaxation temperature (T) cr The molten film component changes from a first state as a film to a second state as a molten film component.

[0120] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition of the melting film component (T0). m The heat distortion temperature (T) hd The molten film component changes from a first state as a film to a second state as a molten film component.

[0121] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the low-processing-temperature polymer composition of the melting film component (T0). m Vicat softening temperature (T) vs The molten film component changes from a first state as a film to a second state as a molten film component.

[0122] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the first multi-fiber low-processing-temperature polymer composition (T0). m The melting temperature (T) m The first plurality of fibers transitions from a first state as the first plurality of fibers to a second state as a molten fiber component.

[0123] This disclosure also relates to articles comprising a first polymer component including a molten region, the first polymer component being thermoformed from a first state as a molded component to a second state as a molten molded component (i.e., a molded component comprising a low-processing-temperature polymer material, wherein at least a portion of the low-processing-temperature polymer material has melted and re-solidified into a new configuration different from its original molded component configuration). The first component may also include a region formed of a high-processing-temperature polymer composition. Alternatively or additionally, the article may also include a second component comprising a high-processing-temperature polymer composition.

[0124] In one aspect, the article includes a first molded part comprising a low-processing-temperature polymer composition comprising one or more thermoplastic polymers. The article may be a component of clothing articles. The article may be a component of sports equipment articles. The article may be a component of footwear articles. The article may be an upper portion for footwear articles. The article may be a sole element for footwear articles.

[0125] In various respects, articles include a second element (e.g., a molding component, film, textile, fiber, yarn) comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first molding component. m At least one of the following: (1) creep relaxation temperature (T) cr (2) Heat distortion temperature (T) hd (3) Vicat softening temperature (T) vs (4) Melting temperature (T) m The first forming component changes from a first state as a forming component to a second state as a molten forming component.

[0126] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature greater than that of the low-processing-temperature polymer composition of the first molded part (T0). m The creep relaxation temperature (T) cr The first forming component changes from a first state as a first forming component to a second state as a molten forming component.

[0127] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first forming element. m The heat distortion temperature (T) hd The first forming element changes from a first state as a forming element to a second state as a molten forming part.

[0128] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, the high-processing-temperature polymer composition exhibiting a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the first forming element. m Vicat softening temperature (T) vs The first forming element changes from a first state as a first forming element to a second state as a molten forming part.

[0129] In another aspect, the article includes a second element comprising a high-processing-temperature polymer composition, which exhibits a melting temperature greater than that of the first multi-fiber low-processing-temperature polymer composition (T0). m The melting temperature (T) m The first plurality of fibers change from a first state as a first forming component to a second state as a molten forming component.

[0130] In one aspect, a knitted upper for footwear articles is provided, the knitted upper comprising a first yarn comprising a low-processing-temperature polymer composition. The knitted upper for footwear articles further comprises a second yarn comprising a high-processing-temperature polymer composition. The first and second yarns at least partially form a plurality of interconnected rows in at least one knitted layer of the knitted upper for footwear articles, the at least one knitted layer having at least a first region, a second region, and a third region, the second region being positioned between the first and third regions, wherein the first region comprises a second yarn with increased concentration compared to the second region, and wherein the third region comprises a first yarn with increased concentration compared to the second region. In some embodiments, this structure may form an outer surface of an article, wherein the first, second, and third regions each form a portion of the outer surface.

[0131] In some aspects, a knitted upper for footwear articles is provided, the knitted upper comprising a molten yarn component comprising a low-processing-temperature polymer composition. The molten yarn component is thermoformed from a first state as a first yarn to a second state as a molten yarn component. The knitted upper for footwear articles also includes a second yarn comprising a high-processing-temperature polymer composition. The molten yarn component and the second yarn at least partially form a surface having at least a first region, a second region, and a third region, wherein the second region is located between the first region and the third region. The first region comprises a second yarn with a higher concentration than the second region, and the third region comprises a molten yarn component with a higher concentration than the second region. In some embodiments, this structure may form the outer surface of an article, wherein the first region, the second region, and the third region each form a portion of the outer surface.

[0132] In some respects, wearable items are footwear items, including but not limited to items such as shoes. Footwear items typically consist of an upper and a sole structure. The upper provides coverage for the foot, comfortably receiving it and fixing it in place relative to the sole structure. Furthermore, the upper typically provides protection for the foot. The sole structure can provide a wide range of support, cushioning, and shock absorption. The sole structure is attached to the lower portion of the upper and is typically positioned between the foot and the ground. In addition to mitigating ground reaction forces (i.e., providing cushioning) during walking, running, and other walking activities, the sole structure can, for example, influence foot movement (e.g., by resisting pronation), impart stability, and provide traction friction. Thus, the upper and sole structures work together to provide a comfortable structure suitable for a wide variety of sports activities.

[0133] The upper forms a structure that provides some or all of the wearer's foot with cover and positions the foot relative to the sole structure of the shoe. The upper forms a cavity inside the footwear to receive the foot. The cavity has a general shape of the foot, and the entrance to the cavity is located at an ankle opening. In some aspects, the upper extends above the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area. The upper can have any design, shape, size, and / or color. For example, in some aspects, such as if the item is a basketball shoe, the upper can be a high-top upper shaped to provide high support to the ankle. Alternatively, in some aspects, such as if the item is a running shoe, the upper can be a low-top upper.

[0134] The upper may also incorporate a lacing system to adjust the fit of the footwear and allow the foot to enter and exit cavities within the upper. Lacing systems are often integrated into the upper to selectively change the size of the ankle opening and allow the wearer to modify certain dimensions of the upper, particularly the girth, to accommodate feet with different proportions. Furthermore, the upper may include a tongue that extends below the lacing system to enhance footwear comfort (e.g., adjusting the pressure applied to the foot via the laces), and the upper may also include a heel stabilizer to limit or control heel movement. Additionally, the upper may include a tongue that extends below the lacing system to enhance adjustability and comfort, and the upper may incorporate a heel stabilizer.

[0135] In some aspects, the sole structure may include one or more components or layers that, individually or collectively, provide a number of properties to the footwear article, such as support, rigidity, flexibility, stability, cushioning, comfort, weight reduction, or other properties. In some aspects, the sole structure may include layers referred to as an insole, a midsole, and an outsole. However, in some aspects, one or more of these components may be omitted. In some aspects, the sole may optionally include a sole plate. In some aspects, the sole structure includes an outsole component comprising an external primary surface that can be exposed and in contact with the ground, and an internal primary surface. In other aspects, the sole structure may also include a midsole component that can be attached to the upper along its entire length. When present, the midsole forms an intermediate layer of the sole structure and serves a variety of purposes, including controlling foot movement and reducing impact.

[0136] A midsole layer, which can be attached to the entire length of the upper, forms the middle layer of the sole structure and serves a variety of purposes, including controlling foot movement and reducing impact. Many midsole constructions are primarily formed from elastic polymer foam materials such as polyurethane (PU) or ethylene-vinyl acetate (EVA) that extend through the length and width of the footwear. The midsole can also incorporate plates, adjusters, fluid-filled chambers, and / or other elements, such as those further reducing force, influencing foot movement, and / or providing stability.

[0137] The outsole forms the ground contact element of footwear and is typically made of a durable, abrasion-resistant material that includes textures or other features that improve traction and friction. The outsole may be made of a durable and abrasion-resistant material (e.g., rubber) that includes textures that improve traction and friction. Optionally, the outsole may also include anti-slip studs.

[0138] In some aspects, footwear articles may also include insoles, which are thin components located inside the upper and adjacent to the plantar (underfoot) surface of the foot to enhance footwear comfort, for example, to wick away moisture and provide a soft, comfortable feel. In some aspects, insoles may be formed from foam materials such as polyurethane foam, foam rubber, or ethylene-vinyl acetate. In some aspects, insoles are not glued to or otherwise attached to the sole structure. Alternatively, insoles may be attached to the sole structure.

[0139] In some aspects, a knitted upper for footwear articles is provided, the knitted upper comprising a plurality of interconnected rows. Each of the plurality of interconnected rows comprises a first yarn and a second yarn. The first yarn comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The knitted upper for footwear articles further comprises at least one knitted layer comprising at least a first zone, a second zone, and a third zone, wherein the second zone is located between the first zone and the third zone. Each of the plurality of interconnected rows extends through the first zone, the second zone, and the third zone, wherein the third zone has a first yarn with increased concentration compared to the second zone. Furthermore, the knitted upper for footwear articles includes anchoring yarns extending through at least a portion of the third zone. The anchoring yarns comprise anchoring yarn compositions comprising one or more polymers. The anchoring yarns exhibit an elongation rate less than that of the first yarns.

[0140] Exemplary aspects of sports equipment, wearable items, and textiles

[0141] As discussed above, certain aspects relate to one or more textiles comprising fibers and / or yarns, said fibers and / or yarns comprising low-processing-temperature polymer compositions and high-processing-temperature polymer compositions. In some aspects, such textiles can be formed into at least a portion of sports equipment articles or wearable articles. In some aspects, the disclosed textiles can be formed into at least a portion of a component of footwear articles. In some aspects, the disclosed textiles can be formed into at least a portion of a component of sports equipment articles. For example, the disclosed textiles can be formed into at least a portion of the upper of a shoe, such as an athletic shoe.

[0142] Now turn to the attached diagram, especially Figure 1A and Figure 1B Footwear item 100 is depicted as an exemplary wearable item. Although Figure 1A and Figure 1B Footwear items are depicted 100, but it should be understood that this disclosure also covers other wearable items. Figure 1A and Figure 1B Footwear item 100 typically includes a ground-facing outsole area 110, an ankle collar area 112, a lateral midfoot area 114a and a medial midfoot area 114b, a toe cap area 116, and a heel area 118. Additionally, footwear item 100 may include multiple eyelets 120, a toe cap area 122, a tongue area 124, and a throat area 126. (As in...) Figure 1A and Figure 1B As shown, footwear item 100 is intended for use with the right foot; however, it should be understood that the following discussion can also be applied to a mirror image of footwear item 100 intended for use with the left foot.

[0143] exist Figure 1A and Figure 1B The footwear article 100 depicted may include at least one textile 102, which at least partially forms part of the footwear article 100. The textile 102 of the footwear article 100 may include at least three separate textile zones, such as zones 104, 106, and 108, that identify specific functional areas of the footwear article 100. In some aspects, these specific functional areas are at least partially related to the targeted incorporation of specific textile media into these textile zones in different amounts, techniques, and combinations (in... Figure 1A and Figure 1B The diagram shows the associated areas (zones 104, 106, and 108). It should be understood that while textile 102 includes three specific functional areas, it also encompasses more than three functional areas.

[0144] In some aspects, the textile region 104 may exhibit rigid or semi-rigid functionality suitable for use as a ground-facing outsole 110 of footwear article 100. Thus, in some aspects, the textile region 104 may be positioned to include at least a portion of the ground-facing outsole 110 of footwear article 100. In some aspects, after thermoforming, the targeted incorporation of a low-processing-temperature polymer composition into the textile region 104 of textile 102 may at least partially provide rigid or semi-rigid functionality for use as a ground-facing outsole 110. As used herein, “thermoforming” refers to a process that may include melting and / or deforming a low-processing-temperature polymer composition and / or one or more thermoplastic polymers and subsequently cooling the melted and / or deformed material to form a panel or film that may be rigid or semi-rigid. The thermoforming process is discussed in detail below.

[0145] Furthermore, in various aspects, another textile region, such as, for example, textile region 108, may exhibit flexibility and / or pliability to accommodate movement from the wearer. In some aspects, textile region 108 may include the ankle collar region 112, the tongue region 124, and / or the throat region 126 of footwear article 100. In various aspects, textile region 108 may contain a high-processing-temperature polymer composition.

[0146] In some aspects, another textile region, such as, for example, textile region 106, may be located between textile regions 104 and 108. In some aspects, textile region 106 may include at least a portion of the outer midfoot region 114a and / or the inner midfoot region 114b on the footwear article 100. In some aspects, textile region 106 may include a combination of a low-processing-temperature polymer composition from textile region 104 and a high-processing-temperature polymer composition from textile region 108. In such aspects, this combination of textile media present in textile region 106 allows textile region 106 to act as a transition between the rigid or semi-rigid functionality of textile region 104 and the flexible and resilient functionality of textile region 108, allowing for a smoother transition from the rigidity to the flexibility of textile 102.

[0147] Furthermore, in this respect, textile region 106 can exhibit less rigidity or semi-rigidity than textile region 104 but more rigidity than textile region 108. Additionally, in the same or alternative respect, textile region 106 can exhibit less flexibility than textile region 108 but more flexible than textile region 104.

[0148] Alternatively or additionally, the three textile areas 104, 106 and 108 may be located at least partially within the mid-shoe area, such as within the outer mid-shoe area 114a and / or the inner mid-shoe area 114b.

[0149] In some respects, in textile region 106, the combination of a low-processing-temperature polymer composition present in textile region 104 and a high-processing-temperature polymer composition present in textile region 108 can impart one or more structural properties to footwear article 100 when exposed to a thermoforming process, such as semi-rigid support in the outer midfoot region 114a and / or the inner midfoot region 114b, and / or impart a three-dimensional shape or three-dimensional structure to one or more portions of footwear article 100.

[0150] In some aspects, such as being able to Figure 1AAs seen in the image, textile region 106 extends from textile region 104 toward eyelet 120. In this aspect, the combination of a textile medium comprising a low-processing-temperature polymer composition and a textile medium comprising a high-processing-temperature polymer composition allows for the transfer of forces transmitted from eyelet 120 or other lacing mechanisms to this combination of textile mediums present in the outer midfoot region 114a and / or the inner midfoot region 114b. In some aspects, for successful transfer of forces transmitted from eyelet 120, textile region 104 and / or the low-processing-temperature polymer composition present in textile region 104 may terminate at region 128, which, when textile 102 is a knitted textile formed on a commercial knitting machine, is a distance of at least about 0.5 cm, about 1.0 cm, or about 2.0 cm from eyelet 120, and / or a distance of at least about 3 stitches, at least about 4 stitches, or at least about 5 stitches below eyelet 120. In this respect, the flexibility and toughness of the high-processing-temperature polymer composition present in region 108 adjacent to eyelet 120 can facilitate the transfer of forces transmitted from eyelet 120 to textile region 106, and / or to the low-processing-temperature polymer composition present in outer midshoe region 114a and / or inner midshoe region 114b.

[0151] exist Figure 1A and Figure 1B In the aspects depicted, textile region 106 is positioned within toe area 116 and heel area 118. In such aspects, the combination of a low-processing-temperature polymer composition and a high-processing-temperature polymer composition can provide structure and / or support due to the rigidity provided by the thermoforming material. Furthermore, the thermoforming material can provide abrasion resistance in toe area 116 and / or heel area 118. Alternatively, textile region 104 can be formed in at least a portion of toe area 116 and / or heel area 118 for increased rigidity or increased abrasion resistance, because textile region 104 contains a larger amount of low-processing-temperature polymer composition or optional positioning of the low-processing-temperature polymer composition (e.g., on an outer knitted surface) compared to textile region 106.

[0152] Figure 1C Describing optional aspects of footwear article 100a. In such aspects, footwear article 100a may generally include at least three types of textile areas: textile area 104a, textile area 106a, and textile area 108a. In some aspects, textile areas 104a, 106a, and 108a may have respectively the features described above. Figure 1A The footwear items 100 discussed share the same characteristics and parameters as textile sections 104, 106, and 108.

[0153] exist Figure 1CIn the aspects depicted, portions of the textile area 104a, such as portions 104b and 104c, can extend upward from the outsole area through the midsole area 115A and toward the multiple eyelets 120a. In such aspects, the rigid or semi-rigid functionality provided by portions 104b and 104c extending from the outsole area through the midsole area 115A to the multiple eyelets 120a can provide increased wearer stability in the midsole area 115A. Furthermore, in all aspects, forces applied through one or more of the multiple eyelets 120a can be at least partially transferred to the rigid or semi-rigid portions 104b and 104c extending through the midsole area 115A, and to the rigid or semi-rigid textile area 104a present in the outsole area, providing increased support and comfort for the wearer.

[0154] In some respects, in addition to providing structure, rigidity, strength and / or support to one or more areas of a wearable item, thermoformed materials can provide waterproof or water-resistant surfaces.

[0155] Figure 2A and Figure 2B A shirt 200 is depicted as an exemplary garment item. Figure 2A and Figure 2B The shirt 200 depicted includes at least one textile 202 that at least partially forms part of the shirt 200. (As shown in...) Figure 2B As best viewed from the center, textile 202 may include three separate textile zones 204, 206a-d, and 208 that can identify specific functional areas of shirt 200. In some respects, these specific functional areas are at least partially associated with the targeted incorporation of specific textile media in different amounts and combinations into these textile zones 204, 206a-d, and 208.

[0156] In some aspects, textile region 204 may include reinforcing areas, such as an outward-facing membrane or patch 210, which may provide abrasion resistance, for example, to elbow region 212 of shirt 200. In such aspects, the patch 210 may be at least partially formed during the thermoforming of textile 202 by melting or deforming the low-processing-temperature polymer composition and subsequently cooling and solidifying the molten material to form patch 210.

[0157] In various aspects, textile region 208 can exhibit flexibility and / or toughness similar to conventional shirt materials. In such aspects, textile region 208 may contain or only contain a high-processing-temperature polymer composition. Furthermore, in some aspects, textile region 206 may at least partially provide a transition within textile 202 from the rigid or semi-rigid patch 210 present in textile region 204 to the flexible and tough portion present in textile region 208. In such aspects, textile regions 206a-d may contain a combination of a low-processing-temperature polymer composition present in textile region 204 and a high-processing-temperature polymer composition present in textile region 208. Although in Figure 2A and Figure 2B Not shown in the text, but textile zones 206b-d also provide a transition to flexible and tough materials such as those present in textile zone 208.

[0158] In some respects, as referenced above Figure 1A and Figure 1B Similar to textile region 106 of textile 102 discussed, this combination of a low-processing-temperature polymer composition from textile region 204 and a high-processing-temperature polymer composition from textile region 208 can provide a seamless or integral transition from patch 210 of shirt 200 to the flexible and resilient portion present in textile region 208.

[0159] Although Figure 2A and Figure 2B This exemplary description of textile areas 204, 206a-d and 208 relates to the elbow area of ​​garment article 200, but it should be understood that textile areas 204, 206a-d and 208 and the associated features can be applied to other areas of shirts or other garment articles, such as the knees, thighs, hips, chest, and / or the lower back area of ​​garment articles, or areas requiring reinforcement, such as areas adjacent to fasteners such as zippers, buttons, hooks and loops, pull cords and the like.

[0160] Now turn Figure 3 A schematic plan view of textile 300 is provided. It should be understood that textile 300 can be any type of textile known to those skilled in the art. A non-limiting list of textiles suitable for use in the wearable articles and methods disclosed herein includes knitted textiles, woven textiles, non-woven textiles, and braided textiles.

[0161] Similar to Figure 1A and Figure 1B Textiles 102 and Figure 2A and Figure 2B Textiles 202, Figure 3Textile 300 includes three types of textile zones. For example, textile 300 includes: textile zone 302, which may include fibers and / or yarns comprising a low-processing-temperature polymer composition; textile zones 306a and 306b, which may include a high-processing-temperature polymer composition; and textile zones 304a and 304b, which may include a combination of fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition. Figure 3 In the textile 300, textile areas 304a and 304b can be located on either side of textile area 302, while textile areas 306a and 306b can be located on the opposite sides of textile areas 304a and 304b, respectively.

[0162] In some aspects, fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile region 302 can impart structural or functional properties to textile 300, which can be used to form wearable articles, when exposed to a thermoforming process. For example, textile region 302 may represent at least a portion forming the ground-facing outsole 110 of a shoe. Figure 1A and Figure 1B Textile 102, textile region 104. In various aspects, fibers and / or yarns comprising a high-processing-temperature polymer composition present in textile regions 306a and 306b can be directed to textile 300, such as in… Figure 1A and Figure 1B The textile region 108 of the footwear article 100 depicted herein is endowed with flexibility or toughness. Furthermore, in various aspects, textile regions 304a and 304b may include a combination of fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile region 302 and fibers and / or yarns comprising a high-processing-temperature polymer composition present in textile regions 306a and 306b to provide structural support and three-dimensional structure for a particular wearable article. Additionally, as discussed above, in some aspects, this combination of fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition in textile regions 304a and 304b can provide an integrated transition between the rigid thermoforming material in textile region 302 and the flexible, tough, high-processing-temperature polymer composition in textile regions 306a and 306b.

[0163] In one or more aspects, textile regions 304a and 304b may include multiple sub-regions, such as sub-regions 305a, 305b, 305c, and 305d of textile region 304a, which may include different combinations and / or different locations of fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition. In some aspects, sub-region 305a may include fibers and / or yarns comprising a low-processing-temperature polymer composition, but not fibers and / or yarns comprising a high-processing-temperature polymer composition present in textile regions 306a and / or 306b. In the same or alternative aspects, sub-region 305d may include fibers and / or yarns comprising a high-processing-temperature polymer composition, but not fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile region 302.

[0164] It should be understood that while only the sub-regions of textile region 304a may be further described herein, such description applies to the sub-regions present in textile region 304b. Furthermore, it should be understood that if only textile regions 304a and / or 306a are further discussed in some descriptions, then such descriptions also apply to textile regions 304b and 306b, respectively.

[0165] In some respects, based on the relative positioning of fibers and / or yarns containing low-processing-temperature polymer compositions and fibers and / or yarns containing high-processing-temperature polymer compositions in textile zones 302, 304a, and 306a, textile 300 may contain low-processing-temperature polymer compositions and / or high-processing-temperature polymer compositions with different concentrations in these textile zones 302, 304a, and 306a.

[0166] As used herein, the term "concentration" refers to clustering or congregation within a given volume. Therefore, the term concentration encompasses measurements of a specified volume (e.g., cm²). 3 The amount of material in the fabric (e.g., weight in grams). For example, in knitted textiles, a first portion of a single knitted layer of the textile may have increased density compared to a second portion of the textile by having a first yarn with more stitches (e.g., knitted stitches, tuck stitches, and / or float stitches) than a second portion of equal size. In another embodiment, in nonwoven textiles, if a first portion of the textile is formed of more first fibers (e.g., weight in grams) than a second portion of equal size, then the first portion of the textile may have first fibers with increased density.

[0167] In various aspects, textile region 302 may include fibers and / or yarns comprising a low-processing-temperature polymer composition with increased concentration compared to textile regions 304a and / or 306a. For example, in such an aspect, textile region 302 may have at least 5 wt% more fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile regions 304a and / or 306a. In another aspect, textile region 302 may have at least 10 wt% more fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile regions 304a and / or 306a. In one aspect, textile region 302 may have at least 25 wt% more fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile regions 304a and / or 306a.

[0168] In the same or alternative aspects, textile region 304a may include fibers and / or yarns comprising a low-processing-temperature polymer composition with increased concentration compared to textile region 306a. For example, in such an aspect, textile region 304a may have at least 5 wt% more fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile region 306a. In another aspect, textile region 304a may have at least 10 wt% more fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile region 306a. In one aspect, textile region 304a may have at least 25 wt% more fibers and / or yarns comprising a low-processing-temperature polymer composition compared to textile region 306a.

[0169] In various aspects, compared to textile regions 302 and / or 304a, textile region 306a may include fibers and / or yarns containing a high-processing-temperature polymer composition with increased concentration. For example, in such an aspect, textile region 306a may have at least 5 wt% more fibers and / or yarns containing a high-processing-temperature polymer composition compared to textile regions 302 and / or 304a. In another aspect, textile region 306a may have at least 10 wt% more fibers and / or yarns containing a high-processing-temperature polymer composition compared to textile regions 302 and / or 304a. In one aspect, textile region 306a may have at least 25 wt% more fibers and / or yarns containing a high-processing-temperature polymer composition compared to textile regions 302 and / or 304a.

[0170] In some aspects, compared to textile region 302, textile region 304a may include fibers and / or yarns containing a high-processing-temperature polymer composition with increased concentration. For example, in such an aspect, textile region 304a may have at least 5 wt% more fibers and / or yarns containing a high-processing-temperature polymer composition than textile region 302. In another aspect, textile region 304a may have at least 10 wt% more fibers and / or yarns containing a high-processing-temperature polymer composition than textile region 302. In one aspect, textile region 304a may have at least 25 wt% more fibers and / or yarns containing a high-processing-temperature polymer composition than textile region 302.

[0171] Figures 4A-4D Exemplary cross-sections of textile regions 302, 304a, and 306a of textile 300 are schematically depicted. Typically, Figure 4A An exemplary cross-section from textile region 306a is depicted, and in some respects further illustrates how this portion of textile region 306a includes fibers and / or yarns comprising a high-processing-temperature polymer composition but not fibers and / or yarns comprising a low-processing-temperature polymer composition present in textile region 302. Figure 4B An exemplary cross-section of textile region 302 is depicted, and in various aspects it is also illustrated how this portion of textile region 302 includes fibers and / or yarns comprising a low-processing-temperature polymer composition but not fibers and / or yarns comprising a high-processing-temperature polymer composition present in textile region 306a. Figure 4C and Figure 4D Two exemplary cross-sections from textile region 304a are depicted, and further illustrated how both fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition are present in these exemplary portions of textile region 304a.

[0172] Now, we will describe textile 300 from the perspective of knitted textiles. Figures 4A-4DThe cross-section is depicted in the diagram. Various processes used to form knitted textiles and the types of yarns that can be used are discussed in detail below. It is anticipated that multiple knitting techniques can be implemented to achieve the described results. For example, in some aspects, a “knitted stitch” can be replaced by a purl stitch to achieve comparable results with different aesthetics and / or textures. For simplicity, “knitted stitch” will be discussed here, but functional equivalents are expected to be substituted. Similarly, a “tuck stitch” can be discussed in specific aspects, but it is also anticipated that alternative stitch techniques can be implemented to achieve comparable results. While relatively simple knitted structures are depicted and discussed, many warp-knitted and weft-knitted structures can be formed, for example, by horizontal knitting, wide-tube circular knitting, narrow-tube jacquard circular knitting, single-sided jacquard circular knitting, double-sided jacquard circular knitting, double-needle-bed Raschel warp knitting, warp knit jacquard, and Trico warp knitting.

[0173] It should be understood that, Figures 4A-4D The cross-sections depicted are schematic, and each cross-section is organized into segments to highlight the potential knitted structures that may exist. First, the potential knitted structures that can exist in the segments of these cross-sections are described.

[0174] Figures 5A-5J Depiction can exist in Figures 4A-4D Exemplary potential knitted structures in the various segments of the cross-section depicted. Figure 5A Depicts the knitting stitch (or sometimes referred to as a jersey stitch) structure 502 formed by the back needle bed 504. It should be understood that, according to conventional stitch diagrams, rows of small circles associated with the back needle bed 504 represent needles (e.g., needle 505) of the back needle bed 504. Furthermore, for the front needle bed, for example, in… Figure 5B The same applies to the anterior needle bed 508 depicted in the diagram; that is, the row of small circles associated with the anterior needle bed 508 represents the needles (e.g., needle 507) in the anterior needle bed 508.

[0175] Figure 5B Depict the knitting stitch structure 506 formed by the front needle bed 508. Figure 5C Depicts a floating and tucked stitch structure 510, which has a tucked stitch formed by a front needle bed 512 and a rear needle bed 514. Figure 5D Depict another floating and tuck stitch structure 516, which has a tuck stitch formed by the front needle bed 518 and the rear needle bed 520. Figure 5E Describe the structure of the floating line trace 522. Figure 5F A knitting and tuck stitch structure 524 is depicted, which has a knitting stitch 524a formed by a back needle bed 528 and a tuck stitch 524b formed by a front needle bed 526. Figure 5G Depict a knitted and float stitch structure 530, which has a knitted stitch formed on the front needle bed 532. Figure 5H Depicts a knitted and float stitch structure 534, which has a knitted stitch formed on the back needle bed 536. Figure 5I Depicts a tuck and float knitting structure 538, which has a tuck stitch formed through the front needle bed 540. Figure 5J Depicts a tuck and float knitting structure 542, which has a tuck stitch formed by the back needle bed 544.

[0176] Now let's return to Textiles 300. Figures 4A-4D The cross-section in the middle. Typically, Figures 4A-4D The cross-sections depicted are similarly structured due to the primary structure of knitted textiles. For example, tubular knitted structures exist in various aspects, including knitted structures primarily formed by the back needle bed (such as in...). Figure 5A The knitting structure 502 depicted in the image and the knitting structure mainly formed on the front needle bed (such as in...) Figure 5B The knitted structure 506 is depicted in the image. Furthermore, in this aspect, the tubular knitted structure is constructed via one or more tucked loops and float stitches (e.g., respectively in...). Figure 5C and Figure 5D The tufted and floating stitch structures 510 and 516 depicted in the text are connected, wherein the tufted stitch is formed by the back needle bed and the front needle bed.

[0177] This connected tubular knitted structure is Figures 4A-4D The three horizontal lines highlighted in the depicted cross-section are used to schematically illustrate the scene. For example, Figure 4A Depicting Figure 3 The cross section 402 of the textile region 306a containing a high-processing-temperature polymer composition.

[0178] Figure 4A The cross-section 402 schematically depicts the top segment 404, the middle segment 406, and the bottom segment 408. The top segment 404 and the bottom segment 408 represent the knitted structures used to form the tubular knitted structures, while the middle segment 406 represents the tufting and float stitch structures that connect the tubular knitted structures together. Therefore, in some aspects, the top segment 404 may include, respectively, […]. Figure 5A and Figure 5F One or more of the knitted structures 502 and 524 depicted herein. Bottom segment 408 may be included in... Figure 5B The knitted structure 506 is depicted in the image. The intermediate segments 406 may include, respectively, those in... Figure 5C and Figure 5D One or more of the knitted structures 510 and 516 depicted in the text.

[0179] Figure 4BThe cross-section 410 depicts a textile region 302 comprising a yarn containing a low-processing-temperature polymer composition. Cross-section 410 includes a top segment 412, a middle segment 414, and a bottom segment 416, which may include the components described above. Figure 4A The same knitted structure is identified in the top segment 404, middle segment 406 and bottom segment 408 of the cross section 402.

[0180] In some aspects, it may be desirable to bulk up the low-processing-temperature polymer composition in textile region 302 to provide the desired thickness and rigidity to the thermoformed textile region 302, for example, to form the ground-facing outsole of footwear articles. In such aspects, textile region 302 may include repeating stitches to increase the concentration of the yarn containing the low-processing-temperature polymer composition relative to other textile regions, such as textile regions 304a and / or 306a. In some aspects, repeating stitches may be provided, for example, by including multiple stitch structures in any one or all of the top segment 412, middle segment 414, and bottom segment 416 of cross section 410. In one embodiment, multiple overlapping loop and float stitch structures (such as in) may be provided in the middle segment 414 of cross section 410. Figure 5C , Figure 5D , Figure 5I and Figure 5J (The structure depicted in the text).

[0181] In some aspects, in regions of textile 300 that include a large number of yarns containing a low-processing-temperature polymer composition, such as textile region 302, anchoring yarns 413 may be provided in textile 300 to help constrain the flow of the molten low-processing-temperature polymer composition and / or to provide a degree of flexibility to the thermoforming material. Figure 4B In the cross-section 410 depicted, the anchoring yarn 413 is shown as existing in an intermediate segment 414 between the top segment 412 and the bottom segment 416. In this respect, this positioning of the anchoring yarn 413 can result in the anchoring yarn 413 being embedded or encapsulated by a polymer composition at a low processing temperature after the textile 300 has been thermoformed.

[0182] Although Figure 4B The anchor yarn 413 is depicted as a straight line, but it should be understood that this is a schematic representation of the anchor yarn 413 and is not intended to specify any particular type of knitting structure. For example, the anchor yarn 413 can be used in many different types of knitting structures such as... Figure 5E and Figure 5G-Figure 5JOne or more of the structures depicted are present in textile 300. In some aspects, the choice of stitch for anchoring yarn 413 may depend on the required resistance to elongation of the material through which anchoring yarn 413 extends. For example, an anchoring yarn stitch with five needles floating between tuck stitches or knit stitches will provide greater resistance to stretching of the material through which anchoring yarn 413 extends compared to an anchoring yarn stitch with only two or three needles floating between tuck stitches or knit stitches. In such embodiments, the different resistance to elongation between the floating lengths is a result of non-linear portions (e.g., stitch loops) that are more prone to elongation than linear segments, resulting in different amounts of resistance to elongation.

[0183] In some respects, when anchor yarn 413 is used as Figure 5G-Figure 5J When one or more of the knitted structures depicted are present, the anchoring yarn 413 extends as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of the yarn containing the low-processing-temperature polymer composition, because the yarn containing the low-processing-temperature polymer composition also acts as... Figure 5A and Figure 5B One or more of the knitted structures are present. Furthermore, in some aspects, the anchor yarn 413 may extend as a float stitch along at least two, at least three, at least four, or at least five adjacent loops of the yarn containing the low-processing-temperature polymer composition, and may also form at least a portion of a tuck stitch and / or a knitted stitch with the yarn containing the low-processing-temperature polymer composition. In such aspects, the length between the tuck stitch or knitted stitch is at least partially formed with the yarn containing the low-processing-temperature polymer composition and the anchor yarn 413, which may extend at least two, at least three, at least four, or at least five adjacent loops of the yarn containing the low-processing-temperature polymer composition. In the same or alternative aspects, the anchor yarn 413 may be sewn at loops spaced apart by the number of needles in a standard needle bed within 50% or 25% of the gauge of the knitting machine used to form at least a portion of the textile 300, for example, a tuck stitch or a knitted stitch.

[0184] Figure 4C and Figure 4D Depicts portions of textile areas 302 and 306a, and a cross-section of textile area 304a. For example, Figure 4C The cross section 418 includes a portion 422 corresponding to textile region 302 and a portion 420 corresponding to textile region 306a. Portions 424a, 424b, 424c and 424d correspond to sub-regions 305a, 305b, 305c and 305d of textile region 304a of textile 300, respectively. Figures 4C-4EThe cross-section is schematically simplified; however, it is contemplated that one or more zones and / or portions of the cross-section may include a variety of fibers and / or yarns with different configurations and concentrations. For example, textile zone 424c in intermediate segment 428 may include both fibers and / or yarns comprising a low-processing-temperature polymer composition and fibers and / or yarns comprising a high-processing-temperature polymer composition, but at a different configuration / concentration than that found in textile zones 424b and / or 424d of intermediate segment 428. In other words, various construction techniques allow for combinations of fibers and / or yarns in a given segment and textile zone by variations of methods of combining, including, attaching, depositing, or applying fibers and / or yarns (e.g., stitch selection), variations of which allow for variations in fiber and / or yarn concentration at the segment level and / or textile zone level.

[0185] Figure 4C The cross section 418 includes the sections mentioned above. Figure 4A and Figure 4B The cross sections 402 and 410 discuss the same type of generally tubular knitted structure. Therefore, cross section 418 includes a top segment 426, a middle segment 428, and a bottom segment 430. The top segment 426, middle segment 428, and bottom segment 430 may each include the sections referenced above. Figure 4A The top segment 404, middle segment 406 and bottom segment 408 of cross section 402 are discussed as the same knitted structure.

[0186] exist Figure 4C In cross section 418, portions 422 and 424a comprise knitted structures made with yarns containing a low-processing-temperature polymer composition, while portions 420, 424d, and 424c comprise knitted structures made with yarns containing a high-processing-temperature polymer composition. However, as provided above, it is contemplated that combinations of fibers and / or yarns based on different stitching techniques can be implemented in the various portions to achieve a transition from one primary material to another.

[0187] Section 424b includes tubular knitted structures made from yarns containing a high-processing-temperature polymer composition; however, the knitted structures formed by the front and back needle beds (using yarns containing a high-processing-temperature polymer composition) are joined via floats and tuck stitches (or equivalent effective stitches) from yarns containing a low-processing-temperature polymer composition. This section 424b illustrates how, after the textile 300 undergoes thermoforming, the low-processing-temperature polymer composition, during melting and solidification, can physically join two outer knitted layers together via a panel or film of thermoforming material. In such an aspect, wearable articles having this type of tubular knitted structure, already thermoformed and joined via an integral thermoforming material, will primarily consist of typical knitted yarn layers joined together via a thermoforming film on opposite outer surfaces of the textile. Such a structure can be used to provide waterproof / water-resistant or other weather-proofing to wearable articles while still maintaining the aesthetics and feel of typical knitted articles.

[0188] and Figure 4C The cross-section is the same as 418. Figure 4D The cross section 432 includes a portion 436 corresponding to textile region 302 and a portion 434 corresponding to textile region 306a. Portions 438a, 438b, 438c and 438d correspond to sub-regions 305a, 305b, 305c and 305d of textile region 304a of textile 300, respectively.

[0189] Figure 4D The top region 440, middle region 442, and bottom region 444 of the cross section 432 can respectively include the above reference. Figure 4A The top segment 404, middle segment 406 and bottom segment 408 of cross section 402 discuss the same knitted structure in order to provide the same type of generally tubular structure.

[0190] In an exemplary aspect, Figure 4DPortions 434 and 438d of cross section 432 include knitted structures comprising yarns containing a high-processing-temperature polymer composition, while portions 436, 438a, and 438b comprise knitted structures made with yarns containing a low-processing-temperature polymer composition. However, as also provided above, it is contemplated that primary but non-exclusive material choices may be used. For example, in portion 438b, yarns containing a high-processing-temperature polymer composition may be present in intermediate region 442 to facilitate material transition. The concentration of yarns containing a high-processing-temperature polymer composition in portion 438b may be less than the concentration of yarns present in portion 438c of the same intermediate region 442. For example, portion 438b may have at least 5 wt%, 10 wt%, or 25 wt% less yarns containing a high-processing-temperature polymer composition than portion 438c of the same intermediate region 442.

[0191] Part 438c includes a tubular structure having yarns comprising a low-processing-temperature polymer composition, the yarns being connected via floats and tuck stitches from yarns comprising a high-processing-temperature polymer composition. In this aspect, after thermoforming, this part 438c can encapsulate the yarns comprising the high-processing-temperature polymer composition within a liner of molten and cooled thermoformed material. In some aspects, such a structure can provide flexibility to thermoformed materials that are otherwise rigid.

[0192] For example, Figure 4E Describing and Figure 4D The cross-section 432 is the same as the cross-section 446, except that the anchoring yarn 448 has been added to at least a portion of the region comprising the yarn containing the low-processing-temperature polymer composition. In some aspects, the anchoring yarn 448 may have the characteristics described above. Figure 4B The anchoring yarn 413 discusses any or all of the properties. For example, the anchoring yarn can be incorporated into the use of... Figure 5E and Figure 5G-Figure 5J In one or more textiles with a knitted structure as depicted in the text.

[0193] If it is possible Figure 4E As seen in the diagram, the anchoring yarn 448 extends from the portion 450 corresponding to the cross-section 446 of the textile region 302, and extends into portions 452a and 452b of the sub-regions 305a and 305b corresponding to the textile region 304a. Furthermore, in this respect, Figure 4E The diagram illustrates that yarns containing low-processing-temperature polymer compositions also exist (e.g., as having...) Figure 5A and Figure 5BThe anchor yarn 448 is at least the same as the anchor yarn 448 in at least a portion of a textile fabric containing one or more types of yarn in a knitted structure. Therefore, in some aspects, the anchor yarn 448 may extend as a float stitch along at least two, three, four, or five adjacent loops of the yarn containing the low-processing-temperature polymer composition. Furthermore, in some aspects, the anchor yarn 448 may extend as a float stitch along at least two, three, four, or five adjacent loops of the yarn containing the low-processing-temperature polymer composition, and may also be used to form at least a portion of a tuck stitch and / or a knitted stitch. In such aspects, between tuck stitches or knitted stitches at least partially formed by the yarn containing the low-processing-temperature polymer composition and the anchor yarn 448, the anchor yarn 448 may extend at least two, three, four, or five adjacent loops of the yarn containing the low-processing-temperature polymer composition. In the same or alternative aspects, the anchoring yarn 448 may be sewn at loops of a quantity within 50% or 25% of the machine number of the knitting machine used to form at least a portion of the textile 300, spaced apart by the number of stitches, for example, a tuck stitch or a knitted stitch.

[0194] As discussed above, in one or more aspects, the anchoring yarn 448 may extend from textile region 302 into textile region 304a and toward textile region 306a. In such an aspect, the anchoring yarn 448 may not extend from textile region 302 into textile region 304a and toward textile region 306a as far as the yarn containing the low-processing-temperature polymer composition extends into region 304a and toward textile region 306a, because there is less need to constrain flow and / or provide flexibility to the thermoforming material during thermoforming, since the yarn containing the high-processing-temperature polymer composition from region 306a is also present in textile region 304a.

[0195] For example, in Figure 4E In cross section 446, the anchoring yarn extends from portion 450 (corresponding to a portion of textile region 302) and into portion 452b (corresponding to sub-region 305b of textile 300). Furthermore, cross section 446 illustrates that the top segment 456 and bottom segment 460 of cross section 446 show yarns containing a low-processing-temperature polymer composition extending from portion 450 toward portion 454 (corresponding to textile region 406a) into portion 452c, exceeding the extension of the anchoring yarn 448 in the same direction. However, in the intermediate segment 458, and in portions 452c and 452d, yarns containing a high-processing-temperature polymer composition are present, which can provide flexibility to the thermoformed textile and / or constrain flow during thermoforming.

[0196] As discussed above, in some respects, when textile 300 is a knitted textile, Figures 4A-4E The cross-section of the textile depicted is described as having a top segment, a bottom segment, and a middle segment, wherein the top and bottom segments can form a tubular knitted structure with a top knitted layer and a bottom knitted layer (and wherein tuck stitches or other connecting stitches present in the middle segment can also form a portion of the tubular knitted structure or a generally knitted structure). In such an aspect, each of the top outer knitted layer and the bottom outer knitted layer may include a plurality of interconnected rows.

[0197] In addition, such as in Figure 3 As can be seen in textile 300, in region 304a, sub-regions 305a-d have at least one interlaced interface, such as interlaced interface 306. The interlaced interface, such as interlaced interface 306, provides an interlaced or non-linear transition between the sub-regions of textile 300 along the width w of the textile. In this respect, when textile 300 is thermoformed, these interlaced interfaces provide a finer, more integral transition between the rigid region formed by the low-processing-temperature polymer composition in textile region 302 and the flexible, resilient region formed by the yarn containing the high-processing-temperature polymer composition in textile region 306a. In various respects, this fine, integral transition, at least partially provided by the interlaced interfaces, can increase the durability or tear resistance of the thermoformed textile 300, in contrast to similar textiles with a linear abrupt transition between integral rigid and flexible materials.

[0198] In the aspect where textile 300 is a knitted textile, the interlacing interface 306 can depict different rows of yarns on the top or bottom outer knitted layer, how these rows can have different amounts of loops (or general stitch selections) of yarns containing a low-processing-temperature polymer composition and / or yarns containing a high-processing-temperature polymer composition. Because textiles can have multiple layers (e.g., top, middle, and bottom), the interlacing interface can be addressed in any combination of layers and is not limited to the exposed or depicted surfaces. Conversely, as provided herein and as contemplated, a transition from a first primary material (e.g., fibers and / or yarns containing a high-processing-temperature polymer composition) to a second primary material (e.g., fibers and / or yarns containing a low-processing-temperature polymer composition) forms the textile, this transition may occur exclusively in the middle layer or in the middle layer combined with one or more outer layers. It should be understood that, for the purposes of the following discussion of knitted layers, it is assumed that when… Figure 3 When textile 300 is a knitted textile, the view of textile 300 depicts the top layer. Furthermore, the same description applies to the bottom knitted layer.

[0199] Figure 6 An exemplary portion 600 of the top layer of textile 300 is schematically depicted, showing a portion of the interlaced interface 306. (As in...) Figure 6 As can be seen, portion 600, the first row 602 of the coil, is interconnected to the second row 604 of the coil. It should be understood that, although in Figure 6 Only two interconnected rows are depicted, but more than two rows may be interconnected in the top knitted layer of textile 300. As used herein, “interconnected” when referring to an interconnected row means how at least a portion of a coil in the first row of the loops is entangled to at least a portion of a coil in the second row of the loops. Figure 6 An exemplary aspect of interconnected rows is depicted, wherein individual loops from a second row 604 interlock with individual loops from a first row 602. As used herein, "interlocking" refers to how a loop from one row can wrap around a loop from another row, such as in a knitted stitch, and also to how a loop can cause another segment of yarn to be pulled through the loop (or through the loop and around the yarn forming the loop) to form a second loop, as in a crochet process.

[0200] As can be seen in section 600 of textile 300, both the first row 602 and the second row 604 comprise two types of yarn: a first yarn 606 which may contain a high-processing-temperature polymer composition and a second yarn 608 which may contain a low-processing-temperature polymer composition. Although only two rows are depicted in section 600, it should be understood that the top knit layer of textile 300 may include any number of rows. In all aspects, each of the rows present in the top knit layer of textile 300 may include two or more types of yarn, such as... Figure 6 As depicted in the text.

[0201] As in Figure 6 As can be seen, each row, for example, the first row 602 and the second row 604, can extend from textile area 302 to textile area 306a (in some aspects, each of the rows can extend from textile area 306a to textile area 306b). In some aspects, such as in Figure 6 As can be seen, the second yarn 608 in both the first row 602 and the second row 604 can extend from textile area 302 into textile area 304a. In the same or alternative aspect, the first yarn 606 can extend from textile area 304a into textile area 306a. It should be understood that although the schematic portion 600 of textile 300 depicts each loop as having only a single yarn, more than one yarn can be present at one or more loops (e.g., another yarn can be combined with...). Figure 6(The 600 coils together form a coiled stitch), such as Figures 4A-4E Depicted in the cross-section.

[0202] As discussed above, the outer knitted layer portion 600 of textile 300 illustrates at least a portion of the interlacing interface 306. In some aspects, the interlacing interface 306 (and any other interlacing interface) can be formed by multiple rows of the same type of yarn extending different distances from one zone (or sub-zone) into the next zone or sub-zone. For example, as in... Figure 6 As can be seen, in the first row 602, the second yarn 608 extends further from textile zone 302 to textile zone 304a and toward textile zone 306a compared to the second yarn extending from textile zone 302 into textile zone 304a and toward textile zone 306a. In this respect, the different distances the second yarn 608 extends into textile zone 304a result in different amounts of loops of the second yarn 608 in each of the first row 602 and the second row 604a, which can change the yarn concentration in a given zone / sub-zone. Therefore, in this respect, within textile zone 304a, loops of the second yarn 608 in the first row 602 can interlock with loops of the second yarn 608 in the first row 602 at the first longitudinal row, while at the second longitudinal row 610, the second yarn 608 in the first row 602 can interlock with loops of the first yarn 606 in the first row 602. In the same or alternative aspects, within textile area 304a, the first yarn 606 in the first row 602 may be interlocked with the first yarn 606 in the second row 604 at the third column 612.

[0203] In one or more aspects, the interlacing interface, such as interlacing interface 306, can result in adjacent rows of multiple rows in textile 300 having different numbers of loops of yarn comprising a low-processing-temperature polymer composition and yarn comprising a high-processing-temperature polymer composition. For example, as in Figure 6 As can be seen in the upper knitted layer portion 600 of the textile 300 depicted, in at least a portion of the textile region 304a, the first row 602 has a different number of loops of the first yarn 606 and / or the second yarn 608 than the second row 604. Furthermore, in the same or alternative aspect, within at least a portion of the textile region 304a, adjacent warp rows may have one or more loops of different yarns. For example, as... Figure 6 As illustrated in the upper knitted layer portion 600 of the textile 300, the warp 610 includes loops of both a first yarn 606 and a second yarn 608, while the warp 612 includes loops of the first yarn 606.

[0204] As discussed above, textiles described herein, which may include fibers and / or yarns comprising a low-processing-temperature polymer composition, may be thermoformed to impart structural properties to wearable articles. Furthermore, as discussed above, the thermoforming process can cause at least a portion of the low-processing-temperature polymer composition present in the textile to melt or deform and subsequently solidify.

[0205] Figure 7A The schematic depiction shows the process prior to thermoforming. Figure 3 The textile region 304a of the upper knitted layer of the textile 300 is a portion 700. Portion 700 includes a first row 702 and a second row 704 having a first yarn 708 comprising a high-processing-temperature polymer composition. The portion also includes a third row 706 of a second yarn 710 comprising a low-processing-temperature polymer composition. In this aspect, the third row 706 of the loops of the second yarn 710 may be interconnected, for example, interlocked with the first row 702 and the second row 704 having the first yarn 708.

[0206] Figure 7B The section 700 after exposure to the thermoforming process is depicted. (As shown by comparison...) Figure 7A and Figure 7B As can be seen, a second yarn 710 comprising a low-processing-temperature polymer composition is thermoformed from yarn material into a molten yarn component 712. In some aspects, the heating step of the thermoforming process at least partially causes the low-processing-temperature polymer composition in the second yarn 710 to melt and flow, and then subsequently solidifies into a molten yarn component 712 by completing the thermoforming process.

[0207] In all aspects, such as in Figure 7A and Figure 7B As can be seen, thermoforming technology has also enabled... Figure 3 The textile 300 has at least a portion of its knitted structure in the upper knitted layer of portion 700 transformed. For example, in Figure 7A The rows 702, 704, and 706 depicted have been transformed such that, at least in part, due to the transformation of the yarn 710 in the third row 706 into molten yarn components 712, portion 700 no longer includes rows of interconnected loops of yarns containing low-processing-temperature polymer compositions and yarns containing high-processing-temperature polymer compositions. As in Figure 7B As can be seen, although thermoforming processes can eliminate Figure 3 The upper knitted layer portion 700 of the textile 300 contains interconnected loops, but the remaining rows 702 and 704 can be connected via molten yarn components 712. In this respect, Figure 3This portion 700 of the upper knitted layer of the textile 300 can fix the positions of rows 702 and 704 relative to each other, as opposed to when rows 702 and 704 are interconnected via rows 706 prior to thermoforming. Furthermore, in this respect, the top portion 714 of the loops of the first row 702 can still be freely interconnected with other rows of yarn, allowing individual adjustment of the level of rigidity and / or three-dimensional forming provided by the textile zone 304a.

[0208] Figure 8 Depicting along Figure 7B The cutting line 8 shown in the diagram Figure 3 The cross-section of the upper knitted layer portion 700 of the textile 300. (As in...) Figure 8 As can be seen, at least a portion of the first yarn 708 can be encapsulated within the molten yarn component 712. Depending on the conditions used during the thermoforming process, the molten yarn component 712 can solidify into a film structure that surrounds at least a portion of the coils of the first row 702 and the second row 704 of the first yarn 708, which comprises a high-processing-temperature polymer composition.

[0209] As in Figure 7B and Figure 8 As can be seen in the aspects depicted, the first yarn 708, comprising a high-processing-temperature polymer composition, does not melt or deform after exposure to a thermoforming process. Furthermore, in some aspects, the first yarn 708 may contain a dye 716 (depicted as spots within the first yarn 708) that does not leach out after exposure to a thermoforming process. For example, as in... Figure 7B and Figure 8 As can be seen, there is no visible leaching of dye 716 from the first yarn 708 into adjacent areas, such as adjacent area 718, of the molten yarn component 712. In some aspects, at least about 80 wt%, at least about 90 wt%, at least about 95 wt%, or at least 99 wt% of dye 716 is retained within or in the first yarn 708. Figure 3 The upper knitted layer of the textile 300 is within the thermoformed portion 700. In the same or alternative aspects, after thermoforming, no dye is visibly leached into the [textile / fabricated / contained / etc.]. Figure 3 The upper knitted layer portion 700 of the textile 300 is incorporated into any other material associated with the final wearable item therein.

[0210] Figure 9A and Figure 9B The following aspects are described, among which Figure 3 The upper knitted layer portion 700 of the textile 300 is exposed to the thermoforming process, but this only results in deformation of the low-processing-temperature polymer composition in the second yarn 710, without eliminating... Figure 7AAt least a portion of the interconnected rows 702, 704, and 706. As used herein, “deformation” and “deforming” in the context of thermoforming processes for knitted textiles refer to altering the structure of the yarn so that the yarn does not melt and flow in a manner that substantially eliminates the knitted structure of the textile (e.g., eliminating one or more interconnected loops or interlocking rows).

[0211] Figure 9A The image depicts the cutting line 9A-B prior to the thermoforming process. Figure 3 The cross-section of the upper knitted layer portion 700 of the textile 300, and Figure 9B The same cross-section is depicted after the thermoforming process. (As shown in...) Figure 9B As can be seen, after exposure to the thermoforming process, the second yarn 710 in the third row 706 has a modified yarn structure 710a, while the structure of the first yarn 708 remains unchanged. In this respect, the second yarn 710 in the third row 706 remains interlocked with the first row 702 and the second row 704, and maintains... Figure 3 The textile 300 has an upper knitted layer portion 700 of an overall knitted structure.

[0212] In some aspects, this altered yarn structure 710a can result in the second yarn 710 being mechanically joined or physically bonded to another yarn, such as the first yarn 708 (or another portion of the second yarn 710). In some aspects, during the thermoforming process, the yarn 710 may have been exposed to a temperature higher than the glass transition temperature T of the polymer composition at the lower processing temperature. g However, the temperature shall not exceed the melting temperature of the low-processing polymer composition. In such an aspect, when the second yarn 710 is exposed to such an elevated temperature, the second yarn may soften and become tough but not melt, allowing the yarn to be slightly molded around at least a portion of an adjacent yarn, such as the first yarn 708, and upon cooling, this altered yarn structure may be mechanically locked in place to physically bond to the adjacent yarn.

[0213] Figures 10A-10C Depicting before and after thermoforming Figure 3 The textile 300 has a textile area 302 with an upper knitted layer portion 1000. Figure 10A Three rows 1010, 1012, and 1014 of yarn containing a low-processing-temperature polymer composition are depicted. Figure 10A The presence of anchor yarn 1016, which extends from floating stitch 1016a and tuck stitch 1016b, is also depicted.

[0214] Figure 10B Depicting the effects of exposure to thermoforming processes Figure 3The same portion 1000 of the upper knitted layer of textile area 302 in textile 300. (As in...) Figure 10B As can be seen, the interlocking rows of yarns 1010, 1012, and 1014 have been transformed into molten yarn components 1018. Furthermore, as in... Figure 10B and Figure 10C (It is along) Figure 10B As can be seen in the cross-section of the cut line 10C, the anchoring yarn 1016 has maintained its yarn structure and is now encapsulated within the molten yarn component 1018. It should be understood that, although in... Figure 10B The anchoring yarn 1016 is depicted as being encapsulated within the molten yarn component 1018, but it is also anticipated that the anchoring yarn 1016 can be at least partially embedded within the molten yarn component 1018, such that at least a portion of the anchoring yarn 1016 is not completely covered within the molten yarn component 1018.

[0215] As discussed above, in some respects, the textiles described herein may include knitted textiles, such as those found in… Figures 4A-10C The image depicts a portion of a knitted textile. A knitted upper for footwear articles is an exemplary knitted textile. In such aspects, at least a portion of the knitted upper of the footwear article, and in some aspects, the upper can be substantially entirely formed of a knitted textile. The knitted textile may additionally or optionally form another element of the footwear article, such as, for example, a midsole or a ground-facing outsole. The knitted textile may have a first side forming an inner surface of the upper (e.g., a cavity facing the footwear article) and a second side forming an outer surface of the upper. The upper including the knitted textile may substantially surround the cavity so as to substantially enclose the foot when the footwear article is in use. The first and second sides of the knitted textile may exhibit different characteristics (e.g., the first side may provide abrasion resistance and comfort, while the second side may be relatively rigid and provide water resistance).

[0216] In various aspects, knitted textiles can be formed as a single, one-piece element during knitting processes such as weft knitting (e.g., using a horizontal knitting machine or a circular knitting machine), warp knitting, or any other suitable knitting process. That is, the knitting process can substantially form the knitted structure of the textile without requiring numerous post-knitting processes or steps. Alternatively, two or more parts of the knitted textile can be formed separately and then attached. In some embodiments, the knitted textile can be shaped after the knitting process to form and maintain the desired shape of the shoe upper (e.g., by using a foot-shaped last). Shaping processes can include attaching the knitted textile to another object by sewing, by using adhesives, or by another suitable attachment process (e.g., Stellar), and / or attaching one part of a knitted component to another part of a knitted component at a seam.

[0217] Using knitted textiles to form shoe uppers can provide advantageous characteristics, including but not limited to specific degrees of elasticity (e.g., expressed as Young's modulus), breathability, flexibility, strength, moisture absorption, weight, and abrasion resistance. These characteristics can be achieved by selecting specific single-layer or multi-layer knitted structures (e.g., rib knitted structures, single-knitted structures, or double-knitted structures), by changing the size and tension of the knitted structure, by using one or more yarns formed from specific materials (e.g., polyester, monofilament, or elastic materials such as spandex), by selecting specific yarn sizes (e.g., denier), or combinations thereof.

[0218] Knitted textiles can also provide desirable aesthetic features by incorporating yarns of different colors or other visual characteristics arranged in specific patterns. The yarns and / or knitting structure of a knitted textile can vary in different locations, allowing the knitted component to have two or more parts with different properties (e.g., the portion forming the throat area of ​​a shoe upper can be relatively elastic, while another portion can be relatively inelastic). In some aspects, knitted textiles can incorporate one or more materials that have properties that change in response to stimuli (e.g., temperature, moisture, electric current, magnetic field, or light).

[0219] In some aspects, a knitted textile may include one or more yarns or strands, referred to herein as “strands,” that are at least partially embedded or otherwise inserted into the knitted structure of the textile during or after the knitting process. The strands may be substantially inelastic to have a substantially fixed length. The strands may extend through multiple rows of the knitted textile or through channels within the textile and may restrict stretching of the textile in at least one direction. For example, a strand may extend generally from the bite line of the upper to the throat area of ​​the upper to restrict stretching of the upper in the lateral direction. The strands may form one or more eyelets for receiving shoelaces and / or may extend around at least a portion of the eyelets formed in the knitted structure of the textile.

[0220] In an optional aspect, the textiles described herein may include nonwoven textiles. The nonwoven textiles described herein may be produced by any conventional method, such as any conventional mechanical, chemical, or thermal method for binding fibers together, including needle entangling and water entangling.

[0221] Figures 11A-11C The following aspects are described, among which Figure 3 Textile 300 is a non-woven textile and undergoes a thermoforming process. Figure 11A yes Figure 3 A schematic depiction of part 1100 of textile area 304a of textile 300. (As shown in...) Figure 11A As can be seen, the portion includes a first group 1110 comprising a first fiber 1116 containing a high-processing-temperature polymer composition, a second group 1112 comprising the first fiber 1116, and a third group 1114 comprising a second fiber 1118 containing a low-processing-temperature polymer composition. It should be understood that portion 1100 of the textile 300 is illustrative, and the placement and spacing of the first fiber 1116 and the second fiber 1118 may vary in the textile.

[0222] Although Figures 11A-11C Not depicted herein, but in the aspect where textile 300 is a nonwoven textile, one or more interfaces between different portions of different fibers may further include one or more interlaced interfaces, for example, interlaced interface 306. In such an aspect, interlaced interface 306 may depict how the transition between regions or subregions of fibers containing low-processing-temperature polymer compositions and / or fibers containing high-processing-temperature polymer compositions with different concentrations does not follow... Figure 3 The width w of the textile 300 appears in a linear manner.

[0223] Now return to Figures 11A-11C And especially Figure 11C In an aspect where the thermoforming process causes the melting and flow of the low-processing-temperature polymer composition in the second fiber 1118, the second fiber 1118 has been transformed into a non-fibrous material 1120, while the first fiber 1116 has not been transformed and therefore remains in fibrous form. In this aspect, the non-fibrous material 1120 can connect the first group 1110 of the first fiber 1116 to the second group 1112 of the first fiber 1116. Figure 11C A cross-section along cut line 11C is shown, which in some respects illustrates how at least a portion of the first fiber 1116 can be encapsulated within the non-fibrous material 1120. In various respects, it is contemplated that at least a portion of the first fiber 1116 can be at least partially embedded within the non-fibrous material 1120 such that the first fiber 1116 is not completely encapsulated by the non-fibrous material 1120.

[0224] Although not depicted in the figure, in some respects, after exposure to the thermoforming process, the second fiber 1118 may not melt and flow, but instead can deform and change shape. Figure 9A and Figure 9B This describes this deformation of the fiber or yarn. (Related to the previous text...) Figure 9A and Figure 9BAs with the deformation of fibers or yarns discussed, in some respects, a second fiber can be deformed and molded onto another first or second fiber (or the same fiber) and mechanically joined or physically bonded to that fiber.

[0225] Processes used in manufacturing

[0226] Some conventional thermoforming processes involve, for example, masking parts of an article that are not intended to be exposed to the thermoforming process, or using only parts of the article that come into contact with or cover the article. Part The tooling process selectively thermoforms only a portion of an article. However, such conventional methods result in a time- and energy-intensive manufacturing process because multiple steps are required to mask and demask portions of the article before and after the thermoforming process, or multiple sets of tools are needed. Other conventional thermoforming processes involve thermoforming article components before assembling them into an article. This conventional process is also time- and resource-intensive because multiple steps and machines are required to individually form the article components before assembling the article. Furthermore, articles formed from several individual components produce multiple seams where the individual components meet, thus providing weaknesses in the article, a less natural feel for the wearer, and / or actual discomfort or injury to the wearer.

[0227] The manufacturing process disclosed herein solves one or more of the aforementioned problems. The manufacturing process disclosed herein utilizes one or more of the molded parts, films, textiles, yarns, and fibers disclosed herein, wherein one or more of the molded parts, films, textiles, yarns, and fibers comprise at least one low-processing-temperature polymer composition as disclosed herein. The manufacturing process disclosed herein also utilizes one or more of the molded parts, films, textiles, yarns, and fibers disclosed herein, wherein one or more of the molded parts, films, textiles, yarns, and fibers comprise at least one high-processing-temperature polymer composition as disclosed herein. The disclosed manufacturing process includes a thermoforming step, wherein the low-processing-temperature polymer composition is softened or melted, while the high-processing-temperature polymer composition does not melt or soften. The thermoforming is performed at a temperature range below at least one of the following properties of the high-processing-temperature polymer composition: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m Thermoforming can be performed at creep relaxation temperatures (T0) of polymer compositions below the high processing temperature. cr Thermoforming can be performed within a temperature range below the Vicat softening temperature (T0) of the polymer composition at its high processing temperature. vs Thermoforming can be performed within a temperature range below the high processing temperature of the polymer composition (T). hdThermoforming can be performed within a temperature range below the melting temperature (T0) of the polymer composition at its high processing temperature. m It is carried out within the temperature range of ).

[0228] For example, in some aspects, as further discussed below, the specific and selective incorporation of low-processing-temperature polymer compositions and high-processing-temperature polymer compositions into an article provides a way to program structural features into an article that can be formed after thermoforming. In some aspects, the article may include a textile comprising both a low-processing-temperature polymer composition and a high-processing-temperature polymer composition, such as a textile comprising at least one of multiple fibers or yarns, wherein at least a portion of the textile comprises the low-processing-temperature polymer composition. In another aspect, the article may include a first forming component, film, textile, yarn, or multiple fibers comprising a low-processing-temperature polymer composition; and a second forming component, film, textile, yarn, or multiple fibers comprising a high-processing-temperature polymer composition, such as a knitted upper of a footwear article comprising a high-processing-temperature polymer composition and a film comprising a low-processing-temperature polymer composition. In yet another aspect, the article may include an aggregation of components, at least a portion of which comprises both the low-processing-temperature polymer composition and the high-processing-temperature polymer composition to which the disclosed thermoforming process has been applied.

[0229] In various respects, because such structural features are constructed into the article based on the positions of the low-processing-temperature polymer composition and the high-processing-temperature polymer composition within the article, these structural features become integrated with each other after thermoforming, allowing for a more natural feel for the wearer or user. For example, a knitting program for electronic knitting equipment can be used to determine the position of the structural features. However, as already mentioned, the manufacturing processes (and the advantages associated with these processes) are not limited to the use of the textiles disclosed herein. For example, a process for forming structural features in the disclosed articles can utilize films containing low-processing-temperature polymer compositions, while textiles containing high-processing-temperature polymer compositions are also contemplated as a process for programming structural features into the disclosed articles. Alternatively, a process for effectively programming structural features into the disclosed articles can utilize molded parts containing low-processing-temperature polymer compositions together with textiles containing high-processing-temperature polymer compositions.

[0230] Furthermore, selectively incorporating low-processing-temperature polymer compositions and high-processing-temperature polymer compositions into articles provides streamlined manufacturing processes. For example, in some aspects, the entire article can be formed by arranging components and exposing the arranged components to a thermoforming process, wherein components containing low-processing-temperature polymer compositions melt, flow, and re-solidify into more rigid structural features, while components containing high-processing-temperature polymer compositions do not deform during the thermoforming process. In such aspects, this allows the entire article to be exposed to the thermoforming process without the need to mask or protect areas that the manufacturer does not wish to melt, flow, and re-solidify, resulting in a more time- and energy-efficient manufacturing process. Moreover, in some cases, using articles described herein in the manufacturing processes described herein also allows for the provision of several different structural features or other advantageous features in the article without the need to assemble individual components into the final article, as such features can be constructed into the article at the textile layer using both low-processing-temperature and high-processing-temperature polymer compositions.

[0231] In all aspects, the thermoforming process occurs at a temperature below that at which the yarn or fiber has already been dyed (e.g., below the temperature at which yarns or fibers containing high-processing-temperature polymer compositions are dyed), such that the dye does not leach from the yarn or fiber and enter the surrounding low-processing-temperature polymer composition during the thermoforming process. Therefore, in order to form the various textiles and articles described herein, the melting temperature of the low-processing-temperature polymer composition in the first yarn or fiber is below the temperature at which a second yarn or fiber, such as a second yarn or fiber containing a high-processing-temperature polymer composition, is dyed.

[0232] Furthermore, compositions with this range of melting temperatures (i.e., below the melting temperature at which the second yarn or second fiber containing the high-processing-temperature polymer composition is dyed) present another problem, because so many of the tested low-processing-temperature polymer compositions evaluated do not produce yarns suitable for use in commercial knitting equipment, as the yarns shrink significantly when exposed to the temperatures at which commercial knitting equipment is typically operated.

[0233] In specific embodiments, the low processing temperature polymer compositions described herein, when present in yarn and used in commercial knitting equipment, exhibit melting characteristics and an acceptable level of shrinkage. For example, in some aspects, the low processing temperature polymer compositions may exhibit a melting temperature T of 135°C or less. m .

[0234] In some aspects, the thermoforming of the articles and textiles described herein can be carried out within a temperature range that causes the low-processing-temperature polymer composition to melt or deform (and subsequently solidify), while the high-processing-temperature polymer composition does not melt and / or deform, thus maintaining the structure of elements such as yarns or fibers containing the high-processing-temperature polymer composition. In such aspects, this thermoforming process can produce more rigid structural components (such as the outsole portion of a shoe) integrally attached to less rigid portions of the article or textile, such as the upper portion of a shoe having yarns or fibers containing high-processing-temperature polymer compositions.

[0235] Therefore, in one aspect, a process for manufacturing articles is provided. The articles may be components of footwear, clothing, or sports equipment. For example, components of sports equipment may be components of hats, bags, balls, and protective gear. The process includes receiving articles comprising a first forming component, a first film, a first textile, a first yarn, or a first fiber; and a second forming component, a second film, a second textile, a second yarn, or a second fiber. The first forming component, first film, first textile, first yarn, or first fiber comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers, wherein the second forming component, second film, second textile, second yarn, or second fiber comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers, and wherein the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m At least one of the following: 1) Creep relaxation temperature T cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs The process also includes placing at least a portion of the article on the molding surface. Furthermore, while at least a portion of the article is on the molding surface, the process includes raising the temperature of the entire article to above the melting temperature T of the polymer composition at the low processing temperature. m And below the creep relaxation temperature T of the high-processing-temperature polymer composition. cr ;2) Heat distortion temperature T hd ; or 3) Vicat softening temperature T vs At least one of the following temperatures. After raising the temperature of the entire article, while holding at least a portion of the article on the molding surface, the temperature of the entire article is lowered to below the melting temperature T of the low-processing polymer composition. m The temperature is used to form thermoformed items.

[0236] In another aspect, a process is provided for manufacturing an upper for clothing articles. The process includes weaving a first row, which includes interlacing a first yarn with a second yarn. The first yarn comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The second yarn comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing-temperature polymer composition exhibits a higher melting temperature (T0) than the low-processing-temperature polymer composition. m At least one of the following: (1) creep relaxation temperature (T) cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m In some aspects, at least a portion of the first yarn is a warp; and at least a portion of the second yarn is a weft. In alternative aspects, at least a portion of the first yarn is a weft; and at least a portion of the second yarn is a warp.

[0237] In another aspect, a process is provided for manufacturing an upper for a shoe. The process includes receiving an upper comprising a first yarn and a second yarn. The first yarn comprises a low-processing-temperature polymer composition containing one or more first thermoplastic polymers. The second yarn comprises a high-processing-temperature polymer composition containing one or more second thermoplastic polymers. The high-processing-temperature polymer composition exhibits a higher melting temperature (T0) than the low-processing-temperature polymer composition. m At least one of the following: (1) creep relaxation temperature (T) cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m In the first portion of the upper, at least one of a first yarn and a second yarn forms a plurality of interconnected loops. The process also includes placing the upper onto a shoe last. Furthermore, the process includes heating the entire upper to a temperature higher than the melting temperature (T0) of the low-processing-temperature polymer composition while it is on the shoe last. m And at least one of the following in the polymer composition below the high processing temperature: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m After heating the entire upper, while the entire upper is on the last, it is cooled to a temperature below the melting temperature T of the first yarn composition. m The temperature is adjusted to form the thermoformed shoe upper.

[0238] In yet another aspect, a process is provided for manufacturing an upper for a shoe. The process includes receiving an upper comprising one or more first fibers, first yarns, first films, or first forming components comprising a low-processing-temperature polymer composition; and one or more second fibers, second yarns, second films, or second forming components comprising a high-processing-temperature polymer composition. Each of the one or more first fibers, first yarns, first films, or first forming components comprises a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. Each of the one or more second fibers, second yarns, second films, or second forming components comprises a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing-temperature polymer composition of the one or more second fibers exhibits a melting temperature (T0) greater than that of the low-processing-temperature polymer composition of the one or more first fibers. m At least one of the following: (1) creep relaxation temperature (T) cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m The upper includes a ground-facing outsole region, and at least a portion of one or more first fibers is present on the ground-facing outsole region. The process further includes placing the upper on a last such that at least a portion of the ground-facing outsole region covers at least a portion of the bottom of the last. The process further includes heating the entire upper to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition of one or more first fibers while it is on the last. m And at least one of the following in a high-processing-temperature polymer composition of one or more second fibers: (1) creep relaxation temperature (T cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m After heating the entire upper, while the entire upper is on the last, it is cooled to below the melting temperature (T0) of the low-processing polymer composition of one or more of the first fibers. m The temperature is adjusted to form the thermoformed shoe upper.

[0239] In another aspect, a process is provided for manufacturing a knitted upper for footwear articles. The process includes knitting a first row comprising loops of a first yarn and loops of a second yarn. The first yarn comprises a low-processing-temperature polymer composition containing one or more first thermoplastic polymers. The second yarn comprises a high-processing-temperature polymer composition containing one or more second thermoplastic polymers. The high-processing-temperature polymer composition exhibits a melting temperature (T0) greater than that of the low-processing-temperature polymer composition. m At least one of the following: (1) creep relaxation temperature (T) cr (2) Vicat softening temperature (T) vs (3) Heat distortion temperature (T) hd (4) Melting temperature (T) m The process also includes knitting a second row comprising loops of a first yarn and loops of a second yarn. At least a portion of the first row and at least a portion of the second row form a plurality of interconnected loops.

[0240] The methods, procedures, and operations described herein are not to be construed as requiring them to be performed in the specific order discussed or illustrated, unless explicitly specified otherwise. Alternative or optional steps may be employed.

[0241] Exemplary pre-heat forming process and thermoforming process

[0242] As discussed above, in some respects, the items and textiles described above, for example... Figure 3 The textile 300 can be formed into at least a portion of a wearable article such as footwear. In such an aspect, the textile can be formed into an upper for footwear, wherein the upper includes a ground-facing outsole portion.

[0243] In some aspects, the article or textile may be combined with additional materials forming the upper of the footwear article. For example, in one or more aspects, the textile may be combined or layered with one or more of an ankle collar lining, ankle collar foam, upper lining, or upper foam layer. In some aspects, one or more of these additional materials may be attached to the textile, for example, by knitting, sewing, or adhesive, prior to thermoforming the textile.

[0244] In some respects, internal support devices or internal support soles may be provided to provide additional comfort and / or support to the wearer of footwear articles formed at least in part from the textiles described herein. Figure 12 and Figure 13A footwear article 1200 is depicted, including a sole plate 1210. The footwear article 1200 includes a textile 1212, which forms an upper 1214 having a ground-facing outsole portion 1216. In some aspects, such as in... Figure 13 The best view is in the middle. Figure 13 A cross-section of footwear article 1200 is depicted, with sole plate 1210 positioned within an inner portion 1218 of footwear article 1200 and contacting the inner surface 1220 of textile 1212. In some aspects, sole plate 1210 may comprise a polymeric material, such as a high-processing-temperature polymeric material, for example, polyether block amide, having a melting or deformation temperature above a certain temperature range within which thermoforming processes are performed, such that the polymeric material does not melt or deform during the thermoforming processes described herein.

[0245] In various aspects, for heel support of the wearer, the heel stabilizer 1222 may be positioned on the inner portion 1218 of the upper 1214 or on the outer portion of the upper 1214, or may be formed part of the upper 1214. In various aspects, similar to the sole plate 1210, the heel stabilizer 1222 may comprise a polymeric material, such as a high-processing-temperature polymeric material, for example, a polyether block amide that is capable of not melting or deforming when exposed to thermoforming processes. In various aspects, similar to the sole plate 1210, the heel stabilizer 1222 may include portions formed of a low-processing-temperature polymeric composition in addition to the portions formed of the high-processing-temperature polymeric composition.

[0246] In some aspects, the insole 1224 may be positioned on top of the sole plate 1210 within the interior 1218 of the footwear article 1200. In such aspects, the insole 1224 may comprise one or more layers of conventional insole materials, such as a foam layer or a memory foam layer and a textile layer. It should be understood that while the sole plate 1210, heel stabilizer 1222, and insole 1224 are depicted as additional materials for forming the upper of the footwear article, other materials, such as plates, toe caps, and / or side structures, may also be added.

[0247] In some respects, the heel stabilizer 1222 and the sole plate 1210 may be positioned within the interior 1218 of the footwear article 1200 prior to thermoforming. In others, the insole may be applied after the thermoforming process is completed.

[0248] In some aspects, such as in Figure 14 In the aspects described herein, the ground-adhesive anti-slip studs 1410 can be applied to footwear 1400. In various aspects, footwear 1400 may include components described above. Figure 12 and Figure 13The footwear items described have the same characteristics as item 1200. (As in...) Figure 14 As can be seen, the ground-adhesive anti-slip stud 1410 can be applied to the ground-facing outsole area 1412 of the footwear article 1400 to provide increased stability and adhesion friction. In some respects, the ground-adhesive anti-slip stud 1410 can be applied to the ground-facing outsole area 1412 after the thermoforming process is completed. In other respects, the ground-adhesive anti-slip stud 1410 can be applied to the ground-facing outsole area 1412 as part of the thermoforming process.

[0249] In all respects, prior to thermoforming the footwear, any of the textiles and other materials discussed above can be knitted, braided, woven, or preformed into a general boot-like shape of the upper, having a ground-facing outsole portion, such as... Figure 15 The upper 1500 depicts a general boot shape. In this respect, the upper 1500 may also include a sole plate or heel stabilizer positioned on the interior 1510 of the upper 1500, such as those described above. Figure 12 The sole plate 1210 and heel stabilizer 1222 are discussed.

[0250] To prepare the shoe upper 1500 for use in a thermoforming process, the shoe upper 1500 is placed on a shoe last 1520, such that the shoe last 1520 enters the interior 1510 of the shoe upper 1500. In some aspects, the shoe last 1520 may be formed from a polymeric material such as a high-processing-temperature polymer composition. In a particular aspect, the shoe last 1520 may be made from a material having a melting temperature T greater than 250°C or greater than 300°C. m Alternatively, it may be formed from polymeric materials with low degradation temperatures, such as, for example, silicone polymers. The shoe last 1520 may be made from other types of materials, provided that such materials do not deform or melt during the thermoforming process, or otherwise adversely affect the thermoforming of the shoe upper. Figure 16 The upper 1500 is depicted, positioned on the shoe last 1520. (As shown in...) Figure 16 As can be seen, the upper 1500 surrounds the last 1520 to cover the bottom portion 1522, the forefoot portion 1524, and the heel portion 1526 of the last 1520. In this respect, the ground-facing outsole portion 1512 of the upper covers the forefoot portion 1524 of the last 1520. Although Figure 15 and Figure 16The upper 1500 is illustrated as having a sock-like structure that surrounds and covers the bottom portion 1522, the forefoot portion 1524, and the heel portion 1526 of the last 1520. However, in other aspects, the upper 1500 may only partially surround the last 1520. Similarly, in other aspects, the upper 1500 may cover only the bottom portion 1522, only the forefoot portion 1524, only the heel portion 1526, or combinations thereof of the last 1520. In yet another aspect, the upper 1500 may cover only a portion of the bottom portion 1522, a portion of the forefoot portion 1524, a portion of the heel portion 1526, or combinations thereof of the last 1520.

[0251] Figure 17 A cross-section of the upper 1500 positioned on the last 1520 is shown along cut line 17. Cross-section 1700 reveals the inner surface 1540 of the last 1520 contacting the upper 1500. Cross-section 1700 also reveals two types of materials present in the upper 1500. For example, cross-section 1700 reveals three types of textile areas forming the upper 1500. (As shown in...) Figure 17 As can be seen, the textile area 1710 associated with the ground-facing outsole portion 1512 of the shoe upper covers the bottom portion 1522 of the shoe last 1520. In this aspect, when the shoe upper is a knitted textile forming a knitted upper, at least a portion of the yarn comprising a low-processing-temperature polymer composition covers at least a portion of the bottom portion 1522 of the shoe last 1520.

[0252] Furthermore, textile area 1714 covers the forefoot portion 1524 of last 1520, while textile area 1712 covers the midfoot portion 1528 of last. In some respects, textile areas 1710, 1712, and 1714 may each have the features described above. Figure 3 The textiles section 302, 304a, 306a discusses any or all of the characteristics.

[0253] In some respects, the first layer may be placed on a molded surface such as a shoe last, prior to an article such as a footwear item or a component of a footwear item. For example, a first layer such as a lining may optionally be placed above a molded surface such as a shoe last. For example, see reference. Figure 17To further illustrate the first layer, the first layer may optionally be placed on a molded surface such as the shoe last before the lining can be placed above the shoe last 1520, such that the forefoot region of the lining covers the forefoot region 1524. Thus, the upper, including textile regions 1710, 1712, and 1714, is then positioned such that the upper covers at least a portion of the lining. Thus, at least a portion of the yarn comprising a low-processing-temperature polymer composition covers at least a portion of the lining. It should be understood that, in some aspects, textile regions 1710, 1712, and 1714 may each have the features referenced above. Figure 3 The textiles section 302, 304a, 306a discusses any or all of the characteristics.

[0254] In another aspect, the outer layer may optionally be positioned on at least a portion of the article positioned on the molding surface and cover at least a portion of the article. The outer layer, which may be a film, may optionally be placed over at least a portion of the article, such as the upper positioned on the molding surface like a shoe last. For example, see reference... Figure 17 To further illustrate the following aspect: the outer layer may optionally be placed over at least a portion of the upper already positioned on the last, such that the textile area 1710 associated with the ground-facing outsole portion 1512 of the upper covers the bottom portion 1522 of the last 1520. Therefore, at least a portion of the upper, including textile areas 1710, 1712, and 1714, may be covered by at least a portion of the outer layer. Thus, at least a portion of the yarn comprising the low-processing-temperature polymer composition contacts at least a portion of the outer layer. It should be understood that, in some aspects, textile areas 1710, 1712, and 1714 may each have the features referenced above. Figure 3 The outer layer may be used in conjunction with the first layer, as described in the preceding paragraphs. (Textiles sections 302, 304a, and 306a may discuss any or all of the characteristics.)

[0255] In some aspects, shaped components such as heel stabilizers or toe caps may optionally be placed on the outer surface 1530 of the upper 1500. Alternatively, shaped components such as heel stabilizers or toe caps may optionally be placed on the inner surface 1540 of the upper 1500. It should be understood that the placement of the shaped components, whether on the outer surface 1530 or the inner surface 1540 of the upper 1500, is completed before the application of a protective sleeve, vacuum, or a protective sleeve and vacuum bag as described below.

[0256] In some aspects, during the thermoforming process, the low-processing-temperature polymer composition can melt and flow. In other aspects, restricting the flow of the melted low-processing-temperature polymer composition can be desirable. In such aspects, a protective sleeve can be applied above the upper positioned on the shoe last. For example, as... Figure 18 and Figure 19 As can be seen, the protective sleeve 1800 is positioned above the upper 1500 positioned on the shoe last 1520. In some aspects, the protective sleeve 1800 may be formed of a polymeric material such as a polymer composition with a high processing temperature. In a particular aspect, the protective sleeve 1800 may be made of a material having a melting temperature T greater than 250°C or greater than 300°C. m The protective sleeve 1800 may be formed from an elastomeric polymer material with a low degradation temperature, such as, for example, a silicone polymer. The protective sleeve 1800 may be made of other types of materials, provided that such materials do not deform or melt during the thermoforming process, or otherwise adversely affect the thermoforming of the upper. In various aspects, the protective sleeve 1800 may apply compressive force to the outer surface 1530 of the upper 1500, which may help limit the flow of the molten low-processing-temperature polymer composition. Furthermore, in such aspects, a vacuum may be applied to the combination of the last 1520, the upper 1500 positioned on the last, and the protective sleeve positioned on the upper 1500. For example, a vacuum-sealed bag may be compressed onto the outside of the protective sleeve 1800 to apply compressive force to the protective sleeve 1800, ensuring that the sleeve 1800 is flush-contact with the outer surface 1530 of the upper 1500. Vacuum bags are discussed in more detail below.

[0257] In some aspects, the protective sleeve 1800 can be used to provide patterns or markings on the outer surface of the upper 1500. For example, the inner surface 1810 of the protective sleeve 1800 may include markings or patterns that can be embossed or imprinted on the outer surface 1530 of the upper 1500 during thermoforming processes due to the melting and cooling of the low-processing-temperature polymer composition in the upper 1500 in combination with the compressive force applied to the upper 1500 through the protective sleeve 1800 (and optionally, a vacuum bag). In such aspects, because the protective sleeve 1800 can cover the entire upper 1500, it is possible for the protective sleeve 1800 to emboss or imprint patterns onto any portion of the outer surface 1530 of the upper 1500 containing the low-processing-temperature polymer composition.

[0258] In some respects, the optional use of both protective sleeves and vacuum bags can be desirable. In such respects, the protective sleeve can be applied above the upper positioned on the shoe last. For example, as... Figure 18 and Figure 19 As can be seen, the protective sleeve 1800 is positioned above the upper 1500 positioned on the shoe last 1520. As disclosed above, the protective sleeve 1800 can be made of a material having a melting temperature T greater than 250°C or greater than 300°C. mOr it may be formed from an elastomeric polymer material with a degradation temperature such as, for example, a silicone polymer. Therefore, the protective sleeve 1800 is positioned on the shoe last and inside the vacuum bag 2010. As used herein, the term "vacuum bag" refers to any material that can be compressed onto the outer surface of an object. It should be understood that various methods of applying compressive force to the protective sleeve or vacuum bag, as discussed in this disclosure, can be used to apply compressive force to both the protective sleeve and the vacuum bag used together.

[0259] In some respects, the use of the protective sleeve 1800 alone, and when used in a vacuum, can effectively reduce the number of air bubbles that become trapped in the polymer material at low processing temperatures during the thermoforming process, compared to the same upper that is thermoformed under similar conditions except without the protective sleeve 1800.

[0260] exist Figures 15-19 In the aspects depicted, the shoe last 1520 is formed of a rigid material. Furthermore, in these aspects, when the shoe last 1520 is made of a rigid material, a compressive force applied via the protective sleeve 1800 (and / or vacuum bag) creates a force or pressure difference between the inner surface 1540 and the outer surface 1530 of the upper 1500 (because the rigid shoe last 1520 at least partially resists this compressive force, resulting in the upper 1500 experiencing compressive force). In such aspects, this pressure difference can at least partially provide the environment necessary to restrict the flow of the molten, low-processing-temperature polymer composition, and / or provide embossing or patterning for the outer surface 1530 of the upper 1500.

[0261] In some aspects, when the last 1520 is formed of a rigid material, the upper 1500 can be positioned on the last 1520, and the outer surface 1530 of the upper 1500 (with or without a protective sleeve 1800) can be exposed to pressure above atmospheric pressure to create this pressure difference. In another aspect, the upper 1500 can be positioned on the last 1520, and negative pressure can be applied between the inner surface 1540 of the upper 1500 and the last 1520 to compress the upper 1500 onto the rigid last 1520.

[0262] In various aspects, the pressure difference across the inner surface 1540 and outer surface 1530 of the upper 1500 also helps to form the three-dimensional structure of the footwear during the thermoforming process. That is, in such an aspect, as the polymer composition melts at a low processing temperature, the molten material and the upper 1500 are forced against a rigid last 1520, which, upon cooling, produces an upper 1500 that takes the shape of the last 1520.

[0263] In an alternative aspect, this force or pressure difference between the inner surface 1540 and the outer surface 1530 of the upper 1500 can be achieved in another way. For example, in some aspects, the last 1520 can be an expandable last 1520 that can apply an outward force to the inner surface 1540 of the upper 1500. In such an aspect, to achieve the pressure difference, the outer surface 1530 of the upper 1500 can contact a material that will at least partially resist the outward force applied by the expansion of the last 1520.

[0264] As discussed above, a vacuum bag can be applied to the upper 1500, which is positioned on the last 1520 and may or may not have a protective cover 1800. Figure 20A The image depicts an upper 1500 positioned on a last 1520 inside a vacuum bag 2010. As used herein, the term "vacuum bag" refers to any material that can be compressed onto the outer surface of an object.

[0265] exist Figure 20A In the aspects described herein, the vacuum bag 2010 may include a valve 2012 for reducing the pressure inside the vacuum bag 2010. For example, the pressure between the outer surface 1530 of the upper 1500 (or the outer surface of the protective sleeve 1800 on the upper 1500) and the interior 2014 of the vacuum bag 2010 may be reduced, which will compress the vacuum bag onto the outer surface 1530 of the upper 1500 (or the outer surface of the protective sleeve 1800 on the upper 1500). Figure 20B A vacuum bag 2010 is depicted compressed onto the outer surface 1530 of the upper 1500 (or the outer surface of the protective sleeve 1800 on the upper 1500). As discussed above, compressing the vacuum bag 2010 onto the upper 1500 at least partially provides the above-described description. Figures 15-19 The pressure difference in the discussion.

[0266] Figure 21 The thermoforming system 2100 is described. Figure 21 The thermoforming system 2100 may include an upper 1500 positioned on a shoe last 1520, wherein a vacuum bag 2010 is compressed onto the upper 1500, as described above relative to... Figure 20A and Figure 20B Discussed.

[0267] As discussed above, the thermoforming process includes raising the temperature of a textile material, such as an upper 1500, to a temperature that can cause at least a portion of the low-processing-temperature polymer composition present in the upper 1500 to melt and flow or deform. Furthermore, the thermoforming process includes subsequently lowering the temperature of the upper 1500 to solidify the molten low-processing-temperature polymer composition into a desired shape, such as a footwear article.

[0268] The thermoforming system 2100 includes a heating zone 2110, which can be configured to heat the entire upper 1500. In various respects, the heating zone 2110 heats the entire upper 1500 to a temperature above the melting temperature T of the low-processing-temperature polymer composition present in the upper 1500. m The temperature.

[0269] In all respects, it should be understood that although the heating used in thermoforming has been specifically discussed with regard to its application in the case of shoe upper 1500, this is only an exemplary aspect of heating and thermoforming for the disclosed articles and processes. That is, this disclosure contemplates that any of the disclosed heating methods used to provide heated zones in thermoforming systems and processes can be used to heat any of the disclosed articles comprising a first forming component, a first film, a first textile, a first yarn or a first fiber, and a second forming component, a second film, a second textile, a second yarn or a second fiber positioned on a molding surface, wherein the entire ensemble is at least partially covered with a vacuum bag, a protective sleeve, or a combination of a protective sleeve and a vacuum bag, and then heated to a temperature above the T0 of the polymer composition at a low processing temperature. m The temperature. The first forming component, the first film, the first textile, the first yarn, or the first fiber comprises a low-processing-temperature polymer composition.

[0270] In various respects, heating the entire upper 1500 can provide a more efficient streamlined thermoforming process. For example, because the molding components, films, textiles, fibers and / or yarns containing low-processing-temperature polymer compositions and those containing high-processing-temperature polymer compositions are selected and targeted at specific areas of the upper, it is not necessary to thermoform only a portion of the upper (such as by, for example, masking a portion of the upper or applying heat to only a portion of the upper), since the high-processing-temperature polymer compositions can be resistant to undergoing any deformation or melting under conditions where low-processing-temperature polymer compositions can be thermoformed. However, alternatively, additional thermoforming steps can be performed on the thermoformed articles of this disclosure. For example, one or more surfaces of the thermoformed article can undergo additional thermoforming processes, such as thermally attaching anti-slip studs to the ground-facing surface of a footwear article prepared using the thermoforming process described herein.

[0271] As discussed above, it is desirable that the thermoforming process does not deform or alter the molded parts, films, textiles, fibers, and / or yarns containing the high-processing-temperature polymer composition. In such an aspect, the heating zone 2110 can heat the entire upper 1500 to below the creep relaxation temperature T of the high-processing-temperature polymer composition or the fibers and / or yarns containing the high-processing-temperature polymer composition. cr Heat distortion temperature Thd Or Vicat softening temperature T vs The temperature of at least one of them.

[0272] In one or more aspects, the heating zone 2110 can raise the temperature of the entire upper 1500 to a temperature from about 90°C to about 240°C. In other aspects, the heating zone 2110 can raise the temperature of the entire upper 1500 to a temperature from about 90°C to about 200°C. In one aspect, the heating zone 2110 can raise the temperature of the entire upper 1500 to a temperature from about 110°C to about 180°C.

[0273] In some aspects, the temperature of the entire upper 1500 can rise for approximately 10 seconds to approximately 5 minutes. In other aspects, the temperature of the entire upper 1500 can rise for approximately 30 seconds to approximately 5 minutes. In one aspect, the temperature of the entire upper 1500 can rise for approximately 30 seconds to approximately 3 minutes.

[0274] In one or more aspects, the heating zone 2110 can expose the entire upper 1500 to a temperature ranging from about 90°C to about 240°C. In other aspects, the heating zone 2110 can expose the entire upper 1500 to a temperature ranging from about 90°C to about 200°C. In one aspect, the heating zone 2110 can expose the entire upper 1500 to a temperature ranging from about 110°C to about 180°C.

[0275] In some aspects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the heating zone 2110 discussed above for approximately 10 seconds to approximately 5 minutes. In other aspects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the heating zone 2110 discussed above for approximately 30 seconds to approximately 5 minutes. In one aspect, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the heating zone 2110 discussed above for approximately 30 seconds to approximately 3 minutes.

[0276] In some aspects, the heating zone 2110 can expose the entire upper 1500 to a pressure of about 50 kPa to about 300 kPa. In other aspects, the heating zone 2110 can expose the entire upper 1500 to a pressure of about 50 kPa to about 250 kPa. In one aspect, the heating zone 2110 can expose the entire upper 1500 to a pressure of about 100 kPa to about 300 kPa.

[0277] In some aspects, the entire upper 1500 may be exposed to the heated zone 2110 multiple times in a row under the above conditions prior to undergoing the cooling step. For example, in some aspects, the entire upper 1500 may be exposed to the heated zone 2110 2-10 times in a row under the above conditions prior to undergoing the cooling step. In alternative embodiments, in some aspects, the entire upper 1500 may be exposed to the heated zone 2110 twice in a row under the above conditions prior to undergoing the cooling step.

[0278] In all aspects, after raising the temperature of the entire upper 1500, the temperature of the entire upper 1500 is lowered to below the melting temperature T of the low-processing polymer composition. m The temperature is maintained for a duration sufficient to cure the low-processing-temperature polymer composition. For example, heating zone 2110 can be heated using thermal energy sources, including but not limited to conventional heaters such as convection heating, conventional ovens, air-circulating ovens or forced hot air ovens, steam, targeted microwave heat, ultraviolet radiation, infrared heating, and any combination thereof. The thermal energy sources may also include multiple thermal energy sources, such as multiple similar sources, for example, multiple heating coils or infrared emitters. Alternatively, the multiple thermal energy sources may include multiple one or more different thermal energy sources, such as multiple heating coils and multiple infrared emitters that can be used simultaneously or sequentially, or selectively in a mode in which only one of the multiple thermal energy sources is used at any given time.

[0279] In some aspects, heating can be performed to transfer heat from another material or object to the entire upper 1500. For example, a molded surface such as a shoe last can itself be directly heated, for example, via a configuration as a resistance heating element. In an alternative aspect, the molded surface such as the shoe last can be preheated to a desired temperature immediately before the upper, textile, or article is positioned on it. In the foregoing aspects, the molded surface itself can act as a heating zone for transferring heat to the entire upper.

[0280] In some aspects, heating of the heating zone can be carried out using radio frequency heating, such as microwave radiation, so that the radio frequency heats the composition via the interaction of the radio frequency field with the composition as part of the shoe upper, textile or article, the composition being such as a low-processing-temperature polymer composition.

[0281] Furthermore, in some aspects, the entire upper 1500 can be exposed to the heating zone 2110 by moving the entire upper 1500 into the heating zone 2110, or by moving the heating zone 2110 to the location where the upper 1500 is positioned and then removing it after the heating step. The movement of the upper 1500 and / or the heating zone 2110 can be automated or semi-automated using a conventional conveyance system.

[0282] In some aspects, after heating the entire upper 1500, the entire upper 1500 is cooled to below the melting temperature T of the low-processing polymer composition. m The temperature. In this respect, by moving to the cooling zone 2112 or by moving the cooling zone 2112 to the upper 1500, the entire upper 1500 can be exposed to the reduced temperature in the cooling zone 2112. The cooling zone 2112 can expose the entire upper 1500 to a pressure of approximately 0 kPa.

[0283] In one or more aspects, the entire upper 1500 may be exposed to a temperature of about -25°C to about 25°C when in the cooling zone 2112. In other aspects, the entire upper 1500 may be exposed to a temperature of about -10°C to about 25°C when in the cooling zone 2112. In one aspect, the entire upper 1500 may be exposed to a temperature from about -10°C to about 10°C when in the cooling zone 2112.

[0284] In some aspects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the cooling zone 2112 discussed above for about 10 seconds to about 5 minutes. In other aspects, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the cooling zone 2112 discussed above for about 10 seconds to about 3 minutes. In one aspect, the entire upper 1500 may be exposed to one or more of the temperatures or ranges of the cooling zone 2112 discussed above for about 10 seconds to about 2.5 minutes.

[0285] In some respects, after the upper 1500 has been cooled as described above, the vacuum bag 2010 and protective cover 1800 can be removed. In such respects, any additional components can now be applied to the upper 1500, such as... Figure 14 1410 anti-slip studs for ground bonding.

[0286] Figure 22 An exemplary process 2200 for manufacturing an upper for a shoe is depicted. Process 2200 may include a step 2210 of receiving an upper comprising a first material or first component formed of a low-processing-temperature polymer composition and a second material or second component formed of a high-processing-temperature polymer composition.

[0287] according to Figure 22 In accordance with the exemplary process 2200 of this disclosure, the low-processing-temperature polymer composition can generally be present in the form of fibers (e.g., fibers substantially composed of the low-processing-temperature polymer composition). The low-processing-temperature polymer composition can be present in the received upper in the form of yarns (e.g., yarns containing the low-processing-temperature polymer composition, yarns formed entirely of fibers containing the low-processing-temperature polymer composition, yarns formed partially of fibers containing the low-processing-temperature polymer composition). Additionally or alternatively, the low-processing-temperature polymer composition can be present in the form of fibers that are not part of the yarn structure. For example, fibers can contain the low-processing-temperature polymer composition or can be substantially composed of the low-processing-temperature polymer composition. The low-processing-temperature polymer composition can also be present in the form of textiles (including knitted textiles, braided textiles, woven textiles and non-woven textiles), films, sheets, or molded articles, such as injection-molded articles. The low-processing-temperature polymer composition can also be present in the form of foam materials.

[0288] While certain aspects of this disclosure have been specifically illustrated with respect to footwear articles or uppers, within the scope of this disclosure, the illustrated aspects are generally to be understood as applicable to other disclosed aspects. For example, any of the disclosed low-processing-temperature polymer compositions can be used to form, make, or manufacture molded parts, films, textiles, or other articles, and used in the processes disclosed herein. Similarly, any of the disclosed high-processing-temperature polymer compositions can be used to form, make, or manufacture molded parts, films, textiles, or other articles, and used in the processes disclosed herein. Thus, any such molded part, film, textile, or other article containing a low-processing-temperature polymer composition may optionally be contacted with a molded part, film, textile, or other article containing a high-processing-temperature polymer composition and positioned on a molding surface. In some aspects, the molding surface may be a mold, a form, or a last. Protective sleeves and / or vacuum bags may be positioned on the molding surface to apply compressive forces to the molding surface and to provide a heated zone to the molding surface, as described in this disclosure.

[0289] In some respects, a second material formed from a high-processing-temperature polymer composition can exhibit a higher melting temperature T than that of a low-processing-temperature polymer composition. m creep relaxation temperature T cr Heat distortion temperature T hd Or Vicat softening temperature T vsAt least one of the following. The material formed from the low-processing-temperature polymer composition may include any or all of the properties of the low-processing-temperature polymer composition described above. The second material formed from the high-processing-temperature polymer composition may include any or all of the properties of the high-processing-temperature polymer composition described above. The second material formed from the high-processing-temperature polymer composition may be in the form of fibers (e.g., fibers composed substantially of the high-processing-temperature polymer composition). The high-processing-temperature polymer composition may be in the received upper in the form of yarns (e.g., yarns containing the high-processing-temperature polymer composition, yarns formed entirely of fibers containing the high-processing-temperature polymer composition, yarns formed partially of fibers containing the high-processing-temperature polymer composition). Additionally or alternatively, the high-processing-temperature polymer composition may be in the form of fibers that are not part of the yarn structure. For example, fibers may contain the high-processing-temperature polymer composition or may be composed substantially of the high-processing-temperature polymer composition. The high-processing-temperature polymer composition may also be in the form of textiles (including knitted textiles, braided textiles, woven textiles and non-woven textiles), films, sheets or molded articles such as injection-molded articles. The high-processing-temperature polymer composition may also be in the form of foam materials. In some respects, the upper may include the above references. Figures 15-21 The shoe upper 1500 may contain any or all of the characteristics described. Furthermore, the shoe upper may use any of the textiles described above, such as... Figure 3 The textiles are made from 300 pieces.

[0290] While the low-processing-temperature polymer composition and the high-processing-temperature polymer composition may exist as separate materials or components of the received upper (e.g., in separate fibers, yarns, textiles, films, etc.), they may also exist in the same component (e.g., yarns comprising fibers formed from the low-processing-temperature polymer composition and separate fibers formed from the high-processing-temperature polymer composition; textiles comprising yarns formed from the low-processing-temperature polymer composition and separate yarns formed from the high-processing-temperature polymer composition). In other words, in the received upper, the low-processing-temperature polymer composition and the high-processing-temperature polymer composition exist in separate materials or components that are at least different from each other at the fiber level.

[0291] In one or more aspects, in the first portion of the upper, when the upper comprises a knitted textile having a first yarn comprising a low-processing-temperature polymer composition and a second yarn comprising a high-processing-temperature polymer composition, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, such as Figure 6 , Figure 7A or Figure 9A The image depicts multiple interconnected coils.

[0292] In step 2220 of process 2200, the shoe upper is placed on the shoe last, such as... Figures 15-17 The shoe last depicted in the image. In various aspects, the shoe last can be formed of a rigid material or it can be an expandable shoe last. Furthermore, as described above, the upper may have a sole plate, heel stabilizer, or other components inserted into the upper before being placed on the shoe last.

[0293] In step 2230 of process 2200, when the entire upper is on the shoe last, the temperature of the entire upper is raised, for example, to a temperature higher than the melting temperature T of the first yarn composition. m And below the creep relaxation temperature T of the second yarn composition. cr Heat distortion temperature T hd Or Vicat softening temperature T vs At least one of the temperatures mentioned above. In all aspects, the entire upper can use the temperature described above. Figure 21 The described thermoforming system 2100 is used for heating. The shoe upper can use the above-mentioned... Figure 21 The thermoforming system is heated by any one or all of the parameters described.

[0294] In step 2240 of process 2200, after heating, while the upper is held on the last, the temperature of the entire upper is reduced to below the melting temperature T of the low-processing-temperature polymer composition. m The temperature. For example, when the entire upper is on the last, the entire upper can be cooled to form a thermoformed upper. In various aspects, the entire upper can use the methods described above regarding... Figure 21 The described thermoforming system 2100 is used for cooling. The upper can use the above-mentioned... Figure 21 The thermoforming system is cooled by any or all of the parameters described.

[0295] When the first material or first component containing the low-processing-temperature polymer composition has been deformed and its original structure has been modified or has melted and solidified into a new physical structure, after the received upper is thermoformed, because thermoforming is performed at or above the melting temperature T of the low-processing-temperature polymer composition... m However, it is lower than the creep relaxation temperature T of the high-processing-temperature polymer composition. cr Or heat distortion temperature T hd Or Vicat softening temperature T vs The process is carried out at high temperatures, so the second material or component (fiber, yarn, textile, sheet, molded article, etc.) containing the polymer composition at high processing temperatures retains its original physical structure (e.g., as fiber, yarn, textile, etc.).

[0296] Figure 23An exemplary process 2300 for manufacturing an upper for a shoe is depicted. Process 2300 may include a step 2310 of receiving an upper comprising a first yarn and a second yarn, wherein the first yarn comprises a low-processing-temperature polymer composition and the second yarn comprises a high-processing-temperature polymer composition. The low-processing-temperature polymer composition may comprise one or more first thermoplastic polymers, and the high-processing-temperature polymer composition may comprise one or more second thermoplastic polymers. In various aspects, the first and second thermoplastic polymers may comprise any or all of the parameters discussed above regarding thermoplastic polymers. In some aspects, the upper may include the parameters referenced above. Figures 15-21 The characteristics of the described upper 1500 may be any or all of the following. Furthermore, the upper may use any of the textiles described above, such as... Figure 3 The textiles are made from 300 pieces.

[0297] In some respects, high-processing-temperature polymer compositions can exhibit a higher melting temperature T than low-processing-temperature polymer compositions. m creep relaxation temperature T cr Heat distortion temperature T hd Or Vicat softening temperature T vs At least one of the following. The low processing temperature polymer composition may include any or all of the properties of the low processing temperature polymer compositions described above. The high processing temperature polymer composition may include any or all of the properties of the high processing temperature polymer compositions described above. Furthermore, the first yarn and the second yarn may exhibit any or all of the properties and parameters discussed above.

[0298] In one or more aspects, in the first part of the shoe upper, at least one of the first yarn and the second yarn forms a plurality of interconnected loops, such as Figure 6 , Figure 7A or Figure 9A The image depicts multiple interconnected coils.

[0299] In step 2320 of process 2300, the shoe upper is placed on the shoe last, such as... Figures 15-17 The shoe last depicted in the image. In various aspects, the shoe last can be formed of a rigid material or it can be an expandable shoe last. Furthermore, as described above, the upper may have a sole plate, heel stabilizer, or other components inserted into the upper before being placed on the shoe last.

[0300] In step 2330 of process 2300, when the entire upper is on the last, the entire upper is heated to a temperature higher than the melting temperature T of the polymer composition at the low processing temperature. m And below the creep relaxation temperature T of the high-processing-temperature polymer composition. cr Heat distortion temperature T hdOr Vicat softening temperature T vs At least one of the temperatures mentioned above. In all aspects, the entire upper can use the temperature described above. Figure 21 The described thermoforming system 2100 is used for heating. The shoe upper can use the above-mentioned... Figure 21 The thermoforming system is heated by any one or all of the parameters described.

[0301] In step 2340 of process 2300, after heating the entire upper, while the entire upper is on the last, it is cooled to form a thermoformed upper. In various aspects, the entire upper can use the methods described above... Figure 21 The described thermoforming system 2100 is used for cooling. The upper can use the above-mentioned... Figure 21 The thermoforming system is cooled by any or all of the parameters described.

[0302] Figure 24 A process 2400 for manufacturing an upper for footwear is described. Process 2400 may include a step 2410 of receiving the upper, which comprises one or more first fibers and one or more second fibers. The one or more first fibers may comprise a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers. The low-processing-temperature polymer composition may have any or all of the properties discussed above regarding low-processing-temperature polymer compositions. The one or more second fibers comprise a high-processing-temperature polymer composition comprising one or more second thermoplastic polymers. The high-processing-temperature polymer composition may have any or all of the properties discussed above regarding high-processing-temperature polymer compositions. In various aspects, the first thermoplastic polymer and the second thermoplastic polymer may comprise any or all of the parameters discussed above regarding thermoplastic polymers. Furthermore, in various aspects, the first fiber and the second fiber may comprise any or all of the properties discussed above regarding fibers.

[0303] In one aspect, the high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition containing one or more first fibers. m creep relaxation temperature T cr Heat distortion temperature T hd Or Vicat softening temperature T vs At least one of them.

[0304] In some aspects, the upper may include a ground-facing outsole area, wherein at least a portion of the first fiber is present in the ground-facing outsole area.

[0305] Process 2400 may include step 2420 of placing the upper on a last such that at least a portion of the ground-facing outsole area covers at least the bottom portion of the last, such as... Figures 15-17 The bottom portion is depicted in the image. In various aspects, the last can be formed of a rigid material or it can be an expandable last. Furthermore, as described above, the upper can have a sole plate and / or heel stabilizer inserted into the upper before being placed on the last.

[0306] Process 2400 may also include heating the entire upper to a temperature above the melting temperature T of the polymer composition at the low processing temperature while it is on the last. m And below the creep relaxation temperature T of the high-processing-temperature polymer composition. cr Heat distortion temperature T hd Or Vicat softening temperature T vs Step 2430 involves at least one of the temperatures described above. In various aspects, the entire upper can utilize the temperature described above. Figure 21 The described thermoforming system 2100 is used for heating. The shoe upper can use the above-mentioned... Figure 21 The thermoforming system is heated by any one or all of the parameters described.

[0307] In step 2440 of process 2400, after heating the entire upper, while the entire upper is on the last, it is cooled to form a thermoformed upper. In various aspects, the entire upper can use the methods described above... Figure 21 The described thermoforming system 2100 is used for cooling. The upper can use the above-mentioned... Figure 21 The thermoforming system is cooled by any or all of the parameters described.

[0308] Figure 25 A process 2500 for manufacturing a knitted upper for footwear articles is described. Process 2500 includes a step 2510 for knitting a first row, the first row comprising loops of a first yarn and loops of a second yarn. In various aspects, the first yarn comprises a low-processing-temperature polymer composition, and the second yarn comprises a high-processing-temperature polymer composition. The low-processing-temperature polymer composition may comprise one or more first thermoplastic polymers, and the high-processing-temperature polymer composition may comprise one or more second thermoplastic polymers. In various aspects, the first and second thermoplastic polymers may include any or all of the parameters discussed above regarding thermoplastic polymers. In some aspects, the upper may include the parameters referenced above. Figures 15-21 The characteristics of the described upper 1500 are any or all of them.

[0309] In some respects, high-processing-temperature polymer compositions can exhibit a higher melting temperature T than low-processing-temperature polymer compositions. m creep relaxation temperature T cr Heat distortion temperature T hd Or Vicat softening temperature T vsAt least one of the following. The low processing temperature polymer composition may include any or all of the properties of the low processing temperature polymer compositions described above. The high processing temperature polymer composition may include any or all of the properties of the high processing temperature polymer compositions described above. Furthermore, the first yarn and the second yarn may exhibit any or all of the properties and parameters discussed above.

[0310] Process 2500 may further include a step 2520 of knitting a second row, the second row comprising loops of a first yarn and loops of a second yarn. In various aspects, the first and second rows can be knitted using any commercial knitting technique as described above. In various aspects, at least a portion of the first and second rows forms a plurality of interconnected loops, such as... Figure 6 Interconnected coils are depicted in the image.

[0311] Figure 26 A process 2600 for forming a knitted article is described. Process 2600 may include step 2610 of knitting a first row comprising loops of a first yarn and a second yarn. In various aspects, the first yarn comprises a low-processing-temperature polymer composition, and the second yarn comprises a high-processing-temperature polymer composition. The low-processing-temperature polymer composition may comprise one or more first thermoplastic polymers, and the high-processing-temperature polymer composition may comprise one or more second thermoplastic polymers. In various aspects, the first thermoplastic polymer and the second thermoplastic polymer may comprise any or all of the parameters discussed above regarding thermoplastic polymers.

[0312] In some respects, high-processing-temperature polymer compositions can exhibit a higher melting temperature T than low-processing-temperature polymer compositions. m creep relaxation temperature T cr Heat distortion temperature T hd Or Vicat softening temperature T vs At least one of the following. The low processing temperature polymer composition may include any or all of the properties of the low processing temperature polymer compositions described above. The high processing temperature polymer composition may include any or all of the properties of the high processing temperature polymer compositions described above. Furthermore, the first yarn and the second yarn may exhibit any or all of the properties and parameters discussed above.

[0313] Step 2620 of process 2600 includes knitting an anchoring yarn into one or more loops of a first yarn present in a first row of loops. The anchoring yarn comprises an anchoring yarn composition, wherein the anchoring yarn composition comprises one or more polymers. The anchoring yarn composition exhibits an elongation less than that of a polymer composition at a low processing temperature. In various aspects, the anchoring yarn may have the characteristics described above. Figure 4B , Figure 4E , Figure 10A and Figure 10B The properties of the anchoring yarns discussed are any one or all of them.

[0314] In this aspect, the first row of loops may exist on the outer surface of the knitted upper. In this aspect, the outer surface of the knitted upper may include a first zone, a second zone, and a third zone, wherein the second zone is located between the first and third zones. Furthermore, in this aspect, the third zone has a first yarn with increased density compared to the second zone. The first, second, and third zones may each include the elements referenced above. Figure 3 The textiles 300 discuss any or all of the characteristics of textiles in areas 306a, 304a and 302.

[0315] Figure 27 A process 2700 for manufacturing an upper for footwear articles is described. Step 2710 of process 2700 includes forming a ground-facing outsole region comprising a first group of one or more first fibers. In such an aspect, the one or more first fibers may comprise a low-processing-temperature polymer composition comprising one or more first thermoplastic polymers.

[0316] Process 2700 may include step 2720 of forming a second region, the second region comprising one or more second fibers and a second group of one or more first fibers. In such an aspect, the one or more second fibers comprise a high-processing-temperature polymer composition containing one or more second thermoplastic fibers. The high-processing-temperature polymer composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition containing one or more first fibers. m creep relaxation temperature T cr Heat distortion temperature T hd Or Vicat softening temperature T vs At least one of the following. The first fiber and the second fiber, the low-processing-temperature polymer composition and the high-processing-temperature polymer composition, as well as the first thermoplastic polymer and the second thermoplastic polymer, may include any or all of the corresponding properties discussed above.

[0317] Textiles, yarns and fibers

[0318] As discussed above, the fibers, yarns, textiles, films, and forming components described herein may include the selective incorporation of low-processing-temperature polymer compositions and / or the selective incorporation of high-processing-temperature polymer compositions. In various aspects, such low-processing-temperature polymer compositions may be present in the form of fibers comprising low-processing-temperature polymer compositions. In some aspects, the fibers comprising low-processing-temperature polymer compositions are substantially free of high-processing-temperature polymer compositions. In other aspects, the fibers comprising low-processing-temperature polymer compositions are substantially composed of low-processing-temperature polymer compositions. According to this disclosure, these fibers can be used to form yarns, which in turn can be used to form textiles, including knitted textiles, woven textiles, or braided textiles. According to this disclosure, these fibers can also be used to form non-woven textiles.

[0319] Similarly, the high-processing-temperature polymer compositions described above can exist in the form of fibers comprising the high-processing-temperature polymer compositions. In some aspects, the fibers comprising the high-processing-temperature polymer compositions are substantially free of the low-processing-temperature polymer compositions. In other aspects, the fibers comprising the high-processing-temperature polymer compositions are substantially composed of the high-processing-temperature polymer compositions. According to this disclosure, these fibers can be used to form yarns, which in turn can be used to form textiles, including knitted textiles, woven textiles, or braided textiles. According to this disclosure, these fibers can also be used to form non-woven textiles.

[0320] In some aspects, fibers and / or yarns comprising low-processing-temperature polymer compositions may also comprise high-processing-temperature polymer compositions. For example, the fiber may be a bicomponent fiber having a low-processing-temperature polymer composition present on at least a portion of the outer surface of the fiber. For example, the low-processing-temperature polymer composition and the high-processing-temperature polymer composition may have a side-by-side structure or a core-and-sheath structure, wherein the low-processing-temperature polymer composition is present within a sheath. In some aspects, the low-processing-temperature polymer composition, the high-processing-temperature polymer composition, or both may also include one or more conventional additives found in yarns or fibers comprising polymeric materials. While the foregoing may describe only the properties and parameters of yarns or yarn compositions, it should be understood that such properties and parameters also apply to fibers or fiber compositions, unless otherwise specified.

[0321] In some aspects, one or more types of yarn may be monofilament yarn or multifilament yarn. In some aspects, yarn may be spun. In all aspects, one or more types of yarn may be formed using conventional techniques, including but not limited to melt spinning, solution spinning, or electrospinning.

[0322] In some respects, the fibers described herein can be fibers of different sizes, including fibers unsuitable for spinning into commercial yarns. The yarns described herein include yarns suitable for use in commercial knitting machines, as well as individual yarns unsuitable for use in commercial knitting machines.

[0323] In some aspects, the yarns and / or fibers described herein can be used to provide specific functionalities. For example, in some aspects, yarns comprising a low-processing-temperature polymer composition can be thermoformed to form a membrane with waterproof or water-resistant properties. In such aspects, a membrane on the outer surface of an article can be provided using yarns and / or fibers comprising a low-processing-temperature polymer material on the outer portion of a textile (including the knitted structure forming the textile).

[0324] As discussed above, in some aspects, one or more of the yarns and / or fibers may be dyed, for example, for aesthetic purposes. In various aspects, the yarns and / or fibers may be dyed using conventional dyeing techniques such as package dyeing or solution dyeing. Typically, package dyeing is a process performed on already formed yarns and / or fibers, while solution dyeing dyes the fibers before they are formed into yarns. In some aspects, yarns or fibers comprising high-processing-temperature polymer compositions may be dyed. In some aspects, yarns or fibers comprising low-processing-temperature polymer compositions are not dyed and may be formed from polymer compositions that are substantially free of pigments or dyes, which can produce areas that are clear or nearly transparent containing the low-processing-temperature polymer composition (e.g., non-yarn or non-fiber materials after thermoforming).

[0325] In some aspects, yarns comprising low-processing-temperature polymer compositions may exhibit a tenacity from about 1 g / denier to about 5 g / denier. In one or more aspects, yarns comprising low-processing-temperature polymer compositions may exhibit a tenacity from about 1.5 g / denier to about 4.5 g / denier. In one aspect, yarns comprising low-processing-temperature polymer compositions may exhibit a tenacity from about 2 g / denier to about 4.5 g / denier. As used herein, “tenacity” refers to a property of the fiber or yarn and is determined using the appropriate test methods and sampling procedures described below in the Property Analysis and Characterization Procedures section.

[0326] In various aspects, yarns comprising a low-processing-temperature polymer composition may exhibit an elongation from about 10% to about 130%. In one or more aspects, yarns comprising a low-processing-temperature polymer composition may exhibit an elongation from about 20% to about 130%. In one aspect, yarns comprising a low-processing-temperature polymer composition may exhibit an elongation from about 40% to about 130%. As used herein, the term "elongation" refers to a property of the fiber or yarn and is determined using the appropriate test methods described below in the Properties Analysis and Characterization Procedures section.

[0327] As discussed above, in some aspects, it may be desirable to utilize yarns suitable for use on commercial knitting equipment. The free-standing shrinkage of a yarn at 50°C is a predictable characteristic for suitable yarns used on commercial knitting machines. In some aspects, yarns comprising a low-processing-temperature polymer composition may exhibit a free-standing shrinkage from about 0% to about 60% when heated from 20°C to 50°C. In one or more aspects, yarns comprising a low-processing-temperature polymer composition may exhibit a free-standing shrinkage from about 0% to about 30% when heated from 20°C to 50°C. In one aspect, yarns comprising a low-processing-temperature polymer composition may exhibit a free-standing shrinkage from about 0% to about 20% when heated from 20°C to 50°C. The term "free-standing shrinkage" as used herein refers to a fiber characteristic and is determined using the corresponding test methods described below in the Characterization and Characterization Procedures section.

[0328] In one or more aspects, the unsupported shrinkage rate of a yarn at 70°C can be a useful indicator of the yarn's ability to be exposed to certain environmental conditions without any significant change in the yarn's physical structure. In some aspects, yarns comprising a low-processing-temperature polymer composition may exhibit an unsupported shrinkage rate from about 0% to about 60% when heated from 20°C to 70°C. In one or more aspects, yarns comprising a low-processing-temperature polymer composition may exhibit an unsupported shrinkage rate from about 0% to about 30% when heated from 20°C to 70°C. In one aspect, yarns comprising a low-processing-temperature polymer composition may exhibit an unsupported shrinkage rate from about 0% to about 20% when heated from 20°C to 70°C.

[0329] In one or more aspects, yarns comprising low-processing-temperature polymer compositions can exhibit a modulus from about 1 MPa to about 500 MPa. In some aspects, yarns comprising low-processing-temperature polymer compositions can exhibit a modulus from about 5 MPa to about 150 MPa. In one aspect, yarns comprising low-processing-temperature polymer compositions can exhibit a modulus from about 20 MPa to about 130 MPa. In another aspect, yarns comprising low-processing-temperature polymer compositions can exhibit a modulus from about 30 MPa to about 120 MPa. In yet another aspect, yarns comprising low-processing-temperature polymer compositions can exhibit a modulus from about 40 MPa to about 110 MPa. As used herein, the term "modulus" refers to the corresponding test method described below in the Characterization and Properties section.

[0330] In one or more aspects, when present in the form of a decorative panel, the low-processing-temperature polymer composition can exhibit a modulus from about 1 MPa to about 500 MPa. In some aspects, in the form of a decorative panel, the low-processing-temperature polymer composition can exhibit a modulus from about 5 MPa to about 150 MPa. In one aspect, in the form of a decorative panel, the low-processing-temperature polymer composition can exhibit a modulus from about 20 MPa to about 130 MPa. In another aspect, in the form of a decorative panel, the low-processing-temperature polymer composition can exhibit a modulus from about 30 MPa to about 120 MPa. In yet another aspect, in the form of a decorative panel, the low-processing-temperature polymer composition can exhibit a modulus from about 40 MPa to about 110 MPa.

[0331] In one or more aspects, when the yarn comprising the low-processing-temperature polymer composition is brought to a melting temperature T higher than that of the low-processing-temperature polymer composition... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 1 MPa to approximately 500 MPa when pressure tested. In various aspects, when yarns comprising a low-processing-temperature polymer composition are brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 5 MPa to approximately 150 MPa when pressure tested. In one or more aspects, the yarn comprising the low-processing-temperature polymer composition is made to reach a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. mThe temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures where pressure tests are conducted at approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 20 MPa to approximately 130 MPa. In one or more aspects, the yarn comprising the low-processing-temperature polymer composition is brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures where pressure tests are conducted at approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 30 MPa to approximately 120 MPa. In one or more aspects, the yarn comprising the low-processing-temperature polymer composition is brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and pressures of 1 atmosphere, the resulting thermoformed materials (e.g., molten yarn components) can exhibit moduli ranging from approximately 40 MPa to approximately 110 MPa.

[0332] In all aspects, when yarns containing low-processing-temperature polymer compositions are present in textiles and have reached a melting temperature T higher than that of the low-processing-temperature polymer compositions... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (or molten yarn component) exhibits cold Ross flex from approximately 5,000 cycles to approximately 500,000 cycles during pressure testing. In one or more aspects, when the yarn containing the low-processing-temperature polymer composition is present in the textile and has reached a temperature above the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (or molten yarn component) exhibits cold Ross flexural deformation ranging from approximately 10,000 cycles to approximately 300,000 cycles during pressure testing. In some aspects, when yarns containing a low-processing-temperature polymer composition are present in textiles and have reached a temperature above the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. mAt temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (or molten yarn component) exhibits cold Ross flexure of at least approximately 150,000 cycles when tested under pressure. As used herein, the term "cold Ross flexure" refers to the corresponding test method described below in the Characterization and Properties section.

[0333] In some aspects, as discussed in detail below, anchoring yarns can be used to help limit the flow of molten materials, such as low-processing-temperature polymer compositions, during thermoforming processes, and / or to impart a certain degree of flexibility to thermoformed materials. In such aspects, anchoring yarns can exhibit an elongation less than that of low-processing-temperature polymer compositions, such as yarns containing low-processing-temperature polymer compositions or molten yarn parts produced by thermoforming such yarns. For example, in some aspects, anchoring yarns can exhibit an elongation at least about 10% less than that of yarns containing low-processing-temperature polymer compositions or molten yarn parts produced by thermoforming yarns containing low-processing-temperature polymer compositions. In one aspect, anchoring yarns can exhibit an elongation at least about 25% less than that of yarns containing low-processing-temperature polymer compositions or molten yarn parts produced by thermoforming yarns containing low-processing-temperature polymer compositions. In another aspect, the anchoring yarn may exhibit an elongation at least about 50% less than that of a yarn comprising a low-processing-temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising a low-processing-temperature polymer composition. In yet another aspect, the anchoring yarn may exhibit an elongation at least about 75% less than that of a yarn comprising a low-processing-temperature polymer composition or a molten yarn component produced by thermoforming a yarn comprising a low-processing-temperature polymer composition. Exemplary anchoring yarns include polyamide yarns, polyolefin yarns, and polyester yarns, including yarns having a toughness from about 5 g / denier to about 10 g / denier.

[0334] Anchoring yarns can be formed from high-processing-temperature polymer compositions comprising one or more polymers. One or more polymers in the high-processing-temperature polymer composition of the anchoring yarn can be thermoplastic polymers. In some aspects, one or more polymers in the high-processing-temperature polymer composition of the anchoring yarn can be the same as one or more polymers in the high-processing-temperature polymer composition forming a second yarn used in textiles comprising the anchoring yarn. In other aspects, one or more polymers in the high-processing-temperature polymer composition of the anchoring yarn are different from one or more polymers in the high-processing-temperature polymer composition forming a second yarn used in textiles comprising the anchoring yarn.

[0335] As discussed above, low-processing-temperature polymer compositions and high-processing-temperature polymer compositions possess different properties in certain aspects. In various aspects, when thermoforming processes are performed at temperatures below the creep relaxation temperature, heat distortion temperature, or Vicat softening temperature of the high-processing-temperature polymer composition, these different properties allow the low-processing-temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from that prior to the thermoforming process (e.g., thermoforming a yarn into a molten yarn component), while the high-processing-temperature polymer composition cannot deform or melt during such a process and can retain its structure (e.g., as a yarn). In such aspects, the molten yarn component formed by the low-processing-temperature polymer composition during the thermoforming process can be integrally connected to an unchanged structure (e.g., yarn or fiber), which can provide a three-dimensional structure and / or other properties for specific spots on a wearable article.

[0336] In each aspect, one or more of the disclosed yarns may be coated yarns. In another aspect, the coated yarn may be any suitable yarn on which a coating layer comprising a thermoplastic coating composition has been formed.

[0337] In some aspects, the thermoplastic coating composition comprises a low-processing-temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a low-processing-temperature polymer composition including thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a low-processing-temperature polymer composition including thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0338] In some aspects, the thermoplastic coating composition comprises a high-processing-temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a high-processing-temperature polymer composition including thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a high-processing-temperature polymer composition including thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0339] In some aspects, the covered yarn can be a monofilament yarn or a multifilament yarn. The yarn can be based on natural or man-made fibers, including polyester yarn, high-tenacity polyester yarn, polyamide yarn, metallic yarn, drawn yarn, carbon yarn, glass yarn, polyethylene yarn or polyolefin yarn, bicomponent yarn, PTFE yarn, ultra-high molecular weight polyethylene (UHMWPE) yarn, liquid crystal polymer yarn, specialty decorative yarn or reflective yarn, or multicomponent yarn including one or more of the aforementioned yarns.

[0340] In some aspects, the thermoplastic coating composition includes TPU. In some aspects, the TPU can be any such material as described in this disclosure, such as a TPU prepared by polymerizing an aromatic or aliphatic isocyanate with a polyether polyol or polycaprolactone using a short-chain ethylene glycol (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of the disclosed TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0341] In various aspects, the thermoplastic coating composition may also contain additives, such as, but not limited to, one or more of thickeners, processing aids, dyes, or colorants. In another aspect, additives are not optional and include at least one thickener. In yet another aspect, additives are not optional and include at least one processing aid. In yet another aspect, additives are not optional and include at least one thickener and at least one processing aid. In some aspects, the thickener may include inorganic materials such as silica, talc, or calcium carbonate (CaCO3).

[0342] In some aspects, as described herein, thickeners can be used during the preparation of thermoplastic coating compositions to improve productivity and matting properties. In other aspects, the thickener is silica powder, talc, or CaCO3. The thickener is used at least in part to increase the viscosity of the thermoplastic coating composition. In yet another aspect, the thickener used in the disclosed thermoplastic coating compositions can be an alloy of resins capable of imparting compatibility with thermoplastic polyurethanes, such as styrene-butadiene-styrene (SBS) block copolymers, styrene-ethylene / butene-styrene (SEBS) resins, polyacetal resins (POM), or styrene-acrylonitrile resins (SAN).

[0343] In some aspects, the thermoplastic coating composition may include a processing agent to improve productivity. In other aspects, the processing agent may be montan wax or a fatty acid ester (C5-C9) with pentaerythritol. Other processing agents are known to those skilled in the art and may also be used in the disclosed thermoplastic compositions. An exemplary commercially available processing aid is ESTANE58277 (Lubrizol).

[0344] In some aspects, coated yarns with a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound used for the coated yarn. In other aspects, TPU compounds with a desired stiffness for the coated yarn can be prepared by controlling the content of raw materials. In yet another aspect, the thickness of the coated yarn can be reduced depending on the thickness of the yarn made of polyester, nylon, spandex, or the like.

[0345] In some aspects, the coated yarn can be prepared by compounding a thermoplastic polymer, such as thermoplastic polyurethane, and optionally one or more additives in a conventional extruder, and then coating the compounded thermoplastic polyurethane coating composition onto the surface of the yarn. In other aspects, the process for preparing the coated yarn includes the steps of: 1) preparing shaped thermoplastic microspheres; and 2) producing the coated yarn. The shaped thermoplastic microspheres can be prepared by the methods disclosed herein, by similar methods known to those skilled in the art, or obtained from commercially available sources.

[0346] The steps for preparing shaped thermoplastic microspheres may include the following: 1) mixing a thermoplastic polymer with various additives such as thickeners and / or processing aids, and feeding the mixture into the hopper of a conventional compound extruder; 2) melting, kneading and compounding the mixture in the cylinder of the compound extruder at a suitable temperature and pressure; 3) cutting the compounded thermoplastic coating composition discharged through the core of the compound extruder in cooling water to form microspheres; and 4) drying the shaped thermoplastic polyurethane microspheres at a suitable temperature for a certain period of time, and aging the dried microspheres at a suitable temperature for a suitable period of time.

[0347] In a particular embodiment, the steps for preparing the shaped thermoplastic microspheres include at least the following steps: 1) mixing thermoplastic polyurethane with various additives such as thickeners and / or processing aids, and feeding the mixture into the hopper of a conventional compound extruder; 2) melting, kneading and compounding the mixture in the cylinder of the compound extruder at a temperature of about 150°C to 250°C and a pressure of about 50 kgf to 150 kgf; 3) cutting the compounded thermoplastic polyurethane discharged through the core of the compound extruder in cooling water to form microspheres; and 4) drying the shaped thermoplastic polyurethane microspheres at a temperature of 60°C to 80°C for about 4 to 6 hours, and aging the dried microspheres at a temperature of 30°C to 50°C for about 7 days or more.

[0348] In some aspects, the steps of producing the coated yarn may include the following steps: 1) mixing shaped thermoplastic polymer spheres prepared as described above with a masterbatch corresponding to the desired color, and feeding the mixture into the hopper of a yarn coating extruder; 2) melting the mixture of shaped thermoplastic polymer spheres and masterbatch in the cylinder of the yarn coating extruder at a suitable temperature and a suitable pressure; 3) coating the composite thermoplastic polymer and masterbatch onto the surface of the yarn passing through the nipple and the core to produce the coated yarn; and 4) winding the coated yarn around a spool using a winding machine.

[0349] Specifically, the steps for producing the coated yarn may include the following: 1) mixing shaped thermoplastic polyurethane spheres with a masterbatch corresponding to the desired color and feeding the mixture into the hopper of a yarn coating extruder; 2) melting the mixture of shaped thermoplastic polyurethane spheres and masterbatch in the cylinder of the yarn coating extruder at a temperature of about 150°C to 250°C and a pressure of about 50 kgf to 150 kgf; 3) coating the composite TPU and masterbatch onto the surface of the yarn (made of polyester, nylon, spandex, or the like) passing through the tube and core to produce the coated yarn; and 4) winding the coated yarn around a spool using a winding machine.

[0350] An exemplary, non-limiting example of a suitable commercially available coated yarn is Dream-Sil, a TPU-coated yarn available from Sambu Fine Chemicals (Korea).

[0351] As discussed above, anchoring yarns can be used to help limit the flow of molten materials, such as low-processing-temperature polymer compositions, during thermoforming processes, and / or to impart a certain degree of flexibility to thermoformed materials. In such an aspect, the anchoring yarn may not melt or deform during the thermoforming process. Therefore, in some aspects, the anchoring yarn may include an anchoring yarn composition comprising one or more third thermoplastic polymers, such that the anchoring yarn composition exhibits a melting temperature T greater than that of the low-processing-temperature polymer composition. m creep relaxation temperature T cr Vicat softening temperature T vs Heat distortion temperature T hd Or melting temperature T m At least one of the following. In some aspects, the anchoring yarn composition may have a specific range associated with these properties discussed above with respect to high processing temperature polymer compositions. In some aspects, the anchoring yarn may be formed from a high processing temperature polymer composition, and therefore may include any thermoplastic polymer discussed above with reference to high processing temperature polymer compositions.

[0352] In all aspects, when according to the AS T described below m When D3418-97 is determined, the fibers or yarns comprising the low-processing-temperature polymer composition contain a melting temperature (T) having a melting temperature from about 90°C to about 120°C. m Polyamides or poly(ether-block-amides). In another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a melting temperature (T) from about 93°C to about 99°C. m In yet another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a melting temperature (T) from about 112°C to about 118°C. m In some respects, when according to the AS T described below m When determined according to D3418-97, the polyamide or poly(ether-block-amide) has a melting temperature of about 90°C, about 91°C, about 92°C, about 93°C, about 94°C, about 95°C, about 96°C, about 97°C, about 98°C, about 99°C, about 100°C, about 101°C, about 102°C, about 103°C, about 104°C, about 105°C, about 106°C, about 107°C, about 108°C, about 109°C, about 110°C, about 111°C, about 112°C, about 113°C, about 114°C, about 115°C, about 116°C, about 117°C, about 118°C, about 119°C, about 120°C, or a melting temperature (T) covered by any of the foregoing values.m Any range of values ​​or the aforementioned melting temperature (T) m Any combination of values.

[0353] In all aspects, when according to the AS T described below m When D3418-97 is determined, fibers or yarns comprising low-processing-temperature polymer compositions contain a glass transition temperature (T0) ranging from about -20°C to about 30°C. g Polyamides or poly(ether-block-amides). In another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a glass transition temperature (T0) from about -13°C to about -7°C. g In yet another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a glass transition temperature (T0) from about 17°C to about 23°C. g In some respects, when according to the AS T described below m When determined according to D3418-97, polyamides or poly(ether-block-amides) have glass transition temperatures (Tg) of about -20°C, about -19°C, about -18°C, about -17°C, about -16°C, about -15°C, about -14°C, about -13°C, about -12°C, about -10°C, about -9°C, about -8°C, about -7°C, about -6°C, about -5°C, about -4°C, about -3°C, about -2°C, about -1°C, about 0°C, about 1°C, about 2°C, about 3°C, about 4°C, about 5°C, about 6°C, about 7°C, about 8°C, about 9°C, about 10°C, about 11°C, about 12°C, about 13°C, about 14°C, about 15°C, about 16°C, about 17°C, about 18°C, about 19°C, and about 20°C. g ( ), any range of glass transition temperature values ​​covered by any of the foregoing values, or any combination of the foregoing glass transition temperature values.

[0354] In all aspects, when according to the AS T described below m When D1238-13 was tested at 160°C with a weight of 2.16 kg, the fibers or yarns containing the low-processing-temperature polymer composition contained fibers or yarns with a thickness of approximately 10 cm. 3 / 10min to approximately 30cm 3 Polyamides or poly(ether-block-amides) with a melt flow index of / 10 min. In another aspect, when according to the AS T described below. m When D1238-13 was tested at 160°C with a weight of 2.16 kg, the polyamide or poly(ether-block-amide) exhibited a temperature range of approximately 22 cm⁻¹.3 / 10min to approximately 28cm 3 Melt flow index per 10 min. In some respects, when according to the AST described below... m When D1238-13 is determined at 160°C using a weight of 2.16 kg, the polyamide or poly(ether-block-amide) has approximately 10 cm⁻¹. 3 / 10min, approximately 11cm 3 / 10min, approximately 12cm 3 / 10min, approximately 13cm 3 / 10min, approximately 14cm 3 / 10min, approximately 15cm 3 / 10min, approximately 16cm 3 / 10min, approximately 17cm 3 / 10min, approximately 18cm 3 / 10min, approximately 19cm 3 / 10min, approximately 20cm 3 / 10min, approximately 21cm 3 / 10min, approximately 22cm 3 / 10min, approximately 23cm 3 / 10min, approximately 24cm 3 / 10min, approximately 25cm 3 / 10min, approximately 26cm 3 / 10min, approximately 27cm 3 / 10min, approximately 28cm 3 / 10min, approximately 29cm 3 / 10min, approximately 30cm 3 Melt flow index / 10min, any range of melt flow index values ​​covered by any of the foregoing values, or any combination of the foregoing melt flow index values.

[0355] In various aspects, when thermoformed panels of polyamide or poly(ether-block-amide) are tested according to the cold Ross flexure test described below, the fibers or yarns comprising the low-processing-temperature polymer composition contain polyamide or poly(ether-block-amide) having a cold Ross flexure test result of about 120,000 to about 180,000. In another aspect, when thermoformed panels of polyamide or poly(ether-block-amide) are tested according to the cold Ross flexure test described below, the polyamide or poly(ether-block-amide) has a cold Ross flexure test result of about 140,000 to about 160,000. In yet another aspect, when thermoformed panels of polyamide or poly(ether-block-amide) are tested according to the cold Ross flexure test described below, the polyamide or poly(ether-block-amide) has a cold Ross flexure test result of about 130,000 to about 170,000. In some aspects, when a thermoformed panel of polyamide or poly(ether-block-amide) is tested according to the cold Ross flexure test described below, the polyamide or poly(ether-block-amide) has a cold Ross flexure test result of about 120,000, about 125,000, about 130,000, about 135,000, about 140,000, about 145,000, about 150,000, about 155,000, about 160,000, about 165,000, about 170,000, about 175,000, about 180,000, any range of cold Ross flexure test values ​​covered by any of the foregoing values, or any combination of the foregoing cold Ross flexure test values.

[0356] In all aspects, when according to the modified AS T for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers with tension as described below. m When determining the thermoformed trim using the D412-98 standard test method, the fibers or yarns comprising the low-processing-temperature polymer composition contain polyamide or poly(ether-block-amide) having a modulus from about 5 MPa to about 100 MPa. In another aspect, when according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers-tension... m When determining the properties of thermoformed trim panels according to the D412-98 standard test method, polyamides or poly(ether-block-amide) have a modulus from about 20 MPa to about 80 MPa. In some aspects, when according to the AST with modifications described below for vulcanized rubbers and thermoplastic rubbers and thermoplastic elastomers—tensile strength… mWhen the D412-98 standard test method is used to test thermoformed panels of polyamide or poly(ether-block-amide), the polyamide or poly(ether-block-amide) has a modulus of about 5 MPa, about 10 MPa, about 15 MPa, about 20 MPa, about 25 MPa, about 30 MPa, about 35 MPa, about 40 MPa, about 45 MPa, about 50 MPa, about 55 MPa, about 60 MPa, about 65 MPa, about 70 MPa, about 75 MPa, about 80 MPa, about 85 MPa, about 90 MPa, about 95 MPa, about 100 MPa, any range of modulus values ​​covered by any of the foregoing values, or any combination of the foregoing modulus values.

[0357] In various aspects, fibers or yarns comprising low-processing-temperature polymer compositions contain polyamides or poly(ether-block-amides) having the following characteristics: when according to the AS T described below m When D3418-97 is determined, the melting temperature is approximately 115°C (T). m ); when according to the AS T described below m When D3418-97 is determined, the glass transition temperature (T) is approximately -10°C. g ); when according to the AS T described below m When D1238-13 was tested at 160℃ with a weight of 2.16kg, the diameter was approximately 25cm. 3 Melt flow index of / 10min; approximately 150,000 cold Ross flexural test results when tested on thermoformed trim according to the cold Ross flexural test described below; and when tested according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers - tension. m When the D412-98 standard test method is used to determine the modulus of thermoformed trim panels, it ranges from approximately 25 MPa to approximately 70 MPa.

[0358] In various aspects, fibers or yarns comprising low-processing-temperature polymer compositions contain polyamides or poly(ether-block-amides) having the following characteristics: when according to the AS T described below m When D3418-97 is determined, the melting temperature is approximately 96°C (T). m ); when according to the AS T described below m When D3418-97 was determined, the glass transition temperature (T) was approximately 20°C. g When thermoformed trim panels are tested according to the cold Ross flexure test described below, approximately 150,000 cold Ross flexure test results are obtained; and when tested according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers - tension. mWhen the D412-98 standard test method is used to determine the modulus of thermoformed trim panels, it is less than or equal to approximately 10 MPa.

[0359] In various aspects, fibers or yarns comprising low-processing-temperature polymer compositions contain polyamides or poly(ether-block-amide) mixtures comprising a first polyamide or a first poly(ether-block-amide) and a second polyamide or a second poly(ether-block-amide), the first polyamide or the first poly(ether-block-amide) having, according to the AS T described below m When D3418-97 is determined, the melting temperature is approximately 115°C (T). m ); when according to the AS T described below m When D3418-97 is determined, the glass transition temperature (T) is approximately -10°C. g ); when according to the AS T described below m When D1238-13 was tested at 160℃ with a weight of 2.16kg, the diameter was approximately 25cm. 3 Melt flow index of / 10min; approximately 150,000 cold Ross flexural test results when tested on thermoformed trim according to the cold Ross flexural test described below; and when tested according to the AST for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers with modifications described below. m When the D412-98 standard test method is used to determine the modulus of thermoformed trim panels, it ranges from about 25 MPa to about 70 MPa. The second polyamide or second poly(ether-block-amide) has the modulus as described below according to AST m When D3418-97 is determined, the melting temperature is approximately 96°C (T). m ); when according to the AS T described below m When D3418-97 was determined, the glass transition temperature (T) was approximately 20°C. g When thermoformed trim panels are tested according to the cold Ross flexure test described below, approximately 150,000 cold Ross flexure test results are obtained; and when tested according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers - tension. m When the D412-98 standard test method is used to determine the modulus of thermoformed trim panels, it is less than or equal to approximately 10 MPa.

[0360] In all aspects, yarns comprising low-processing-temperature polymer compositions have deniers of about 750 to about 1100.

[0361] In various aspects, yarns comprising a low-processing-temperature polymer composition have a yarn tenacity greater than or equal to about 1.5 g / denier when tested according to EN ISO 2062 with modifications described below. In another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn tenacity from about 1.5 g / denier to about 3.0 g / denier when tested according to EN ISO 2062 with modifications described below. In yet another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn tenacity from about 1.7 g / denier to about 1.8 g / denier when tested according to EN ISO 2062 with modifications described below. In yet another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn tenacity from about 3.3 g / denier to about 3.6 g / denier when tested according to EN ISO 2062 with modifications described below. In some aspects, yarns comprising low-processing-temperature polymer compositions have yarn tenacity of about 1.5 g / denier, about 1.6 g / denier, about 1.7 g / denier, about 1.8 g / denier, about 1.9 g / denier, about 2.0 g / denier, about 2.1 g / denier, about 2.2 g / denier, about 2.3 g / denier, about 2.4 g / denier, about 2.5 g / denier, about 2.6 g / denier, about 2.7 g / denier, about 2.8 g / denier, about 2.9 g / denier, about 3.0 g / denier, any range of tenacity values ​​covered by any of the foregoing values, or any combination of the foregoing tenacity values, when tested according to EN ISO 2062 with modifications described below.

[0362] In various aspects, yarns comprising a low-processing-temperature polymer composition have a yarn elongation of less than or equal to about 150% when tested according to EN ISO 2062 with modifications described below. In another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn elongation of from about 30% to about 130% when tested according to EN ISO 2062 with modifications described below. In yet another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn elongation of from about 115% to about 120% when tested according to EN ISO 2062 with modifications described below. In even another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn elongation of from about 120% to about 140% when tested according to EN ISO 2062 with modifications described below. In yet another aspect, yarns comprising a low-processing-temperature polymer composition have a yarn elongation of from about 35% to about 45% when tested according to EN ISO 2062 with modifications described below. In some aspects, yarns comprising low-processing-temperature polymer compositions have yarn elongation of about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about 100%, about 105%, about 110%, about 115%, about 120%, about 125%, about 130%, any range of elongation values ​​covered by any of the foregoing values, or any combination of the foregoing elongation values, when tested according to EN ISO 2062 with modifications described below.

[0363] In various aspects, the yarn comprising the low-processing-temperature polymer composition has a yarn shrinkage rate of less than or equal to about 15% when tested at 50°C according to the methods described below. In another aspect, the yarn comprising the low-processing-temperature polymer composition has a yarn shrinkage rate of from about 70% to about 13% when tested at 50°C according to the methods described below. In yet another aspect, the yarn comprising the low-processing-temperature polymer composition has a yarn shrinkage rate of from about 9.5% to about 10.5% when tested at 50°C according to the methods described below. In yet another aspect, the yarn comprising the low-processing-temperature polymer composition has a yarn shrinkage rate of from about 0% to about 5% when tested at 50°C according to the methods described below. In some aspects, yarns comprising low-processing-temperature polymer compositions have yarn shrinkage rates of about 0%, about 0.5%, about 1.0%, about 1.5%, about 2.0%, about 2.5%, about 3.0%, about 3.5%, about 4.0%, about 5.5%, about 6.0%, about 6.5%, about 7.0%, about 7.5%, about 8.0%, about 8.5%, about 9.0%, about 9.5%, about 10%, any range of shrinkage rates covered by any of the foregoing values, or any combination of the foregoing shrinkage rates, when tested at 50°C according to the methods described below.

[0364] In various aspects, yarns comprising low-processing-temperature polymer compositions have a melting enthalpy (a measure of crystallinity) from about 15 J / g to about 50 J / g, as tested according to the methods described herein. In another aspect, yarns comprising low-processing-temperature polymer compositions have a melting enthalpy from about 17 J / g to about 23 J / g, as tested according to the methods described herein. In yet another aspect, yarns comprising low-processing-temperature polymer compositions have a melting enthalpy from about 35 J / g to about 42 J / g, as tested according to the methods described herein. In some aspects, yarns comprising low-processing-temperature polymer compositions have melting enthalpies of about 15 J / g, about 20 J / g, about 25 J / g, about 30 J / g, about 35 J / g, about 40 J / g, about 45 J / g, about 50 J / g, any range of melting enthalpy values ​​covered by any of the foregoing values, or any combination of the foregoing melting enthalpy values, as tested according to the methods described herein.

[0365] In all aspects, yarns comprising low-processing-temperature polymer compositions have a yarn toughness of about 2.0 g / denier to about 2.2 g / denier when tested according to EN ISO 2062 with modifications as described below; a yarn elongation of about 116% to about 122% when tested according to EN ISO 2062 with modifications as described below; a yarn shrinkage of about 8% to about 12% when tested at 50°C according to the methods described below; and a melting enthalpy of about 18 J / g to about 22 J / g when tested according to the methods described herein. The intended yarns include yarns having any values ​​within a given range, where the given range includes values ​​equal to or about the lower or upper limit of the given range.

[0366] In all aspects, yarns comprising low-processing-temperature polymer compositions have a yarn toughness of about 3.2 g / denier to about 3.6 g / denier when tested according to EN ISO 2062 with modifications as described below; a yarn elongation of about 37% to about 43% when tested according to EN ISO 2062 with modifications as described below; a yarn shrinkage of about 0% to about 3% when tested at 50°C according to the methods described below; and a melting enthalpy of about 35 J / g to about 42 J / g when tested according to the methods described herein. The intended yarns include yarns having any values ​​within a given range, where the given range includes values ​​equal to or about the lower or upper limit of the given range.

[0367] In all aspects, the yarn comprising the low-processing-temperature polymer composition includes a first yarn and a second yarn, the first yarn having a yarn toughness of about 2.0 g / denier to about 2.2 g / denier when tested according to EN ISO 2062 with modifications as described below; a yarn elongation of about 116% to about 122% when tested according to EN ISO 2062 with modifications as described below; a yarn shrinkage of about 8% to about 12% when tested at 50°C according to the method described below; and a melting enthalpy of about 18 J / g to about 22 J / g when tested according to the method described herein. The intended yarn includes yarns having any values ​​within a given range, the given range including values ​​equal to or about the lower or upper limit of the given range. The second yarn has a yarn tenacity of about 3.2 g / denier to about 3.6 g / denier when tested according to EN ISO 2062 with modifications as described below; a yarn elongation of about 37% to about 43% when tested according to EN ISO 2062 with modifications as described below; a yarn shrinkage of about 0% to about 3% when tested at 50°C according to the method described below; and a melting enthalpy of about 35 J / g to about 42 J / g when tested according to the method described herein. The intended yarn includes yarns having any values ​​within a given range, where the given range includes values ​​equal to or about the lower or upper limit of the given range.

[0368] Shaped items and membranes

[0369] As discussed above, the films and molded parts disclosed herein may include the selective incorporation of low-processing-temperature polymer compositions and / or the selective incorporation of high-processing-temperature polymer compositions. In various aspects, such low-processing-temperature polymer compositions may be present in the form of films or molded parts comprising low-processing-temperature polymer compositions. In some aspects, films or molded parts comprising low-processing-temperature polymer compositions are substantially free of high-processing-temperature polymer compositions. In other aspects, films or molded parts comprising low-processing-temperature polymer compositions are substantially composed of low-processing-temperature polymer compositions. These molded parts may be manufactured by any suitable means known in the art for manufacturing molded parts, such as polymer extrusion, polymer blow molding, injection molding, and machining. These films may be manufactured by any suitable means known in the art for manufacturing films, such as polymer extrusion.

[0370] Similarly, the high-processing-temperature polymer compositions described above can exist in the form of films or molded parts comprising high-processing-temperature polymer compositions. In some aspects, the films or molded parts comprising high-processing-temperature polymer compositions substantially do not contain low-processing-temperature polymer compositions. In other aspects, the films or molded parts comprising high-processing-temperature polymer compositions are substantially composed of high-processing-temperature polymer compositions. These molded parts can be manufactured by any suitable means known in the art for manufacturing molded parts, such as polymer extrusion, polymer blow molding, injection molding, and machining. These films can be manufactured by any suitable means known in the art for manufacturing films, such as polymer extrusion.

[0371] In some aspects, films or molded parts comprising low-processing-temperature polymer compositions may also comprise high-processing-temperature polymer compositions. For example, the film or molded part may be a bicomponent material formed by co-extrusion or co-injection of a low-processing-temperature polymer composition and a high-processing-temperature polymer composition.

[0372] In some aspects, the membranes or molded parts described herein can be used to provide specific functionalities. For example, in some aspects, a membrane comprising a low-processing-temperature polymer composition can be thermoformed to form a membrane having waterproof or water-resistant properties. In such aspects, a membrane on the outer surface of an article can be provided using a membrane comprising a low-processing-temperature polymer material.

[0373] As discussed above, in some aspects, films or molded parts may be colored, for example, for aesthetic purposes. In various aspects, films or molded parts may be colored using conventional coloring techniques. In some aspects, films or molded parts comprising low-processing-temperature polymer compositions are not colored and may be formed from polymer compositions that are substantially free of pigments, colorants, or dyes, which can result in areas that are clear or nearly transparent containing the low-processing-temperature polymer composition (e.g., non-yarn or non-fiber materials after thermoforming).

[0374] In one or more aspects, films or molded parts comprising low-processing-temperature polymer compositions can exhibit moduli from about 1 MPa to about 500 MPa. In some aspects, yarns comprising low-processing-temperature polymer compositions can exhibit moduli from about 5 MPa to about 150 MPa. In one aspect, yarns comprising low-processing-temperature polymer compositions can exhibit moduli from about 20 MPa to about 130 MPa. In another aspect, yarns comprising low-processing-temperature polymer compositions can exhibit moduli from about 30 MPa to about 120 MPa. In yet another aspect, yarns comprising low-processing-temperature polymer compositions can exhibit moduli from about 40 MPa to about 110 MPa. As used herein, the term "modulo" refers to the corresponding test method described below in the Characterization and Analysis of Properties section.

[0375] In one or more aspects, when a film or molded part comprising a low-processing-temperature polymer composition is brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 1 MPa to approximately 500 MPa when pressure tested. In various aspects, when yarns comprising a low-processing-temperature polymer composition are brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition... m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 5 MPa to approximately 150 MPa when pressure tested. In one or more aspects, the yarn comprising the low-processing-temperature polymer composition is made to reach a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. mAt temperatures where pressure tests are conducted at approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 20 MPa to approximately 130 MPa. In one or more aspects, the yarn comprising the low-processing-temperature polymer composition is brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures where pressure tests are conducted at approximately 20°C and 1 atmosphere, the resulting thermoformed material (e.g., a molten yarn component) can exhibit a modulus from approximately 30 MPa to approximately 120 MPa. In one or more aspects, the yarn comprising the low-processing-temperature polymer composition is brought to a temperature higher than the melting temperature T of the low-processing-temperature polymer composition. m The temperature is then increased to a level below the low processing temperature of the polymer composition, T. m At temperatures of approximately 20°C and pressures of 1 atmosphere, the resulting thermoformed materials (e.g., molten yarn components) can exhibit moduli ranging from approximately 40 MPa to approximately 110 MPa.

[0376] As discussed above, low-processing-temperature polymer compositions and high-processing-temperature polymer compositions possess different properties in certain aspects. In various aspects, these different properties allow the low-processing-temperature polymer composition to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from its pre-thermoforming structure (e.g., thermoforming from a film or molded part into a molten or partially molten film or molded part), while the high-processing-temperature polymer composition cannot deform or melt during such a process and can retain its structure (e.g., as a film or molded part). In such aspects, molten yarn components formed from low-processing-temperature polymer compositions during thermoforming can be integrally attached to an unchanged structure (e.g., a textile or article, or another film or another molded part), which can provide a three-dimensional structure and / or other properties for specific points on a wearable article.

[0377] In various aspects, the film or forming component may be a covered film or a covered forming component. In other aspects, the covered film or covered forming component may be any suitable film or forming component on which a coating comprising a thermoplastic coating composition or other suitable coating has been formed.

[0378] In some aspects, the thermoplastic coating composition comprises a low-processing-temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a low-processing-temperature polymer composition including thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a low-processing-temperature polymer composition including thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0379] In some aspects, the thermoplastic coating composition comprises a high-processing-temperature polymer composition and optionally one or more additives. In other aspects, the thermoplastic coating composition comprises a high-processing-temperature polymer composition including thermoplastic polyurethane and optionally one or more additives. In still other aspects, the thermoplastic coating composition comprises a high-processing-temperature polymer composition including thermoplastic poly(ether-block-amide) and optionally one or more additives.

[0380] In some aspects, the thermoplastic coating composition includes TPU. In some aspects, the TPU can be any such material as described in this disclosure, such as a TPU prepared by polymerizing an aromatic or aliphatic isocyanate with a polyether polyol or polycaprolactone using a short-chain ethylene glycol (e.g., 1,4-butanediol) as a chain extender, or a mixture of different types of the disclosed TPUs. Alternatively, in other aspects, the TPU can be a commercially available TPU.

[0381] In various aspects, the thermoplastic coating composition may also contain additives, such as, but not limited to, one or more of thickeners, processing aids, dyes, or colorants. In another aspect, additives are not optional and include at least one thickener. In yet another aspect, additives are not optional and include at least one processing aid. In yet another aspect, additives are not optional and include at least one thickener and at least one processing aid. In some aspects, the thickener may include inorganic materials such as silica, talc, or calcium carbonate (CaCO3).

[0382] In some aspects, as described herein, thickeners can be used during the preparation of thermoplastic coating compositions to improve productivity and desmoothing properties. In other aspects, the thickener is silica powder, talc, or CaCO3. The thickener is used at least in part to increase the viscosity of the thermoplastic coating composition. In yet another aspect, the thickener used in the disclosed thermoplastic coating compositions can be an alloy of resins capable of imparting compatibility with thermoplastic polyurethanes, such as styrene-butadiene-styrene (SBS) block copolymers, styrene-ethylene / butene-styrene (SEBS) resins, polyacetal resins (POM), or styrene-acrylonitrile resins (SAN).

[0383] In some aspects, the thermoplastic coating composition may include a processing agent to improve productivity. In other aspects, the processing agent may be montan wax or a fatty acid ester (C5-C9) with pentaerythritol. Other processing agents are known to those skilled in the art and may also be used in the disclosed thermoplastic compositions. An exemplary commercially available processing aid is ESTANE58277 (Lubrizol).

[0384] In some aspects, a coated film or molded part with a desired color can be produced by adding a masterbatch corresponding to the desired color during the production of the TPU compound for the coated film or molded part. In other aspects, a TPU compound with a desired hardness for the coated film or molded part can be prepared by controlling the content of raw materials.

[0385] In some aspects, the coated film or molded part can be prepared by compounding a thermoplastic polymer, such as thermoplastic polyurethane, and optionally one or more additives in a conventional extruder, and then coating the compounded thermoplastic polyurethane coating composition onto the surface of the film or molded part. In other aspects, the process for preparing the coated film or molded part includes the steps of: 1) preparing shaped thermoplastic microspheres; and 2) producing the coated film or molded part. The shaped thermoplastic microspheres can be prepared by the methods disclosed herein, by similar methods as known to those skilled in the art, or obtained from commercially available sources.

[0386] The steps for preparing shaped thermoplastic microspheres may include the following: 1) mixing a thermoplastic polymer with various additives such as thickeners and / or processing aids, and feeding the mixture into the hopper of a conventional compounding extruder; 2) melting, kneading and compounding the mixture in the cylinder of the compounding extruder at a suitable temperature and pressure; 3) cutting the compounded thermoplastic coating composition discharged through the core of the compounding extruder in cooling water to form microspheres; and 4) drying the shaped thermoplastic polyurethane microspheres at a suitable temperature for a certain period of time, and aging the dried microspheres at a suitable temperature for a suitable period of time.

[0387] In a particular embodiment, the steps for preparing the shaped thermoplastic microspheres include at least the following steps: 1) mixing thermoplastic polyurethane with various additives such as thickeners and / or processing aids, and feeding the mixture into the hopper of a conventional compound extruder; 2) melting, kneading and compounding the mixture in the cylinder of the compound extruder at a temperature of about 150°C to 250°C and a pressure of about 50 kgf to 150 kgf; 3) cutting the compounded thermoplastic polyurethane discharged through the core of the compound extruder in cooling water to form microspheres; and 4) drying the shaped thermoplastic polyurethane microspheres at a temperature of 60°C to 80°C for about 4 to 6 hours, and aging the dried microspheres at a temperature of 30°C to 50°C for about 7 days or more.

[0388] In all aspects, when according to the AS T described below m When D3418-97 is defined, the formed part or film contains a melting temperature (T) ranging from about 90°C to about 120°C. m Polyamides or poly(ether-block-amides). In another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a melting temperature (T) from about 93°C to about 99°C. m In yet another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a melting temperature (T) from about 112°C to about 118°C. m In some respects, when according to the AS T described below m When determined according to D3418-97, the polyamide or poly(ether-block-amide) has a melting temperature of about 90°C, about 91°C, about 92°C, about 93°C, about 94°C, about 95°C, about 96°C, about 97°C, about 98°C, about 99°C, about 100°C, about 101°C, about 102°C, about 103°C, about 104°C, about 105°C, about 106°C, about 107°C, about 108°C, about 109°C, about 110°C, about 111°C, about 112°C, about 113°C, about 114°C, about 115°C, about 116°C, about 117°C, about 118°C, about 119°C, about 120°C, or a melting temperature (T) covered by any of the foregoing values. m Any range of values ​​or the aforementioned melting temperature (T) m Any combination of values.

[0389] In all aspects, when according to the AS T described below m When D3418-97 is defined, the formed part or film contains a glass transition temperature (T0) ranging from about -20°C to about 30°C. gPolyamides or poly(ether-block-amides). In another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a glass transition temperature (T0) from about -13°C to about -7°C. g In yet another aspect, when according to the AS T described below m When D3418-97 is determined, the polyamide or poly(ether-block-amide) has a glass transition temperature (T0) from about 17°C to about 23°C. g In some respects, when according to the AS T described below m When determined according to D3418-97, polyamides or poly(ether-block-amides) have glass transition temperatures (Tg) of about -20°C, about -19°C, about -18°C, about -17°C, about -16°C, about -15°C, about -14°C, about -13°C, about -12°C, about -10°C, about -9°C, about -8°C, about -7°C, about -6°C, about -5°C, about -4°C, about -3°C, about -2°C, about -1°C, about 0°C, about 1°C, about 2°C, about 3°C, about 4°C, about 5°C, about 6°C, about 7°C, about 8°C, about 9°C, about 10°C, about 11°C, about 12°C, about 13°C, about 14°C, about 15°C, about 16°C, about 17°C, about 18°C, about 19°C, and about 20°C. g ( ), any range of glass transition temperature values ​​covered by any of the foregoing values, or any combination of the foregoing glass transition temperature values.

[0390] In all aspects, when according to the AS T described below m When D1238-13 was tested at 160°C with a weight of 2.16 kg, the formed part or film contained a diameter of approximately 10 cm. 3 / 10min to approximately 30cm 3 Polyamides or poly(ether-block-amides) with a melt flow index of / 10 min. In another aspect, when according to the AS T described below. m When D1238-13 was tested at 160°C with a weight of 2.16 kg, the polyamide or poly(ether-block-amide) exhibited a temperature range of approximately 22 cm⁻¹. 3 / 10min to approximately 28cm 3 Melt flow index per 10 minutes. In some respects, when according to the AST described below... m When D1238-13 is determined at 160°C using a weight of 2.16 kg, the polyamide or poly(ether-block-amide) has approximately 10 cm⁻¹. 3 / 10min, approximately 11cm 3 / 10min, approximately 12cm 3 / 10min, approximately 13cm 3 / 10min, approximately 14cm 3 / 10min, approximately 15cm 3 / 10min, approximately 16cm 3 / 10min, approximately 17cm 3 / 10min, approximately 18cm 3 / 10min, approximately 19cm 3 / 10min, approximately 20cm 3 / 10min, approximately 21cm 3 / 10min, approximately 22cm 3 / 10min, approximately 23cm 3 / 10min, approximately 24cm 3 / 10min, approximately 25cm 3 / 10min, approximately 26cm 3 / 10min, approximately 27cm 3 / 10min, approximately 28cm 3 / 10min, approximately 29cm 3 / 10min, approximately 30cm 3 Melt flow index / 10min, any range of melt flow index values ​​covered by any of the foregoing values, or any combination of the foregoing melt flow index values.

[0391] In various aspects, when a thermoformed panel of polyamide or poly(ether-block-amide) is tested according to the cold Ross flexure test described below, the formed part or film contains polyamide or poly(ether-block-amide) having a cold Ross flexure test result of about 120,000 to about 180,000. In another aspect, when a thermoformed panel of polyamide or poly(ether-block-amide) is tested according to the cold Ross flexure test described below, the polyamide or poly(ether-block-amide) has a cold Ross flexure test result of about 140,000 to about 160,000. In yet another aspect, when a thermoformed panel of polyamide or poly(ether-block-amide) is tested according to the cold Ross flexure test described below, the polyamide or poly(ether-block-amide) has a cold Ross flexure test result of about 130,000 to about 170,000. In some aspects, when thermoformed panels of polyamide or poly(ether-block-amide) are tested according to the cold Ross flexure test described below, the polyamide or poly(ether-block-amide) has a cold Ross flexure test result of about 120,000, about 125,000, about 130,000, about 135,000, about 140,000, about 145,000, about 150,000, about 155,000, about 160,000, about 165,000, about 170,000, about 175,000, about 180,000, any range of cold Ross flexure test values ​​covered by any of the foregoing values, or any combination of the foregoing cold Ross flexure test values.

[0392] In all aspects, when according to the modified AS T for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers with tension as described below. m When determining thermoformed trim panels according to the D412-98 standard test method, the formed part or film contains polyamide or poly(ether-block-amide) having a modulus from about 5 MPa to about 100 MPa. In another aspect, when according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers-tension... m When determining the properties of thermoformed trim panels according to the D412-98 standard test method, polyamides or poly(ether-block-amide) have a modulus from about 20 MPa to about 80 MPa. In some aspects, when according to the AST with modifications described below for vulcanized rubbers and thermoplastic rubbers and thermoplastic elastomers—tensile strength… mWhen testing thermoformed decorative panels of polyamide or poly(ether-block-amide) according to the D412-98 standard test method, the polyamide or poly(ether-block-amide) has a modulus of about 5 MPa, about 10 MPa, about 15 MPa, about 20 MPa, about 25 MPa, about 30 MPa, about 35 MPa, about 40 MPa, about 45 MPa, about 50 MPa, about 55 MPa, about 60 MPa, about 65 MPa, about 70 MPa, about 75 MPa, about 80 MPa, about 85 MPa, about 90 MPa, about 95 MPa, about 100 MPa, any range of modulus values ​​covered by any of the foregoing values, or any combination of the foregoing modulus values.

[0393] In various aspects, the formed part or film comprises a polyamide or poly(ether-block-amide) having the following characteristics: when according to the AS T described below m When D3418-97 is determined, the melting temperature is approximately 115°C (T). m ); when according to the AS T described below m When D3418-97 is determined, the glass transition temperature (T) is approximately -10°C. g ); when according to the AS T described below m When D1238-13 was tested at 160℃ with a weight of 2.16kg, the diameter was approximately 25cm. 3 Melt flow index of / 10min; approximately 150,000 cold Ross flexural test results when tested on thermoformed trim according to the cold Ross flexural test described below; and when tested according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers - tension. m When the D412-98 standard test method is used to determine the modulus of thermoformed trim panels, it ranges from approximately 25 MPa to approximately 70 MPa.

[0394] In various aspects, the formed part or film comprises a polyamide or poly(ether-block-amide) having the following characteristics: when according to the AS T described below m When D3418-97 is determined, the melting temperature is approximately 96°C (T). m ); when according to the AS T described below m When D3418-97 was determined, the glass transition temperature (T) was approximately 20°C. g When thermoformed trim panels are tested according to the cold Ross flexure test described below, approximately 150,000 cold Ross flexure test results are obtained; and when tested according to the AST with modifications described below for vulcanized rubber and thermoplastic rubber and thermoplastic elastomers - tension. m When the D412-98 standard test method is used to determine the modulus of thermoformed trim panels, it is less than or equal to approximately 10 MPa.

[0395] In various aspects, the formed component or film compr...

Claims

1. A shoe upper, comprising: A textile product, comprising: a first reflow material; and a second yarn or a second fiber; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second yarn or the second fiber comprises a high processing temperature composition; wherein the textile comprises an outermost layer comprising a first region and a second region; and wherein the first region comprises an increased concentration of the first reflow material as compared to the second region.

2. The upper according to claim 1, wherein the second yarn comprises a dyed yarn. 3 . The upper of claim 1 , wherein the one or more first thermoplastic polymers include one or more of polyesters, polyethers, polyamides, polyurethanes, and polyolefins. 4 . The upper of claim 3 , wherein the one or more first thermoplastic polymers include one or more thermoplastic copolyamides.

5. The upper of claim 3, wherein the one or more first thermoplastic polymers include one or more thermoplastic polyether block amide (PEBA) copolymers. 6 . The upper of claim 1 , wherein the outermost layer further comprises a transition region between the first region and the second region, wherein the transition region comprises a reduced concentration of the first reflow material compared to the first region. 7 . The upper of claim 6 , wherein the transition region includes an increased concentration of the first reflow material as compared to the second region.

8. An article comprising: A textile product, comprising: a first reflow material; and a second yarn or a second fiber; wherein the first reflow material comprises a low processing temperature polymer composition comprising one or more first thermoplastic polymers; wherein the second yarn or the second fiber comprises a high processing temperature composition; wherein the textile comprises an outermost layer comprising a first region and a second region; and wherein the first region comprises an increased concentration of the first reflow material as compared to the second region.

9. The article of claim 8, wherein the one or more first thermoplastic polymers comprise one or more of polyesters, polyethers, polyamides, polyurethanes, and polyolefins.

10. The article of claim 8, wherein the textile comprises one or more second thermoplastic polymers comprising one or more of a thermoplastic polyester and a thermoplastic polyamide.

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