Recovery of waste yarn

Abstract

The invention relates to a method for producing a component at least partially from waste yarn. In some embodiments, the waste yarns may be distributed over a surface and bonded to each other over the surface. The component may be at least a portion of an upper for an article of footwear, article of apparel, or article of athletic equipment.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing components at least partially from waste yarns and corresponding components. Background Art

[0002] Various products are formed at least partially from fabric elements. For example, articles of clothing, such as sportswear and shirts, trousers, jackets, footwear or other articles, are typically formed from various fabric elements. During the process of manufacturing fabric elements, waste is generated, which typically includes edges or cut-off parts of finished or intermediate fabric elements or cut ends from yarns. Although fabric manufacturers are optimizing these processes to reduce the usual waste generation, at least so far, this cannot be completely avoided. Therefore, the recycling of waste plays an important role in the textile industry.

[0003] However, the recycling methods known in the art generally require energy-intensive methods that convert the waste into raw materials for another product of mostly lower quality. Therefore, there is a continuing need for innovation in the recycling of waste generated during the production of fabric elements. Summary of the Invention

[0004] The present invention provides a method for manufacturing components at least partially from waste yarns. The method may include collecting waste yarns from a previous manufacturing process and recycling them in a method that includes binding the waste yarns to each other. The waste yarns can be collected, sorted and distributed on a surface for binding. In some cases, the surface may include the surface of a fabric element to which the waste yarns are bound.

[0005] A first embodiment (I) of the present invention relates to a method for manufacturing components (360, 500, 501, 600, 700, 701, 702) at least partially from waste yarns (110, 120, 210, 220, 310, 320, 410, 520, 620, 810), wherein the method comprises: (a) providing (910) the waste yarns; (b) distributing (920) the waste yarns on a first surface (230, 330, 530, 630, 830); and (c) binding (930) at least a part of the distributed waste yarns to each other.

[0006] In a second embodiment (II), the waste yarns according to the first embodiment (I) at least comprise a thermoplastic polymer material.

[0007] In a third embodiment (III), at least 70%, preferably at least 80%, more preferably at least 90%, most preferably more than 95% of the waste yarns according to the first embodiment (I) or the second embodiment (II) comprise unconsolidated waste yarns.

[0008] In a fourth embodiment (IV), the waste yarn according to any one of embodiments (I)–(III) comprises consolidated waste yarn.

[0009] In a fifth embodiment (V), the bonding according to any one of embodiments (I)–(IV) comprises applying heat and pressure to the distributed waste yarn.

[0010] In a sixth embodiment (VI), the waste yarn according to any one of embodiments (I)–(V) comprises residual yarn.

[0011] In a seventh embodiment (VII), the method according to any one of embodiments (I)–(VI) further comprises separating the waste yarn from the fabric element before providing the waste yarn.

[0012] In an eighth embodiment (VIII), the fabric element according to the seventh embodiment (VII) is made of a wire or yarn wound around a plurality of anchor points.

[0013] In a ninth embodiment (IX), the method according to any one of embodiments (I)–(VIII) further comprises mechanically sorting the waste yarn and / or shortening the length of the waste yarn according to length, denier or density before distributing the waste yarn on the first surface.

[0014] In a tenth embodiment (X), the method according to any one of embodiments (I)–(IX) further comprises arranging the waste yarn on a movable second surface (350, 430, 450, 850) having a plurality of openings (433, 833), wherein the distribution further comprises moving the movable surface above the first surface such that the waste yarn passes through the openings and reaches the first surface.

[0015] In an eleventh embodiment (XI), the second surface according to the tenth embodiment (X) is attached to a device (890), and the method further comprises controlling the movement pattern of the device based on at least one actuator.

[0016] In a twelfth embodiment (XII), the distribution according to any one of embodiments (I)–(XI) comprises uniformly distributing the waste yarn on the first surface.

[0017] In a thirteenth embodiment (XIII), the distribution according to any one of embodiments (I)–(XI) comprises distributing the waste yarn on a first region of the first surface such that a first density of the distributed waste yarn is produced in the first region, and distributing the waste yarn on a second region of the first surface such that a second density of the distributed waste yarn is produced in the second region, wherein the second density is less than the first density.

[0018] In the fourteenth embodiment (XIV), the combination according to any one of embodiments (I)–(XIII) includes producing a sheet (221, 321).

[0019] In the fifteenth embodiment (XV), the method according to the fourteenth embodiment (XIV) further includes cutting at least a portion of the sheet into the shape of the component.

[0020] In the sixteenth embodiment (XVI), the component according to the fifteenth embodiment (XV) is at least a portion of one of the following: an upper (360, 560) for a footwear item, a clothing item, or a sports equipment item.

[0021] In the seventeenth embodiment (XVII), the first surface according to any one of embodiments (I)–(XVI) includes a first fabric component (530, 630).

[0022] In the eighteenth embodiment (XVIII), the first fabric element according to the seventeenth embodiment (XVII) includes at least one layer of yarn arranged in a pattern.

[0023] In the nineteenth embodiment (XIX), the method according to the seventeenth embodiment (XVII) or the eighteenth embodiment (XVIII) further includes arranging at least a second fabric element (534, 634) on the distributed waste yarn before the combination.

[0024] In the twentieth embodiment (XX), the second fabric element according to the nineteenth embodiment (XIX) includes at least one layer of yarn arranged in a pattern.

[0025] In the twenty - first embodiment (XXI), the first surface according to any one of embodiments (I)–(IX) is part of a mold.

[0026] In the twenty - second embodiment (XXII), the combination according to the twenty - first embodiment (XXI) includes molding waste yarn in a mold to form a component.

[0027] In the twenty - third embodiment (XXIII), the component according to any one of embodiments (I)–(XV) or (XVII)–(XXII) is at least a portion of a footwear item, in particular a heel counter, an insole board, a reinforcement element (700, 701, 702), a midfoot component, or an outsole component.

[0028] In the twenty - fourth embodiment (XXIV), the component according to any one of embodiments (I)–(XXIII) consists of at least 50% by weight, preferably at least 70% by weight, more preferably at least 90% by weight of waste yarn, and most preferably consists entirely of waste yarn.

[0029] The twenty-fifth embodiment (XXV) of the present invention relates to a component (360, 500, 501, 600, 700, 701, 702) manufactured by the method according to one of embodiments (I)–(XXIV). BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Possible embodiments of the present invention will be further described below with reference to the following drawings. The drawings, together with the description, are also used to explain the principles of the disclosed embodiments and to enable those skilled in the relevant art to manufacture and use them. These drawings are intended to illustrate rather than limit. Although the present invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the present invention to these specific embodiments. In the drawings, the same reference numerals denote the same or functionally similar elements.

[0031] Figures 1A - 1B A schematic diagram showing an embodiment of waste yarn is shown.

[0032] Figures 2A - 2D A schematic diagram showing an embodiment of manufacturing a component from waste yarn is shown.

[0033] Figures 3A - 3E A schematic diagram showing an embodiment of manufacturing a footwear item partially from waste yarn is shown.

[0034] Figures 4A - 4F A schematic diagram showing various embodiments of a box including different opening patterns is shown.

[0035] Figures 5A - 5B A schematic diagram showing an embodiment of waste yarn distributed on a fabric element is shown.

[0036] Figures 6A - 6B A schematic diagram showing an embodiment of waste yarn distributed between two fabric layers is shown.

[0037] Figure 6C A schematic diagram showing an embodiment of a frame including a plurality of anchor points is shown.

[0038] Figure 6D A schematic diagram showing an embodiment of a footwear item including waste yarn is shown.

[0039] Figure 6E A schematic diagram showing an embodiment of a jig for arranging waste yarn in an intended area of a fabric element is shown.

[0040] Figure 6F A schematic diagram showing a fabric component according to Figure 6E in which waste yarn is arranged in the intended area.

[0041] Figures 7A - 7C A schematic diagram showing an embodiment of a component including waste yarn molded in different shapes is shown.

[0042] Figure 8 A schematic diagram showing an embodiment of a robotic arm distributing waste yarn on a first surface.

[0043] Figure 9 A block diagram showing an embodiment of a method of manufacturing a component from waste yarn. Detailed Description

[0044] The indefinite articles "a", "an", and "the" include plural referents unless expressly contradicted or the context clearly dictates otherwise.

[0045] The term "comprising" is an open transitional phrase. The list of elements following the transitional phrase "comprising" is a non-exclusive list, such that elements other than those specifically recited in the list may also be present. The phrase "consisting essentially of" limits the composition of a component to the specified materials and those materials that do not materially affect the basic and novel characteristics of the component. The phrase "consisting of" limits the composition of a component to the specified materials and excludes any unspecified materials.

[0046] Embodiments of the present invention are described herein in detail with reference to the embodiments shown in the accompanying drawings, wherein like reference numerals are used to indicate like or functionally similar elements. References to "one embodiment", "some embodiments", "certain embodiments", etc., indicate that the described embodiments may include a particular feature, structure, or characteristic, but each embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, these phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is considered within the knowledge of those skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0047] The method according to an embodiment of the present invention is designed to improve known waste recycling methods and provide a fabric component including waste, so as to at least partially overcome the above-mentioned disadvantages of the prior art. These problems or disadvantages can be solved by the methods described herein, particularly by the embodiments. Exemplary embodiments of the present invention are described herein.

[0048] The present invention provides a method of manufacturing a component at least partially from waste yarn. The method may include the steps of providing waste yarn, distributing the waste yarn on a first surface, and binding at least a portion of the distributed waste yarn to each other.

[0049] In this way, and as described herein, the present invention provides a method in which waste yarn is incorporated into a new component without the need for labor-intensive and costly methods to prepare the waste yarn for further use.

[0050] The waste yarn can comprise at least a thermoplastic polymer material. As is generally known, thermoplastic polymer materials become flexible or moldable at a material-specific temperature (referred to as the glass transition temperature) and solidify upon cooling. This process can be repeated. Thus, the shape of the thermoplastic polymer material can be adjusted. Thermoplastic polymer materials are different from thermosetting polymer materials, which form irreversible chemical bonds during the curing process, and the curing process also occurs at a material-specific temperature. Once hardened, thermosetting polymer materials do not become flexible after being reheated.

[0051] In addition to the waste yarn comprising at least one thermoplastic polymer material, the waste yarn can further comprise up to 40 wt% of yarn made from a thermosetting polymer material. In some preferred embodiments, the waste yarn can comprise up to 25 wt% of the thermosetting polymer material. In some preferred embodiments, the waste yarn can comprise up to 10 wt% of the yarn made from a thermosetting polymer material. If both the waste yarn comprising at least one thermoplastic polymer material and the waste yarn made from a thermosetting polymer material are combined, the thermoplastic polymer material of the waste yarn comprising at least one thermoplastic polymer material can be used to bind itself and the waste yarn made from a thermosetting polymer material together. Such embodiments enable the recycling of materials, such as aramids.

[0052] In some embodiments, at least 70% of the waste yarn can comprise unconsolidated waste yarn. In some preferred embodiments, at least 80% of the waste yarn can comprise unconsolidated waste yarn. In some preferred embodiments, at least 90% of the waste yarn can comprise unconsolidated waste yarn. In some preferred embodiments, at least 95% of the waste yarn can comprise unconsolidated waste yarn. In some preferred embodiments, 100% of the waste yarn can be unconsolidated waste yarn. The term "unconsolidated" as used herein generally refers to loose waste yarn that is not mechanically connected and / or not bound together. For example, the ends of the yarn removed from a spool or fabric can comprise unconsolidated waste yarn. Based on the high percentage of unconsolidated waste yarn, the distribution of the waste yarn can be more accurate or generally improved compared to waste yarn with a lower percentage of unconsolidated waste yarn.

[0053] Additionally or alternatively, the waste yarn can include consolidated waste yarn. As used herein, the term "consolidated" generally refers to yarns joined together and / or not in a loose yarn state. For example, the consolidated waste yarn can include mechanically joined and / or bonded fabric pieces, which can be produced during a previous manufacturing process of the fabric element. In particular, consolidated defective parts and pattern cut waste can be used. Mechanically joined pieces can include, for example, knitted or woven fabric pieces. Bonded pieces can include pieces of yarn bonded together. The piece can correspond to an area cut or separated from the fabric element. Additionally, the part can also correspond to the entire fabric element that will not be sold or used. According to the present invention, these pieces can be cut or chopped into smaller pieces before being distributed on the first surface.

[0054] The bonding can include applying heat and pressure to the distributed waste yarn. By heating the waste yarn, the material can be softened or partially melted so that by applying pressure, the yarns can be joined together. In this way, no additional glue, resin or adhesive is required to join the waste yarn together. In these embodiments, the first surface can be the surface of a hot press or a non-stick plate adapted to be placed inside a hot press. Thus, the waste yarn can be directly arranged on the surface adapted to be placed inside the hot press.

[0055] The waste yarn can include leftover yarn. As used herein, leftover yarn is a portion of yarn that is too short to be used in manufacturing a new fabric element. The leftover yarn can correspond to the remaining portion of the yarn left on a spool after manufacturing a fabric element or to the yarn of a new spool that, for example, has no foreseen use. If a fabric element has been manufactured by winding a thread or yarn around a plurality of anchor points, the leftover yarn can also be the cut yarn from such a process, especially the waste from separating the fabric element and the frame on which the anchor points are arranged. Additionally, the waste yarn can come from cutting the pattern-matching shape of a finished fabric element.

[0056] The method can further include the step of separating the waste yarn from the fabric element before providing the waste yarn. The fabric element can be manufactured by winding a thread or yarn around a plurality of anchor points. In addition to or as an alternative to the leftover yarn, the waste yarn can include cut ends or edge regions from the fabric element. For example, in recent years, a new technique has been developed in the textile industry, in which a fabric element is manufactured by winding one or more threads or yarns around predetermined anchor points. After winding the desired pattern, the central part of the winding pattern is usually consolidated, while in the edge region, the unconsolidated yarn remains wound around the anchor points. These unconsolidated yarns can be separated from the consolidated pattern, for example, cut. The separated portion of the yarn can be the waste yarn according to the present invention.

[0057] A fabric element made by winding a thread or yarn around a plurality of anchor points can be made by any of the methods described in U.S. Patent 10,874,172 or U.S. Patent 11,602,196, the entire contents of both patents being incorporated herein by reference.

[0058] The method may further include the step of mechanically sorting the waste yarn according to length, denier or density and / or the step of shortening the length of the waste yarn, both steps being capable of being performed before distributing the waste yarn on the first surface. Shortening may include, for example, mechanically pulverizing the fabric element from which the waste yarn is derived. This ensures a consistent length of the waste yarn. Thereby, a uniform distribution, high quality and production efficiency can be obtained. Since the waste yarn can include yarns of various lengths, deniers and densities, each of the sorting and shortening of the waste yarn can result in a more uniform distribution of the length, denier or density of the waste yarn. Thereby, the manufacturing method according to the present invention can provide components of high quality and / or reproducible quality. In addition, each of the length, denier or density of the yarn can further affect at least one physical property of the component according to the present invention. Examples of physical properties can be stretchability, drapability, durability, abrasion resistance, etc.

[0059] The method may further include the step of disposing the waste yarn on a movable second surface having a plurality of openings. Additionally, the distributing step may further include moving the movable surface above the first surface such that the waste yarn passes through the openings onto the first surface. In this way, the shape of the second surface and / or the plurality of openings can be specifically optimized for the type of waste yarn available. The type of waste yarn can include one or more of the thickness of the waste yarn, the length of the waste yarn, the hardness of the waste yarn, the material composition of the waste yarn, the bending characteristics of the waste yarn, etc. The shape of the plurality of openings can be cut into the second surface by laser, CNC milling, water jet cutting, plasma cutting, 3D printing or by other known techniques. This can provide a high-precision shape of the plurality of openings. However, alternative cutting devices similar to knives or scissors can also be applied. The second surface can be part of a box in which the waste yarn can be disposed. The moving step may further include shaking the box.

[0060] The process of moving the movable surface such that the waste yarn passes through the openings can be used as an embodiment of mechanically sorting the waste yarn. For example, depending on the shape of the openings, only waste yarns reaching a specific diameter can fit through. Thus, the openings can define an upper limit on the diameter of the waste yarn after performing the sorting process. Additionally or alternatively, sorting of the waste yarn based on the density of the waste yarn can be performed by disposing the waste yarn in a liquid. Waste yarns having a higher density compared to the liquid will sink. Waste yarns having a lower density compared to the liquid will float. It can be noted that various sorting processes can also be combined to further increase the uniformity of the sorted waste yarn.

[0061] The second surface can be attached to the device, and the method can further include the step of controlling the movement pattern of the device and / or the second surface based on at least one actuator. The actuator can advantageously generate an exact movement pattern that can be pre-programmed. For example, the device can include a robotic arm and / or a computer numerical control (CNC) device.

[0062] The distribution can include uniformly distributing the waste yarn on the first surface. The uniform distribution of the waste yarn can result in a sheet having a substantially constant thickness after bonding. The term "substantially" is understood here to include small deviations from a constant thickness based on manufacturing errors. These small deviations can be on the order of up to 5%.

[0063] Optionally, the distribution can include distributing the waste yarn on a first region of the first surface such that a first density of the distributed waste yarn can be produced in the first region, and distributing the waste yarn on a second region of the first surface such that a second density of the distributed waste yarn can be produced in the second region, where the second density can be less than the first density. In this way, a map of varying density across the first surface can be generated, which includes the first density and the second density or includes more than two different densities across the first surface. The second density can be zero. Thus, a region without distributed waste yarn can be produced. The distribution of the waste yarn at various densities can be controlled by the movement pattern of the device to which the second surface can be attached. For example, it can be controlled by a robotic arm, a CNC device, or an actuator.

[0064] The bonding can include producing a sheet. The sheet can provide a source material for new components. If the volume of the waste yarn is large enough, the method of manufacturing the sheet can be a continuous method. In a continuous process, the sheet can be wound into a roll and stored or directly processed into components. In these embodiments, the method can further include the step of cutting at least a portion of the sheet into the shape of a component. The component can be at least a part of one of the following: an upper for a footwear item, a clothing item, or a sports equipment item. In this way, the waste yarn can be reused as a component of a new product without the need for a labor-intensive and energy-intensive pre-recycling process.

[0065] The first surface can include a first fabric element. Thus, the waste yarn can be directly attached to the first fabric element after bonding. For example, the waste yarn can be arranged on a specific region of the first fabric element for providing a reinforcement and / or cushioning element. For example, if the first fabric element corresponds to an upper for a footwear item, the specific region can include the toe region or the heel counter region in the finished footwear item. However, other fabric areas known in the art that include reinforcement and / or cushioning characteristics are also applicable, such as the elbow region of a piece of clothing, etc.

[0066] The first fabric element may include at least one layer of yarn arranged in a pattern. The layer arranged in a pattern may include a knitted layer, a woven layer, or a layer made by winding one or more threads or yarns around a predetermined anchor point. Thus, any waste yarn generated during the manufacture of the fabric element during knitting, weaving, or winding can be reused in combination with the same or other fabric elements. Accordingly, these embodiments of the present invention can produce fabric components that generate zero waste yarn during their production.

[0067] The method may further include the step of arranging at least a second fabric element on the distributed waste yarn before bonding. The first and second fabric elements may provide a frame or sandwich structure for the waste yarn. Thus, the first and second fabric elements may be attached to each other after bonding based on the waste yarn disposed between the two layers. Additionally, the waste yarn may be distributed on opposite surfaces of the first fabric element. Thus, the first fabric may be sandwiched by the waste yarn. In this embodiment, a second fabric element is not required to achieve a three-layer construction with a particularly high content of waste yarn. Alternatively, the waste yarn may be arranged on the surface of the first fabric element. The surface may be an outer or inner surface of a footwear item or a clothing item. In other words, the sandwich structure may be inverted such that the fabric elements are disposed between two layers of distributed waste yarn. To this end, a first layer of waste yarn may be distributed on a first surface, which may be, for example, a surface adapted to be placed in a hot press. Then, the fabric element may be arranged on the first layer of distributed waste yarn. Then, a second layer of waste yarn may be distributed on the fabric element.

[0068] The second fabric element may include at least one layer of yarn arranged in a pattern. By arranging the waste yarn between two fabric elements each including yarn arranged in a pattern, the thickness of the resulting component can be effectively increased. In particular, the process of winding a thread or yarn around an anchor point in a pattern may need to be repeated multiple times to achieve a sufficient thickness of the fabric element so manufactured. Thus, arranging the waste yarn between two fabric elements, each of which includes at least one layer of yarn wound around an anchor point, may be particularly advantageous for generating a sufficient thickness in a highly efficient manner.

[0069] The first surface may be part of a mold. Thus, the waste yarn can be directly arranged within the mold rather than arranging the waste yarn on the surface of a hot press or a fabric element.

[0070] The bonding may include molding the waste yarn in a mold to form a component. Thus, a structural element can be efficiently manufactured based on the waste yarn. Depending on the mold, a flat component with a substantially constant thickness or a structured component with a varying thickness can be provided.

[0071] The component can be at least a part of a footwear item. In one embodiment, the component can be an inner heel counter. The inner heel counter can provide support at the wearer's heel and is not visible in the finished product. Thus, regardless of the color composition of the available waste yarn, the inner heel counter provides a sustainable solution for reducing waste yarn. In another embodiment, the component can be an outer heel counter or an outsole component. In another embodiment, the component can be an insole board. The insole board can provide a favorable pressure distribution, which can be particularly relevant for footwear items with studs. In another embodiment, the component can be a reinforcement element for a midsole or a midfoot component. These embodiments of the component can provide a beneficial increase in bending stiffness. In yet another embodiment, the waste yarn can be used as a cushioning element. In particular, the waste yarn can be sandwiched between an outer fabric (e.g., the fabric of the upper that is exposed to the outside of the footwear item) and an inner fabric (e.g., the lining of the upper).

[0072] The component can comprise at least 50% by weight of waste yarn. In some preferred embodiments, the component can comprise at least 70% by weight of waste yarn. In some preferred embodiments, the component can comprise at least 90% by weight of waste yarn. In some preferred embodiments, the component can consist entirely of waste yarn. Thereby, the present invention provides an environmentally friendly method for manufacturing a component. First, the component can consist entirely of waste, i.e., waste yarn, generated during the manufacture of different products or at least account for the majority by weight of the waste. Second, at least if the component consists entirely of waste yarn, no additional glue, adhesive, or resin is required to manufacture the component according to the present invention.

[0073] On the other hand, the present invention provides a component manufactured according to one of the above methods.

[0074] As discussed above regarding the method of manufacturing a component, the various advantages, embodiments, and functions of the present invention also similarly apply to the embodiments of the component and are not repeated herein for the sake of brevity.

[0075] Hereinafter, exemplary embodiments of the present invention are described in more detail with reference to a method of manufacturing a component at least partially from waste yarn. Although specific combinations of features are described below for the exemplary embodiments of the present invention, it should be understood that the present invention is not limited to such embodiments. In particular, not all features must be present to implement the present invention, and embodiments can be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0076] Figure 1AEmbodiment 100 of waste yarn 110 is described. Waste yarn 110 can be generated during the process of manufacturing a fabric element. For example, waste yarn 110 can correspond to the front edge region or the cut-off region of the fabric element. Waste yarn 110 can include residual yarn, which can correspond to the yarn left on the spool after manufacturing the fabric. The remaining yarn is generally too short to be used for manufacturing additional fabric and is typically thrown into landfills or recycled in energy-intensive processes.

[0077] Waste yarn 110 includes an unconsolidated thermoplastic polymer material, which can at least form part of the sheath of waste yarn 110. Thus, if exposed to heat, at least the sheath portion of waste yarn 110 can soften or melt. If the heated waste yarn 110 is further exposed to pressure, waste yarn 110 binds together after cooling to room temperature. The result of this binding method is shown in Figure 1B , which describes the binding of waste yarn 120. Figure 1A The waste yarn 110 of corresponds to the bound waste yarn 120 after the hot pressing process.

[0078] Figures 2A through 2D An embodiment of the process for manufacturing a component according to the present invention is depicted. Figure 2A Step 200 is shown, which describes the collection of waste yarn 210 in a container, which may have been generated during the manufacture of a fabric element. Then, in Figure 2B Step 201 as shown, these waste yarns 210 are distributed on a first surface 230. The first surface 230 can be a non-stick plate suitable for placement in a hot press. In step 202, as Figure 2C shown, the first surface 230 is arranged between a first heating plate 231 and a second heating plate 232 of a hot press 235. After applying heat and pressure in the hot press 235, the previous waste yarns 210 now bind together to form a sheet 221 of bound waste yarn 220, as Figure 2D shown in step 203 of . Then, by cutting out a corresponding shape from the sheet 221, the sheet 221 of bound waste yarn 220 can be further processed into any desired component. The cutting can be performed by any known cutting device 240, such as scissors, knives, lasers, cutting dies, other automatic cutting machines, etc.

[0079] Figures 3A through 3E Another embodiment of the process for manufacturing a component according to the present invention is depicted. In this embodiment, the component is an upper 360 for a footwear item, where the upper 360 includes (and in some embodiments consists almost entirely of) bound waste yarn 320. Figure 3AStep 300 is shown, which describes the waste yarn 310 being collected in a container 350. The waste yarn 310 may have been generated during the manufacture of a fabric element. Additionally, in order to produce a more uniform yarn distribution and thus a higher quality manufactured part, the length of the waste yarn 310 is shortened before it is placed in the container 350. Thereby, multiple waste yarns can all have substantially the same length, where a 10% difference in length is still considered to have substantially the same length. Then, in Figure 3B In step 301 shown, the shortened waste yarn 310 is distributed on a first surface 330. The distribution can be performed by moving a container 350 having a plurality of openings on its bottom surface above the first surface 330. The movement can be done by hand or by a computer-controlled device such as a robotic arm or a CNC device. The first surface 330 can be a non-stick plate adapted to be placed in a hot press. The container 350 can include a cartridge as described herein.

[0080] Figure 3C Step 302 is depicted, which results in a flat sheet 321 of combined waste yarn 320 after heat and pressure are applied to the distributed waste yarn 310. It can be noted that the process of producing a flat sheet of combined yarn described here can be produced not as a separate sheet in a hot press, but can also be produced in a continuous rolling process on a conveyor belt, which results in a long strip of combined waste yarn.

[0081] Then, the flat sheet 321 of combined waste yarn 320 can be cut into a shape for manufacturing an upper 360 and attached to an insole 361, which can also be cut from the flat sheet 321. Thus, the upper 360 including the insole 361 described in Figure 3D step 303 includes combined waste yarn 320 (and in some embodiments consists almost entirely of it). Finally, the upper 360 is disposed on and attached to a sole 370, which is described in Figure 3E step 304. By this method, the waste yarn 310 that might have been thrown into a landfill in the art is used to manufacture a new part in the form of an upper of a footwear item.

[0082] Figures 4A through 4EDescribes a plurality of embodiments of the cassette 450, which is adapted to evenly distribute the waste yarn 410 on a first surface. All embodiments 400 - 404 are described as polyhedral meshes, which result in the cassette 450 after the assembly process. Each cassette 450 includes a bottom surface 430, which includes a plurality of openings 433. The openings 433 can be cut into the bottom surface 430 by any suitable cutting device. In some preferred embodiments, a laser can be used to cut the openings 433. The pattern of the openings can be adjusted based on the desired level of even distribution of the waste yarn 410 on the first surface, where smaller openings can achieve a more even distribution than larger openings. However, larger openings can reduce the time required to distribute a desired amount of the waste yarn 410 on the first surface. Additionally, depending on the diameter of the available waste yarn 410, larger or smaller openings can be preferred. Similarly, depending on whether the waste yarn 410 is at least partially mechanically interconnected, such as knitted or woven, which may require larger openings compared to substantially individual waste yarn 410, smaller openings may be advantageous in such cases. The pattern can generally be adapted to prevent multiple plied waste yarns 410 from being distributed on the first surface.

[0083] Figure 4A The openings 433 of the embodiment 400 of the cassette 450 depicted in [depiction] include a pattern of rows of small rectangular openings. For example, in some embodiments, Figure 4A The openings 433 of the embodiment 400 of the cassette 450 depicted in [depiction] include a pattern of three rows of seventeen small rectangular openings. Figure 4B The openings 433 of the embodiment 401 of the cassette 450 shown in [illustration] include a pattern of partially overlapping rows of alternately odd - and even - numbered small rectangular openings. For example, in some embodiments, Figure 4B The openings 433 of the embodiment 401 of the cassette 450 depicted in [depiction] include a pattern of six rows of partially overlapping alternately eleven and twelve small rectangular openings. Figure 4C The openings 433 of the embodiment 402 of the cassette 450 depicted in [depiction] include a pattern of partially overlapping rows of alternately even - and odd - numbered cross - shaped openings. For example, in some embodiments, Figure 4C The openings 433 of the embodiment 402 of the cassette 450 depicted in [depiction] include a pattern of nine partially overlapping rows having alternately six and five cross - shaped openings. Figure 4D The openings 433 of the embodiment 403 of the cassette 450 depicted in [depiction] include a pattern of rows of square openings. For example, in some embodiments, Figure 4D The openings 433 of the embodiment 403 of the cassette 450 depicted in [depiction] include a pattern of seventeen rows of twelve square openings. Figure 4E The openings 433 of the embodiment 404 of the cassette 450 depicted in [depiction] include a pattern of rows of circular openings. For example, in some embodiments, Figure 4EThe opening 433 of the embodiment 404 of the cartridge 450 depicted in [description] includes a pattern of twenty-eight rows of twenty-one circular openings.

[0084] Figure 4F An embodiment 403 of the cartridge 450 in an assembled state is depicted. Thus, the cartridge 450 includes a bottom surface 430 having an opening (e.g., the square opening 433) as described above. In addition, unconsolidated waste yarn 410 is disposed within the cartridge 450 such that movement or shaking of the cartridge 450 causes individual or small bundles of waste yarn 410 to pass through the opening 433. Before disposing the waste yarn 410 in the cartridge 450, the waste yarn may have been mechanically sorted to include only waste yarn up to a specific denier limit. In addition, the waste yarn may also be shortened such that no waste yarn 410 has a length greater than an upper length limit (e.g., 20 cm).

[0085] It can be noted that the cartridge 450 must be understood as only one embodiment of the second surface, and other embodiments such as a plate can also be understood according to the present invention.

[0086] Figure 5A and Figure 5B Each of [relevant figures] depicts an embodiment of the components 500, 501, in which waste yarn is disposed on the fabric element 530. Thus, in these embodiments, the first surface includes a fabric element or at least one fabric layer.

[0087] Figure 5A An embodiment of the component 500 having the shape of the fabric element 530 is depicted, which is adapted to be processed into an upper for a footwear item. The fabric component 530 can be divided into a toe region 561, a midfoot region 562, and a heel region 563. In the embodiment 500, waste yarn has been disposed in the toe region 561 and the heel region 563. After applying heat and pressure to the distributed waste yarn and the fabric component 530, the combined waste yarn 520 is attached to the fabric component 530. Thereby, based on the combined waste yarn 520, reinforcement of these regions in the assembled upper can be provided to a wearer of a footwear item including the upper. In addition, the combination of waste yarn that is typically thrown into landfills provides an environmentally friendly process for reusing waste materials.

[0088] Figure 5BDepicts an embodiment of component 501 according to the present invention, where waste yarn is distributed between a first fabric element 530 and a second fabric element 534. The fabric elements 530 and 534 correspond to fabric layers in the form of a mesh. After applying heat and pressure, the combined waste yarn 520 is attached to the first fabric element 530 and the second fabric element 534. In this case, the advantages described with respect to embodiment 500 including a single fabric layer can also be applied. Additionally, the sandwich arrangement provides a versatile reinforcing fabric that can be attached or arranged in areas of clothing, footwear items, or sports equipment that require additional support or stiffening. Alternatively, the sandwich structure can be inverted. Thus, one layer of the fabric elements 530, 534 can be arranged between two layers of waste yarn.

[0089] Figure 6A Depicts an embodiment of component 600 according to the present invention. Component 600 is adapted to be processed into an upper 660 for a footwear item. Thus, component 600 can be divided into a toe region 661, a midfoot region 662, and a heel region 663. Component 600 includes a first fabric layer 630 that is manufactured by winding multiple continuous threads around anchor points 681 of a frame 680. Thus, the first fabric layer 630 includes a pattern of continuous threads that is neither knitted nor woven. On top of the first fabric layer 630, waste yarn 610 is at least partially distributed in the toe region 661 and the heel region 663. As shown in FIG. 6a, the density of the distributed waste yarn 610 is higher in the heel region 663 compared to the toe region 661, where the density of the distributed waste yarn 610 is minimal or substantially zero in the midfoot region 662. Additionally, in order to fix the distributed waste yarn 610 prior to the bonding process, a second fabric layer 634 has been arranged on top of the distributed waste yarn. The second fabric layer 634 is also manufactured by winding at least one continuous thread around the anchor points 681 of the frame 680. Thus, the waste yarn 610 is sandwiched between the first fabric layer 630 and the second fabric layer 634, which is also shown in Figure 6B in an enlarged view showing Figure 6A region 601. The sandwich structure of the first fabric layer 630, the waste yarn 610, and the second fabric layer 634 can be further processed in a hot press, cut out from the frame 680, and assembled onto the upper of a footwear item having reinforced toe and heel counters. This illustrates another advantageous embodiment of reusing waste yarn according to the present invention.

[0090] It can be noted that other distributions of the waste yarn 610 are possible. For example, the waste yarn can be evenly distributed over the entire first fabric layer 630 to effectively increase the thickness of the first fabric layer. Thus, by arranging the waste yarn 610 between two wound fabric layers, the time required to wind the threads around the anchor points 681 to produce the desired thickness or height of component 600 can be significantly reduced.

[0091] It should also be noted that the present application is not limited to a sandwich structure having exactly three layers. Thus, according to the present invention, sandwich structures including more than three layers, such as four, five, six or more layers, are also applicable. In these embodiments, an alternating arrangement of fabric layers and distributed waste yarn layers can be advantageous. For example, the component 501 of FIG. 5 and / or Figure 6A the component 600 shown in may include additional distributed waste yarn layers disposed on top of the second fabric layers 534, 634.

[0092] Figure 6C is described as similar to Figure 6A An embodiment 602 of a frame 680 similar to the frame shown is suitable for manufacturing an upper for a footwear item. The frame 680 includes a plurality of anchor points 681 around which continuous threads can be wound to form a pattern of fabric elements. Generally, the winding pattern must be separated from the frame 680, which can be performed after consolidating or thermally pressing the interior 683 of the winding pattern. After consolidation, the interior 683 can be cut or punched from the frame 680, which leaves an exterior 682 in the form of unconsolidated waste yarn that can be processed according to the methods described herein.

[0093] Figure 6D A footwear item 603 including a component according to the present invention is depicted. The footwear 603 includes a sole 670 and an upper 660. The upper 660 includes a fabric layer 630 that is manufactured by winding threads around anchor points as described above. In addition, to reinforce the collar region of the upper 660, waste yarn has been disposed on the fabric layer 630 in the collar region and bonded to the upper 660. Thus, the upper 660 includes bonded waste yarn 620 in the form of a reinforcing top layer in the collar region.

[0094] In some embodiments, the waste yarn can be disposed in the desired collar region by using a jig that is disposed on top of the fabric layer 630 during the placement / distribution of the waste yarn. Such a jig covers the regions outside the collar region such that no waste yarn is distributed in the covered regions. In addition, the jig exposes the collar region such that the waste yarn can be specifically distributed in the collar region. Figure 6E An example of a jig 690 placed on another fabric element 691 is shown, which is used to form a part of the upper of a footwear item. As described above, the fabric element 691 has been manufactured by winding threads around anchor points. The jig 690 covers a first region 692 of the fabric element 691. The jig 690 includes an opening 694 that exposes a second region 693 of the fabric element 691. As can be seen from Figure 6FAs can be seen, the waste yarn 695 has been inserted into the opening 694 of the jig 690. In the illustrated embodiment, the opening 694 has been completely filled with the waste yarn 695. Thereby, the resulting fabric element 691 is covered by the waste yarn 695 in the shape of the opening 694 of the jig. Subsequently, the waste yarn 695 can be consolidated.

[0095] Generally, an exemplary method of manufacturing a fabric component such as the component 600 described above may include the following steps. First, the method may include defining a plurality of peripheral anchor points. The method may also include the step of winding a continuous thread around the plurality of peripheral anchor points to form a thread pattern. The continuous thread may include a plurality of thread lines, each thread line extending between two corresponding peripheral anchor points. The method may also include the step of joining the continuous thread at the intersection points between the lines. The joining may be limited to a central region, or the joining may not include an edge region of the thread pattern. The method may further include the step of separating the joined thread pattern from the peripheral anchor points. The separation may generate waste yarn. The waste yarn may originate from a joined region or a non-joined region of the thread pattern. The method may also include the step of distributing the waste yarn over the joined thread pattern. Thus, the waste yarn may be disposed on the same thread pattern from which they have been separated. The method may further include the step of joining at least a portion of the distributed waste yarn to each other and / or to the joined thread pattern. In other words, the method of manufacturing a component as described herein may be combined with a known process of winding a thread or yarn around anchor points. This may result in a fabric element having the advantages of the component as described herein, wherein, additionally, zero waste yarn may be generated during the manufacture of the fabric element.

[0096] Figures 7A - 7C Embodiments of components 700, 701, and 702 according to the present invention are depicted. To manufacture components 700, 701, and 702, waste yarn is placed within a mold, and particularly on the bottom surface of the mold. Similar to the hot pressing described above, the mold also applies heat and pressure to the distributed waste yarn and presses the waste yarn into a desired shape.

[0097] For example, as Figure 7A shown, the component 700 includes joined waste yarn 720 (and in some embodiments consists entirely thereof), which is molded into a flat reinforcing component 700. The component 700 can be used to reinforce a portion of a shoe upper. The component 700 includes four eyelets 734 and two openings 733 for improving ventilation of the corresponding shoe upper including the component 700.

[0098] Figure 7BThe illustrated component 701 depicts an embodiment which is similar to component 700 and includes combined waste yarn 720 (which in some embodiments consists entirely thereof). Component 701 also includes a surface structure 733. Thus, during consolidation of component 701, the surface structure is pressed into component 701. These surface structures must be understood as merely one embodiment of a molded component with a structured surface according to the present invention. Generally, any shape and form can be manufactured by molding waste yarn 720 in a mold. The variation in local thickness introduced by the surface structure can be used to alter the stiffness and bending characteristics of the component.

[0099] Figure 7C Another embodiment of component 702 according to the present invention is depicted. Component 702 includes surface structures 733a and 733b and includes combined waste yarn 720 (and in some embodiments consists entirely thereof). Component 702 also has the shape of a sole for a footwear item. In particular, component 702 can be particularly advantageous for spiked footwear items. To this end, component 702 includes various surface structures 733a which are at least partially arranged at the locations where the spikes are attached in the finished shoe. Thus, the surface structures 733a provide additional stiffness to those areas which are exposed to increased pressure based on the attached spikes when worn by a user. In addition, component 702 also includes additional surface structures 733b which are adapted to provide increased flexural stiffness to the sole including component 702.

[0100] Figure 8 An embodiment 800 of a method for manufacturing a component according to the present invention by utilizing a robotic arm 890 is depicted. A plate 850 is attached at the end of the robotic arm 890. The plate 850 includes a plurality of openings 833 which may correspond to one of the openings described above with respect to Figures 4A to 4F On the bottom surface of the plate 850, shortened or cut waste yarn 810 is arranged. In addition, a first surface 830 is arranged below the plate 850, which may be a surface adapted to be placed within a hot press or the tray of a hot press. The robotic arm 890 also includes a plurality of joints 891 which may be configured to move the plate 850 in a predetermined pattern. The movement can be adjusted such that small bundles of waste yarn 810 or preferably even only individual waste yarn 810 are evenly distributed on the first surface 830. By utilizing a robotic arm 800 or another computer-controlled device such as a CNC device, a uniform distribution of the waste yarn 810 on the first surface 830 can be provided, which enables the production of a flat sheet of combined waste yarn with a substantially constant thickness and yarn density after the consolidation process.

[0101] Figure 9Depicts an embodiment of a method 900 for manufacturing a component according to the present invention. The method includes the step of providing 910 waste yarn as described above. The method further includes the step of distributing 920 the waste yarn on a first surface as described above. The method further includes the step of binding 930 at least a portion of the distributed waste yarn to each other as described above.

[0102] While various embodiments have been described herein, they are presented by way of example and not limitation. Based on the teachings and guidance presented herein, it should be apparent that changes and modifications are intended to be within the meaning and scope of the equivalents of the disclosed embodiments. Thus, it will be apparent to those skilled in the art that various changes in form and detail may be made to the embodiments disclosed herein without departing from the spirit and scope of the invention. The elements of the embodiments presented herein are not necessarily mutually exclusive, but may be interchangeable to meet various situations, as will be appreciated by those skilled in the art.

[0103] These embodiments are illustrative of the invention and not restrictive. Other suitable modifications and adjustments of the various conditions and parameters that are obvious to those skilled in the art and commonly encountered in the art are also within the spirit and scope of the invention.

[0104] It should be understood that the language or terminology used herein is for the purpose of description and not limitation. The breadth and scope of the present invention should not be limited by any of the above exemplary embodiments.

Claims

1. A method of manufacturing a component at least partially from waste yarn, the method comprising: (a) providing waste yarn; (b) distributing the waste yarn on the first surface; as well as (c) combining at least a portion of the distributed waste yarns with each other.

2. The method according to claim 1, wherein the waste yarn comprises at least a thermoplastic polymer material.

3. The method of claim 1, wherein at least 70% of the waste yarn comprises unconsolidated waste yarn.

4. The method of claim 1, wherein the waste yarn comprises consolidated waste yarn.

5. The method of claim 1, wherein the combining comprises applying heat and pressure to the distributed waste yarn.

6. The method of claim 1, wherein the waste yarn comprises leftover yarn.

7. The method of claim 1, further comprising separating the waste yarn from a textile element prior to providing the waste yarn.

8. The method according to claim 7, wherein: The textile element is made by winding a thread or yarn around a plurality of anchor points.

9. The method of claim 1, further comprising mechanically sorting the waste yarn according to length, denier or density and / or shortening the length of the waste yarn before distributing the waste yarn on the first surface.

10. The method of claim 1, further comprising disposing the waste yarn on a movable second surface having a plurality of openings, wherein the distributing further comprises moving the movable second surface over the first surface such that the waste yarn passes through the plurality of openings onto the first surface. 11 . The method of claim 10 , wherein the movable second surface is attached to a device, and the method further comprises controlling a movement mode of the device based on at least one actuator.

12. The method of claim 1, wherein the distributing comprises evenly distributing the waste yarn on the first surface.

13. The method according to claim 1, wherein the distribution includes distributing the waste yarn on a first area of ​​the first surface so that a first density of the distributed waste yarn is generated in the first area, and distributing the waste yarn on a second area of ​​the first surface so that a second density of the distributed waste yarn is generated in the second area, and wherein the second density is less than the first density.

14. The method of claim 1, wherein the combining comprises producing a sheet.

15. The method of claim 14, further comprising cutting at least a portion of the sheet into the shape of the component.

16. The method of claim 15, wherein the component is at least a portion of one of: an upper for an article of footwear, an article of apparel, or an article of sporting equipment.

17. The method of claim 1, wherein the first surface comprises a first textile element.

18. The method according to claim 17, wherein: The first textile element includes at least one layer of yarn arranged in a pattern.

19. The method of claim 17, further comprising arranging at least a second textile element on the distributed waste yarn prior to said combining.

20. The method according to claim 19, wherein: The second textile element includes at least one layer of yarn arranged in a pattern.

21. The method of claim 1, wherein the first surface is part of a mold.

22. The method of claim 21, wherein the combining comprises molding the waste yarn in the mold to form the component.

23. The method of claim 1, wherein the component is at least a portion of: a heel counter, an insole plate, a reinforcement element, a midfoot component, or an outsole component.

24. The method of claim 1, wherein the component comprises at least 50% by weight waste yarn.

25. A component manufactured according to the method of claim 1.

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