Wearable article with patterned filament overlay

Abstract

A wearable article may include at least one panel forming a back portion extending along a person's back and a shoulder portion extending forward from the back portion. A patterned filament overlay (PFO) is positioned on the shoulder portion, the PFO being in the form of individually formed lines of material extending either self-intersecting or self-side-by-side.

Description

[0001] Cross-referencing of related patent applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 685,141, filed August 20, 2024, entitled “POLYMER DEPOSITION,” the entire disclosure of which is incorporated herein by reference. This application also claims the benefit of co-pending U.S. Provisional Patent Application No. 63 / 685,175, filed August 20, 2024, entitled “POLYMER DEPOSITION,” the entire disclosure of which is incorporated herein by reference. This application relates to co-pending U.S. Patent Application No. 19 / 286,996, filed July 31, 2025, the entire disclosure of which is incorporated herein by reference. Background Technology

[0003] Many wearable items, whether clothing or equipment, are used to bear and distribute loads. For example, running vests are typically used to carry water bottles and other supplies. Backpacks are used to store and carry clothing, devices, etc. Seatbelts are typically used to suspend a person wearing a harness. Over time, many of the clothes and equipment people wear also tend to wear out.

[0004] Textiles play a vital role in the functionality of footwear and other textile products, especially in applications involving movement and mobility. The types of yarns and materials used, as well as the textile structures employed to manufacture these textiles, can be tailored to optimize performance for specific applications. However, these inherent textile properties are often insufficient for environments requiring extreme durability, cushioning, or custom mechanical properties. Therefore, we need to improve textiles used in footwear and other performance-based textile environments. Attached Figure Description

[0005] Figure 1 This is a schematic view illustrating a portion of an example molten filament manufacturing system.

[0006] Figure 2A This is a view showing an example path of a nozzle passing through the textile along the Z-axis and performing a Z-axis sinking mechanical locking within the textile, where dots or balls represent markers of polymer flow.

[0007] Figure 2B It shows the use Figure 1 The system (with) Figure 2A The nozzle path in the example textile (see bottom perspective view) allows the polymer to penetrate.

[0008] Figure 2C yes Figure 2BTop perspective view of a polymer penetrating the textile.

[0009] Figure 3A Through Figure 1 The example system is a top perspective view of an example cushioning structure formed by a polymer pattern sprayed or printed on an example textile.

[0010] Figure 3B Through Figure 1 The example system is a top perspective view of an example cushioning structure formed by a polymer pattern sprayed or printed on an example textile.

[0011] Figure 3C Through Figure 1 The example system is a top perspective view of an example cushioning structure formed by a polymer pattern sprayed or printed on an example textile.

[0012] Figure 4A Through Figure 1 The example system is a top perspective view of different patterns of polymers sprayed or printed on example textiles.

[0013] Figure 4B It shows that it has been passed Figure 1 A perspective view of an example structure of a three-dimensional grid or pattern of polymer sprayed and sandwiched between a pair of textile layers.

[0014] Figure 5 It is a perspective view of an example structure having a patterned filament overlay printed on an example textile, wherein a protective layer with few or no perforations is printed on top of the patterned filament overlay.

[0015] Figure 6A It shows through Figure 1 A perspective view of different printed layouts or patterns of a three-dimensional grid of polymer sprayed onto an example textile.

[0016] Figure 6B It shows through Figure 1 A perspective view of different printed layouts or patterns of a three-dimensional grid of polymer sprayed onto an example textile.

[0017] Figure 6C It shows through Figure 1 A perspective view of different printed layouts or patterns of a three-dimensional grid of polymer sprayed onto an example textile.

[0018] Figure 6D It shows through Figure 1 A perspective view of different printed layouts or patterns of a three-dimensional grid of polymer sprayed onto an example textile.

[0019] Figure 6E It shows through Figure 1 A perspective view of different printed layouts or patterns of a three-dimensional grid of polymer sprayed onto an example textile.

[0020] Figure 7A It is a perspective view showing the polymer being sprayed and penetrated onto the example textile to give the example textile an example texture.

[0021] Figure 7B It is a perspective view showing the polymer being sprayed and penetrated onto the example textile to give the example textile an example texture.

[0022] Figure 7C It is a perspective view showing the polymer being sprayed and penetrated onto the example textile to give the example textile an example texture.

[0023] Figure 7D It is a perspective view showing the polymer being sprayed and penetrated onto the example textile to give the example textile an example texture.

[0024] Figure 8A It is shown in passing Figure 1 A schematic diagram of an example embossing of an example texture on a polymer sprayed or printed onto an example textile.

[0025] Figure 8B It is shown in passing Figure 1 A schematic diagram of an example embossing of an example texture on a polymer sprayed or printed onto an example textile.

[0026] Figure 8C It is shown in passing Figure 1 A schematic diagram of an example embossing of an example texture on a polymer sprayed or printed onto an example textile.

[0027] Figure 9 Through Figure 1 A perspective view of an example wave pattern of polymer sprayed or printed onto an example textile.

[0028] Figure 10 It shows through Figure 1 The system sprays or deposits different polymers onto the example textile to form an example structure. (Perspective view)

[0029] Figure 11A , Figure 11B and Figure 11C This is a perspective view showing a portion of the example spacer / buffer structure.

[0030] Figure 12A , Figure 12B and Figure 12CThis is a perspective view showing a portion of the example spacer / buffer structure.

[0031] Figure 13A This is a cross-sectional view of a portion of an example extruded polymer line used for patterning a filament overlay.

[0032] Figure 13B This is a cross-sectional view of a portion of an example extruded polymer line used for patterning a filament overlay.

[0033] Figure 13C This is a cross-sectional view showing a portion of an example extruded polymer filament used for patterning a filament overlay.

[0034] Figure 13D This is a cross-sectional view of a portion of an example extruded polymer line used for patterning a filament overlay.

[0035] Figure 13E This is a cross-sectional view of a portion of an example extruded polymer line used for patterning a filament overlay.

[0036] Figure 13F This is a cross-sectional view of a portion of an example extruded polymer line used for patterning a filament overlay.

[0037] Figure 13G This is a cross-sectional view of a portion of an example extruded polymer line used for patterning a filament overlay.

[0038] Figure 14A This is a front perspective view of an example running vest when it is worn and has an example patterned filament overlay.

[0039] Figure 14B This is a rear perspective view of the example running vest in Figure 14 when worn.

[0040] Figure 15 yes Figure 14A An enlarged perspective view shows an example patterned filament overlay.

[0041] Figure 16A yes Figure 15 A cross-sectional view of the patterned filament coating.

[0042] Figure 16B yes Figure 15 A cross-sectional view of the patterned filament coating.

[0043] Figure 16C yes Figure 15 A cross-sectional view of the patterned filament coating.

[0044] Figure 16D yes Figure 15A cross-sectional view of the patterned filament coating.

[0045] Figure 17 yes Figure 15 A cross-sectional view of a portion of the patterned filament overlay.

[0046] Figure 18A This is a front perspective view of the example backpack when it is being worn and has an example patterned filament overlay.

[0047] Figure 18B yes Figure 18A The example backpack is shown in a side perspective view when it is being worn.

[0048] Figure 18C This is a front view of an example shoulder strap for a backpack, featuring an example patterned filament overlay.

[0049] Figure 19 yes Figure 18A The example backpack's front perspective.

[0050] Figure 20 yes Figure 18A A perspective view of an example backpack with an example hip strap or waist belt.

[0051] Figure 21 This is a front perspective view of an example seatbelt with an example waist belt and example leg loops, the example leg loops having an example patterned filament overlay.

[0052] Figure 22 It is shown Figure 21 The front view of a portion of the example seat belt's lap belt.

[0053] Figure 23 It is shown Figure 21 The front view of the example leg loop portion of the example seat belt.

[0054] Figure 24 This is a front perspective view showing a portion of a pair of leg coverings with example foot inner circumferences, the example foot inner circumferences having example patterned filament overlays.

[0055] Figure 25 yes Figure 24 An enlarged view of a portion of a pair of leg coverings in the example, showing the example patterned filament overlay.

[0056] Figure 26 It is a cross-sectional view showing a portion of a pair of leg coverings with example foot inner circumferences, the example foot inner circumferences having example patterned filament overlays.

[0057] Figure 27 This is an enlarged view of a portion of a pair of leg coverings in the example, showing the example patterned filament overlay.

[0058] Figure 28 This is a rear view of example shorts with an example patterned filament overlay.

[0059] Figure 29 yes Figure 28 The example is a left-side view of shorts.

[0060] Figure 30 yes Figure 28 The enlarged portion of the shorts.

[0061] In all the accompanying drawings, the same reference numerals denote similar but not necessarily identical elements. The drawings are not necessarily drawn to scale, and the dimensions of some parts may be exaggerated to more clearly illustrate the examples shown. Furthermore, the drawings provide examples and / or embodiments consistent with the specification; however, the specification is not limited to the examples and / or embodiments provided in the drawings. Specific Implementation

[0062] This technology relates to textiles and their manufacturing methods and processes, for use in, for example, footwear, apparel, outdoor products, and other suitable textile categories that can benefit from performance improvements. This technology overcomes the shortcomings of existing technologies and provides additional advantages.

[0063] Various embodiments of this technology particularly provide methods and processes for directly depositing thermoplastic materials onto textile surfaces to achieve regional, gradient, or overall performance enhancements. These textiles and related materials exhibit improved mechanical properties, bonding quality, and manufacturability, enabling the assembly of reinforced textile components for applications in footwear, advanced equipment, technical apparel, and other fields. Deposition can occur on planar films or non-textile substrates, including substrates that can be thermally bonded to textiles or structural components in post-processing.

[0064] This technology provides a method and system for reinforcing textile matrices by computer-controlled deposition of polymer materials (preferably thermoplastic polymers) using fused filament fabrication (FFF) or similar extrusion-based additive manufacturing techniques. This technology enables programmable and spatially controlled modification of the textile surface, thereby improving the mechanical, thermal, and aesthetic properties of the resulting textile. In at least one embodiment, this technology provides a method for heat-treating polymer filaments or particles via a heated extrusion nozzle that moves relative to the textile matrix in multiple degrees of freedom. The nozzle deposits the polymer along a predetermined tool path, which is typically continuous to avoid stringing artifacts due to polymer viscosity and flow behavior. The nozzle can translate along the X and Y axes to define a path through the textile surface, while the Z-axis position can be varied to control the bonding depth with the fabric. For example, during deposition, the nozzle can be lowered toward or towards the textile matrix to press the molten polymer into the pores of the textile matrix. This process also increases the bonding surface area for bonding with the textile structure and achieving mechanical interlocking. This process can be applied to textiles, whether stationary or in motion, and can be performed on flat or wavy surfaces. This basic process forms the basis for the improved treatments and techniques detailed below.

[0065] In some embodiments, this technology provides a controlled method for depositing one or more polymers onto textiles to enhance the properties of the resulting textile components, such as abrasion resistance, durability, flexibility (toughness), moisture management, tensile strength, elasticity, thermal conditioning, etc. This process ensures precise application of the polymer in three-dimensional space, enabling customizable and efficient modifications, making it ideal for footwear, apparel, mountaineering equipment, robotics, harnesses, bags, luggage, and other specialized applications.

[0066] In some embodiments, such as a running vest, this technology provides a textile component. The vest may include a woven fabric matrix bonded to an inner surface. A continuously deposited polymer material may be applied to the woven fabric matrix to form an abrasion-resistant polymer layer, wherein a first portion of the continuously deposited polymer material at least partially spans the thickness of the woven fabric matrix. A second portion of the continuously deposited polymer material extends from the first portion and is fixedly bonded to at least a second outer surface of the woven fabric matrix. The second portion of the continuously deposited polymer material is lifted and extends outwardly away from the woven fabric matrix.

[0067] In some embodiments, the thickness of the woven fabric matrix may be a first thickness, and the second portion of the continuously deposited polymer material includes an integrally connected first segment and a second segment, wherein the first segment has a second thickness of the polymer material, and the second segment has a third thickness different from the second thickness. The third thickness may be greater than the second thickness. The thickness of the second portion of the continuously deposited polymer material may vary along the length of the second portion. The thickness of the woven fabric matrix may be the first thickness, and at least one segment of the first portion of the continuously deposited polymer material has a second thickness substantially equal to the first thickness of the woven fabric matrix.

[0068] This application discloses example garments and equipment worn by an individual for carrying and distributing loads. Each example garment and equipment includes a patterned filament overlay. For the purposes of this disclosure, a “patterned filament overlay” (PFO) refers to a series of individual, distinct polymer material filaments or arrangements of polymer material lines deposited on a substrate (e.g., a textile, fabric, or other material panel). In contrast to a monolayer film or sheet deposited or laminated on a substrate, individual, distinct polymer material filaments or polymer material lines are extruded from a nozzle as at least one of the substrate and the nozzle moves relative to each other in at least one dimension. The individual, distinct polymer material filaments or polymer material lines may intersect each other, may stack, or may extend along side-by-side or non-overlapping paths.

[0069] In some disclosed embodiments, the patterned filament overlay comprises a single polymer filament or polymer line having segments that intersect each other at least five times along its length, or having at least five segments that extend parallel to or side by side with each other. In some disclosed embodiments, the diameter of the single polymer filament or polymer line may range from 0.1 to 10 mm. In other embodiments, the diameter may range from 0.2 to 2 mm. In some embodiments, the diameter or width of the polymer film and / or polymer line may vary along the length of the polymer filament or polymer line; different segments of the line may have different widths or diameters. For example, the rate at which the extrusion nozzle and the substrate move relative to each other, or the rate of polymer extrusion, may be controlled to change the width or diameter of the polymer filament or polymer line forming the patterned filament overlay. For the purposes of this disclosure, the use of the term "line" does not necessarily mean that the line follows a straight path; a "line" may extend along a curved, tortuous, or straight path.

[0070] Individual, distinct filaments or strands of polymer materials can be patterned to enhance various properties of clothing or equipment. For example, patterned filament overlays can provide varying degrees of cushioning in specific locations. Patterned filament overlays can provide varying degrees of abrasion resistance for specific external parts of clothing or equipment. Patterned filament overlays can provide varying degrees of stiffness and / or structural strength in selected locations. Patterned filament overlays can provide varying degrees of breathability for selected parts of clothing or equipment.

[0071] The various properties offered by patterned filament overlays can be tuned by altering the properties of the patterned filament overlays in different regions. The properties of the patterned filament overlays can be varied between different regions to accommodate different performance requirements and the different stress and wear levels associated with each region.

[0072] At least one variable property may include one or more properties selected from the group of properties consisting of layout, thickness, density, penetration, and layering. Layout refers to a discontinuous pattern of polymer layers. For example, a first layout may have intersecting polymer lines that cross or intersect each other in a first manner, while a second layout may have intersecting polymer lines that cross or intersect each other in a second, different manner. A third layout may have non-intersecting polymer lines (lines that do not intersect each other) or polymer lines that are connected but do not intersect each other. Different polymer lines in different layouts may have different linewidths or different path shapes (zigzag paths, wavy or curved paths, or polygonal paths).

[0073] Thickness refers to the thickness of the patterned filament overlay and the height of the patterned filament overlay. In contrast to "penetration," height or thickness is independent of penetration and includes portions extending below and above the outer surface of the substrate panel. A first region may have a patterned filament overlay of a first thickness, while a second, different region may have a second thickness different from the first thickness. In some embodiments, the penetration of a portion of the patterned filament overlay may remain uniform while the thickness varies, thereby providing enhanced abrasion resistance in certain areas and greater flexibility in other specific areas.

[0074] Density refers to the extent to which the patterned filament overlay covers the outer surface of the substrate panel. The more openings and / or the larger the number of openings in the patterned filament overlay, the lower the density of the patterned filament overlay. Density can be expressed as a percentage of the surface area of ​​the region or portion of the patterned filament overlay covered by the polymer material (excluding openings in the patterned filament overlay where the polymer layer does not cover the substrate panel).

[0075] Penetration refers to the extent to which a polymer layer penetrates one or more substrate panels. For example, the substrate on which PFO is deposited may be made of grids, textiles, or fabrics having openings or voids into which the polymer material of the polymer layer may impregnate or penetrate before hardening (curing or hardening). The extent to which the polymer layer penetrates the substrate panel and extends below the outer surface of the substrate panel may vary by region. In some embodiments, at least a portion of the polymer layer may penetrate to the substrate panel without rising above the outer surface of the substrate panel; the outer surface of a portion of the polymer layer may be flush with or level with the outer surface of the substrate panel, or below the outer surface of the substrate panel. In some embodiments, a patterned filament overlay is formed by extruding or jetting a fluid polymer material onto a substrate panel using one or more nozzles, wherein the spacing between the nozzle and the substrate panel (in some embodiments, the nozzle tip of the nozzle 28 of the extruder 26 (as described above) is at a z-axis height above the substrate panel, substrate textile 38), the viscosity of the polymer material, the absorption characteristics of the substrate panel, and / or the pressure of the extruded / jet polymer material can be controllably varied to control the extent to which the patterned filament overlay penetrates relative to one or more substrate panels.

[0076] In some embodiments, the penetration depth of the patterned filament overlay can vary gradually and uniformly. In some embodiments, the penetration depth of the patterned filament overlay formed from a polymer material can vary gradually. In some embodiments, the penetration depth of the patterned filament overlay can be characterized by spaced-out penetrations, wherein points where each layer penetrates deeper into the substrate panel establish a series of spaced-out panel-penetrating anchors to secure the patterned filament overlay. At the end of the deposition path, the nozzle can be gradually lowered to finer the printed features. This can reduce stress concentration, improve adhesion, and enhance durability in bendable and abrasion-prone areas. Depositing material along the cut edge can fuse the fibers and form a sealed boundary. This can be done before or after cutting the textile to obtain a clean, abrasion-resistant edge.

[0077] Layering refers to the number or manner in which polymer wires are extruded or deposited on top of each other to form a patterned filament overlay. For example, a first set of polymer wires can be extruded onto a substrate panel, and then a second set of polymer wires can be extruded onto the first set, resulting in a patterned filament overlay with greater height. This additional height can be achieved by depositing the polymer wires directly on top of each other or by crisscrossing the polymer wires (with the second set of polymer wires bridging portions of the first set). This layering can be layout-dependent and may affect the density of the patterned filament overlay.

[0078] In some embodiments, the first and second polymer lines can be deposited or sprayed simultaneously with the addition of polymer material at a sufficiently high temperature to melt the substrate polymer material (when the substrate polymer line is a thermoplastic material), thereby fusing the first and second polymer lines. In some embodiments, the first and second lines and / or the overlay second polymer lines can be deposited or sprayed onto the first substrate polymer line before the first substrate polymer line has solidified or hardened, thereby fusing or mixing the first and second polymer lines. In some embodiments, the first and second polymer lines can be formed of the same polymer or have the same base polymer. In some embodiments, the first and second polymer lines can be formed of different polymers. The first and second polymer lines can have different linewidths and / or different heights.

[0079] Figure 1 The diagram schematically illustrates a portion of an example molten filament manufacturing system 20, which includes a print bed 24, a thermoplastic material applicator (in the form of an extruder 26 with nozzles 28), a polymer supply device 30, an extruder position actuator 32, a print bed actuator 34, and a controller 36. The print bed 24 supports a substrate textile 38 on which fluid or liquid (i.e., flowable) polymer material 39 is deposited. The extruder 26 controllably jets and deposits the polymer onto the substrate textile 38 through the nozzles 28. In the illustrated example, the extruder 26 provides dynamic flow of the polymer to dynamically control or change the linewidth or path width. In some embodiments, the nozzles 28 have controllable, adjustable orifice sizes, allowing the linewidth to dynamically vary as the polymer 39 is deposited. In other embodiments, the nozzles 28 can have various cross-sectional shapes, such as circular, elliptical, cross-shaped, or other specific nozzle geometries configured to tailor the deposition profile / profile of the liquid polymer. Specific nozzle geometries can also facilitate the direct bonding of the textile to molded components such as running vests, harnesses, and ski pants.

[0080] As used herein, the terms "textile" and "film" are used interchangeably to refer to a substrate or superstrate used as a flexible planar surface. Examples of these materials include knit, woven, non-woven, extruded films, and blown films, which can be made from various types of yarns, including natural and high-performance yarns. These materials can have traditional textile structures, such as jersey knit or plain weave, or more complex structures, including but not limited to 3D spaced mesh, warp knit, or leno weave. These materials can also undergo secondary processing, such as die-cutting, texturing, foaming, flocking, laser cutting, or burnishing, to alter properties, appearance, or provide variations in texture or 3D volume.

[0081] As used herein, “polymer” can refer to any thermosetting or thermoplastic polymer, or other materials that may become liquid or change viscosity by heating, chemical reaction, or dissolving in a solution. In the illustrated example, system 20 includes a melt filament manufacturing (FFF) system, wherein polymer supply device 30 includes a filament spool around which a filament of a thermoplastic material (e.g., thermoplastic polyurethane (TPU)) is wound. The filament (under the control of supply actuator 31) is supplied to extruder 26, which heats the filament to a temperature above its melting point and adjustably sprays the fluid thermoplastic material onto a base textile. The rate at which the fluid is sprayed through the nozzle or the rate at which the filament is supplied to extruder 26 is controllable. In some embodiments, the filament may simply be drawn from a freely rotating spool, thus omitting the supply actuator. In other embodiments, polymer supply device 30 may include a container containing a polymer that flows to extruder / applier 26 for deposition onto a base textile. In other embodiments, the polymer may include other forms or types of thermoplastic polymers, or it may include thermosetting polymers.

[0082] In some embodiments, textile 38 and polymer 39 are compatible or have similar compositions to enhance the bonding between polymer 39 and textile 38. For example, in some embodiments, such as when polymer 39 contains TPU, textile 38 may contain a TPU fabric having TPU extruded yarns woven or knitted into the fabric. In some embodiments, textile 38 may include multicore yarns with TPU to facilitate the use of nylon or other aramid fibers to provide the required strength. TPU helps improve abrasion resistance and bonding. Due to the compatibility or similar chemical composition / chemical properties between textile 38 and polymer 39, recycling or reuse is beneficial.

[0083] Polymer 39 (supplied to extruder 26 in liquid form or in filament form and then heated or converted to a liquid state) can have a variety of different hardnesses and properties. In some embodiments, the polymer feed may be formulated with additives to influence mechanical or aesthetic properties. A foaming agent may be added to cause the polymer to expand during extrusion, thereby producing properties such as low density and high cushioning. In some embodiments, the degree of foaming or foam grade of the polymer may depend on the foaming agent and the temperature of polymer jetting or extrusion. Therefore, the temperature at which the polymer is extruded by extruder 26 can be varied or controlled to dynamically control the degree of foaming, thereby dynamically controlling the size or thickness of polymer 39 on or within textile 38, and / or controlling the hardness of the deposited polymer 39. An example of such a foamed polymer is a foamed thermoplastic polymer. An example of such a foamed polymer is a foamed polymer in filament form that is in a liquid state before extrusion or deposition. An example of such a foamed thermoplastic polymer filament is RECREUS. TM Commercially available FILAFLEX FOAMY TM In some embodiments, the system can use multiple nozzle heads, material changes, or platform transfers to alternate between different polymer feeds (of varying hardness or composition). This allows for mixed use to achieve zoned protection, comfort, or visual effects.

[0084] Various methods can be used to bond the polymer 39 to the textile 38. As described above, in some embodiments, this bonding can be achieved through surface bonding, wherein the polymer 39 and at least a portion of the textile 38 have similar chemical properties to facilitate chemical bonding or fusion. In other embodiments, this bonding can be further promoted or alternatively promoted by mechanical bonding. Examples of mechanical bonding include fiber entanglement and mesh flocking / locking. Fiber entanglement involves abrading the textile to isolate, separate, or expose individual yarns from the remaining textile, wherein the isolated yarns are subsequently wrapped with polymer 39. Mesh flocking / locking involves printing the polymer through the textile 38, for example by lowering the nozzle 28 to enter or through the Z-dip of the textile 38, or by raising the textile 38 to allow the nozzle 28 to pass through or enter the textile 38.

[0085] Polymer deposition can be configured to bond multiple textile layers. Figures 2A-2C An example of a mechanical lock is shown. Figure 2AThe path 43 of nozzle 28 along the Z-axis through and within textile 38 is shown to achieve such Z-axis sinking mechanical locking (dots or balls represent blips indicating polymer flow). In some embodiments, polymer may be deposited between two layers of textile 38. In other embodiments, a primer or adhesive may be applied to the fabric to enhance the bond between polymer 39 and textile 38.

[0086] Extrusion position actuator 32 includes one or more steppers, stepper motors, or other actuating devices for moving the extruder 26 in the X and Y axis directions (horizontal directions in the figure), and in some embodiments, moving the extruder 26 axially (towards and away from the print bed 24). Print bed position actuator 34 includes one or more stepper motors, hydraulic devices, pneumatic devices, or other devices configured to move the print bed (and the carried substrate textile 38) in the X and Y axis directions (horizontal directions in the figure), and in some embodiments, moving the print bed (and the carried substrate textile 38) in the Z axis direction (towards and away from the extruder / applier 26). In some embodiments, one of the extrusion position actuator 32 and the print bed position actuator 34 may be omitted, wherein the print bed 24 or the extruder 26 is stationary, while the other of the print bed or the extruder 26 can move in three-dimensional space.

[0087] The controller 36 includes a processing unit 40 and a non-transitory computer-readable medium 42, containing instructions for instructing the processing unit to output control signals that control one or more of the following operations: supplying thermoplastic material to the extruder 26, positioning the extruder 26 via an extrusion position actuator 32, and positioning the print bed 24 via a print bed position actuator 34. In some embodiments, the controller 36 may execute one or more stored programs for controlling the supply of a base textile to the print bed, controlling the supply of a specific thermoplastic material to the extruder 26, and controlling the rate of material deposition on the base textile and the location where the thermoplastic material is applied to or deposited on or within the base textile. Subsequently, the thermoplastic material 39 cools to a cured state on or within the base textile 38. In embodiments where the polymer comprises a thermosetting polymer material, the thermosetting polymer material is crosslinked or cured on or within the textile 38.

[0088] In some embodiments, the instructions contained in the medium 42 may instruct the processor 40 to output control signals, causing the actuators 32 and / or 34 to deposit the polymer 39 in a three-dimensional pattern onto the textile 38, thereby forming a cushioning element. A specific application of the cushioning element may be the upper of a footwear item (shoe), or in some embodiments, the sole of a footwear item. Figures 3A-3CExamples of different cushioning structures formed by polymers 39 with different patterns printed on textile 38 are shown. The various polymer structures, layouts, or patterns deposited on a substrate fabric or textile as described below can be used as part of a footwear item or shoe.

[0089] One or more deposition paths can be arranged in aligned, offset, or intersecting patterns to form adjustable buffer zones with specific hardness, elasticity, and shear resistance. For example... Figure 4A As shown, the pattern of polymer 39 on textile 38 can be varied, thereby providing different cushioning qualities / performances within a single, monolithic frame made of polymer material 39. Figure 4B As shown, a three-dimensional grid or patterned polymer 39 may be sandwiched between a pair of textile layers 38. In some embodiments, the bonding between the two layers of textile 38 may be achieved by chemical bonding or melting, wherein the polymer is deposited on the first layer, and wherein a second overlay is positioned on the printed layer prior to the curing of the polymer 39. In some embodiments, after such curing, the second overlay of textile 38 may be positioned over the printed layer of polymer 39, but the second layer of polymer 39 is deposited / printed over the second overlay of textile 38 such that the second layer of polymer is fused with and encapsulates the second overlay of textile 38.

[0090] The printing geometry can be customized to the tensile, bending, or shear properties of the substrate textile. Furthermore, it is possible to create locked areas, anisotropic stiffness, or dynamic response feature profiles. For example... Figure 5 As shown, polymer 39 can be deposited in a pattern, wherein an open-cell three-dimensional structure 100 is formed on textile 38, and a low-porosity or non-porosity protective layer 102 of polymer 39 is printed or formed on the open-cell three-dimensional structure 100. This configuration can provide a protective surface on soft cushioning. This configuration can be formed into a single, integral, monolithic framework made of polymer 39 in a single deposition flow process. In other embodiments, structure 100 can be formed first, followed by the formation of protective layer 102, which is applied at a certain temperature to fuse with the substrate structure 100. Figures 6A-6E As shown, the controller 36 causes the applicator 26 to form different patterns or three-dimensional grids of polymer 39 on the textile 38, wherein different patterns can provide different properties for the polymer layer and the substrate textile 38, such as different flexibility or tensile properties. Specific layers or patterns can protect the substrate layer or pattern.

[0091] Intentional Z-axis movement during deposition can create textured surfaces, providing aesthetic effects such as improved grip, flexibility, or those unattainable through flat printing. Post-deposition surface shaping can be achieved using a heated texture plate that remelts the polymer surface, imparting 3D textures, patterns, or branding elements. In some embodiments, controller 36 can output control signals to cause applicator 26 to form various textures on textile 38 using polymer 39. Figure 7A An example tool path 53 is shown, where a nozzle controlled by the actuator of system 20 forms such a texture. Figures 7A-7C An example of a texture formed by polymer 39 on textile 38 is shown. Such a texture is formed not only by controlling the XY directions of nozzle 28 (and / or print bed 24) but also by controlling the Z-axis positioning of nozzle 28 (and / or print bed 24). Controller 36 can also control the flow rate to provide this surface texture.

[0092] like Figure 8A As shown, in some embodiments, when the polymer is in a liquid or imprintable state, the overlay 57 can be pressed onto the printed polymer 39 (a second polymer between the textile 38 and the embossing plate) to form a texture, which can be a surface texture (a rough or recessed surface that matches the surface of the plate 57) or a design, graphic, or logo. In some embodiments, the polymer 39 can be injected into the textile 38 and contact the substrate texture / embossing plate that provides the texture, design, graphic, or logo. Figures 8A-8C Examples of such textures, patterns, or logos are shown. Figure 8B An embossed pattern 58 in a jet polymer 39 on a textile 38 is shown. Figure 8C This illustrates embossing a logo or other graphic image 63 onto a polymer deposited on textile 38 (before the polymer cures or hardens).

[0093] like Figure 9 As shown, controller 36 can be configured to output a control signal causing applicator 26 to apply polymer 39 onto textile 38 in a wavy pattern. Polymer 39 may be elastic to adjust the elasticity of the substrate textile 38. Thus, the arrangement of the wavy lines of polymer 39 can provide stretch or elasticity in the Y-axis direction (the wavy lines bend back to straight when textile 38 is stretched in the Y-axis direction) but resist stretching in the X-axis direction.

[0094] Figure 10 Examples are shown of a first polymer 39-1 deposited along the Y-axis and a different second polymer 39-2 deposited along the X-axis. The different polymers 39-1 and 39-2 can have different physical properties, thereby altering the overall properties of the textile 38 in the X and Y axis directions.

[0095] In some embodiments, multiple textile layers can be joined by depositing polymers between or around the embedded structures to form a composite material or 3D bonded textile assembly. For example, Figures 11A-11C A portion of example spacer / buffer structure 2412 is shown. Structure 2412 is similar to structure 2312, except that, as Figure 11B and Figure 11C As shown, the grid 2339 has a varying height in at least one length and / or width dimension. In the illustrated example, the grid 2339 has a lower height, and the central portion 2343 gives the grid 2339 an upwardly concave profile. In the illustrated example, the covering polymer 2351 has a uniform thickness or height; for example, the outer contour of structure 2412 has a corresponding concave profile or curvature. In some embodiments, the polymer 2351 may have a non-uniform height or thickness in at least one dimension to amplify the curvature of the outer contour or to present a substantially flat or planar outer contour.

[0096] Figures 12A-12C A partial structure of example spacer / buffer structure 2512 is shown. Structure 2512 is similar to structure 2412, except that structure 2512 includes a cover polymer 2551 instead of a cover polymer 2351. Cover polymer 2551 comprises a polymer deposited in liquid form and subsequently cured or hardened. Cover polymer 2551 is deposited on cover textile 2348 at two spaced locations above mesh 2339, penetrating textile 2348 and bonded or fused to the substrate portion of mesh 2339 at the spaced locations. In the example shown, cover polymer 2551 comprises a pair of polymer lines or strips deposited at and connected to opposite ends of mesh 2339. Figure 12CAs shown, the cover polymer 2551 anchors two spaced portions of the cover textile 2348 to stretch the cover textile 2348 above and off (and away from contact with) the top surface of the substrate recess of the mesh 2339. Thus, structure 2512 provides a surface texture primarily defined by the textile 2348 while providing airflow between the textile 2348 and the top surface of the substrate recess of the mesh 2339. Like the cover polymer 2351, the cover polymer 2551 may be formed of a polymer compatible with or identical to the polymer forming the mesh 2339 or at least a portion of the mesh 2339 located below and in contact with the cover polymer 2551. In some embodiments, the cover polymer 2551 and the mesh 2339 are formed of a TPU polymer. In some embodiments, one or both surfaces of the textile 2348 have a compatible polymer coating or film, such as a TPU coating or film, to further enhance adhesion. In the illustrated example, the cover polymer 2551 penetrates and extends through the textile 2348 and connects to the mesh 2339, thereby forming a mechanical lock relative to the textile 2348. In other embodiments, the covering polymer 2551 may not penetrate the textile 2348, wherein the mesh 2339 is fixed to a portion of the textile 2338, and wherein the upper surface of the textile 2340 is fixed to the covering polymer 2551. In such embodiments, the covering polymer 2551 can serve as a reinforcing rib. In the illustrated example, the mesh 2339 consists of a series of parallel lines (such as... Figure 12A As shown, the grid 2339 is formed to allow the structure to bend or fold about an axis parallel to these lines. It should be understood that the grid 2339 can have various other patterns, shapes, or geometries. As mentioned above, textiles 2338 and 2348 can comprise different textiles with different performance characteristics. In some embodiments, textiles 2338 and 2348 can be textiles of the same type having the same properties.

[0097] Each of the aforementioned spacers / buffers can be used for a variety of purposes. For example, each of the aforementioned spacers / buffers can be used at specific locations on clothing or equipment worn by a person, where the clothing or equipment presses against the person's body structure. For example, each of the spacers / buffers can be applied to portions of clothing or equipment that abut against the top of the shoulders of the person wearing the clothing or equipment. Similarly, each of the spacers / buffers can also be used in areas of clothing or equipment that abut against the waist. In other embodiments, each of the spacers / buffers can also be used in other areas of clothing or equipment. Each of these spacers / buffers can be applied to other articles, such as garments, clothing, or other structures.

[0098] Figure 13AThe diagram shows a cross-sectional view of a portion of an extruded polymer line 5070, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5071 of the upper 5030, for example, using the extruder 26 of the manufacturing system 20 described above. The line 5070 may be located in any of the aforementioned areas of the shoe 5020 or in other areas of the upper 5030. The line 5070 includes a surface portion 5072 and a series of spaced-apart panel-penetrating anchors 5073.

[0099] The surface portion 5072 extends along the outer surface of the panel 5071 and is higher than the outer surface of the panel 5071. In the example shown, the surface portion 5072 does not penetrate the surface of the panel 5031.

[0100] Anchor 5073 protrudes from orifice portion 5072 and penetrates panel 5071, extending from surface portion 5072 below surface 5074 of panel 5071. Anchor 5073 can be formed by lowering nozzle 28 to a position closer to surface 5074 during polymer material spraying, increasing the pressure of polymer material spraying, and / or reducing the viscosity of the sprayed polymer material, such that the sprayed polymer penetrates surface 5074 at the illustrated spatial position. In one embodiment, nozzle 28 moves along illustrated path 5075, temporarily lowers towards surface 5074 at position 5076, dives or sinks towards surface 5074 during polymer material spraying, then vertically raises nozzle 28 away from surface 5074, and translates through surface 5074 to the next position 5076.

[0101] After penetration, the polymer material cures, providing spaced mechanical interlocking or anchoring relative to the perforated panel 5071. Anchors 5073 hold the surface portion 5072 in place to prevent the line 5070 from separating from the panel 5071. Because the anchors 5073 are spaced, this fixation can be achieved with less material and adds less weight to the shoe 5020.

[0102] As shown by the dashed lines, in some embodiments, an additional layer 5078 may be formed on top of the surface portion 5072. In some embodiments, the additional layer 5078 may comprise a polymeric material and may be extruded by the system 20. In some embodiments, the additional layer 5078 may be applied while the surface portion 5072 is in a liquid state to facilitate welding or bonding of the layer 5078 to the surface portion 5072. In some embodiments, the additional layer 5078 may be formed of the same base polymeric material to facilitate welding. In other embodiments, the additional layer 5078 may be formed of a different material. In some embodiments, the additional layer 5078 may be in the form of a perforated panel, such as fabric or textile, wherein the additional layer 5078 and the surface portion 5072 are pressed against each other while the surface portion 5072 is in a liquid state, such that the surface portion 5072 penetrates and impregnates the perforations of the additional layer 5078. In this embodiment, hardening or curing of the surface portion 5072 results in a mechanical interlock with the perforated additional layer 5078. In other embodiments, the additional layer 5078 may be adhesively bonded to the surface portion 5072 of the line 5070.

[0103] Figure 13B This is a cross-sectional view showing a portion of an example extruded polymer line 5080, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5081 of the upper 5030, for example, using the extruder 26 of the manufacturing system 20 described above. The line 5080 can be located in any of the aforementioned areas of the shoe 5020 or other areas of the upper 5030. The line 5080 comprises a line of extruded polymer material produced by a nozzle 28 moving along a path 5085, wherein the nozzle 28 gradually rises and falls relative to the outer surface 5084. The line 5080 gradually transitions between different first portions 5086 and second portions 5087, the first portion 5086 being entirely above the surface 5084, and the second portion 5087 having most or all of its thickness at or below the surface 5084. Compared to line 5070, which provides anchor points at varying intervals, line 5080 is anchored to panel 5081 to span a larger area of ​​surface 5084, where a portion of surface 5084 (corresponding to portion 5087) coincides with the outermost surface of upper 5030. Line 5080 undulates along surface 5084, unlike line 5070.

[0104] Figure 13CThis is a cross-sectional view showing a portion of an example extruded polymer line 5090, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5091 of the upper 5030, for example, using the extruder 26 of the manufacturing system 20 described above. Line 5090 can be disposed in any of the aforementioned areas of the shoe 5020 or other areas of the upper 5030. Line 5090 comprises a line of extruded polymer material produced by a nozzle 28 moving along a path 5095, wherein the nozzle 28 gradually rises and falls relative to the outer surface 5094 (similar to the extrusion of line 5080), sharply inserts into the surface 5094 at each location 5097, and then rises vertically to form deeper penetrating anchors 5093 at intervals. Similar to line 5080, line 5090 gradually transitions between different first portions 5096 and second portions 5097, with the first portion 5096 entirely above surface 5094 and most or all of the thickness of the second portion 5097 located at or below surface 5094. Line 5090 provides gradual anchoring while providing stronger and deeper anchors 5093 at spaced intervals.

[0105] Figure 13D The diagram shows a cross-sectional view of a portion of an extruded polymer line 5108, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5101 of the upper 5030 using the extruder 26 of the aforementioned manufacturing system 20. Line 5108 may be located in any of the aforementioned areas of the shoe 5020 or other areas of the upper 5030. Line 5108 comprises a line of extruded polymer material generated by a nozzle 28 moving along a path 5105, wherein the nozzle 28 initially lowers such that the extruded polymer material penetrates the surface 5104 of the panel 5101 (mechanically interlocked with the material of the perforated panel 5101), while also partially projecting upwards along the entire length of line 5108 above the surface 5104 to achieve abrasion resistance. At a specific location 5107, the nozzle 28 is raised during extrusion and then lowered before translating to the next location 5107. This results in the line 5108 being provided with posts or supports 5109, which are further raised above those portions of the line 5108 that protrude above the surface 5104. These supports 5109 may provide additional protrusions or protrusions at spaced locations along the line 5108 to improve abrasion resistance.

[0106] As shown by the dashed lines, in some embodiments, an additional layer 5078 may be formed on top of the support column 5109. In some embodiments, the additional layer 5078 may comprise a polymeric material and may be extruded by the system 20. In some embodiments, the additional layer 5078 may be applied while the support column 5109 is in a liquid state, thereby promoting welding or bonding of the layer 5078 to the support column 5109. In some embodiments, the additional layer 5078 may be formed of the same base polymeric material as the line 5108 to promote welding. In other embodiments, the additional layer 5078 may be formed of a different material.

[0107] In some embodiments, the additional layer 5078 may be in the form of a perforated panel, such as fabric or textile, wherein the additional layer 5078 and the support 5109 are pressed against each other while the support 5109 is in a liquid state, such that the support 5109 penetrates and impregnates the perforations of the additional layer 5078. In such embodiments, curing or hardening of the polymeric material of the support 5109 results in a mechanical interlock with the perforated additional layer 5078. In other embodiments, the additional layer 5078 may be adhesively bonded to the support 5109 of the thread 5108. In some embodiments, the support 5109 creates a space between the additional layer 5078 and the thread 5108. In embodiments where the polymeric material is flexible or elastic, the support 5109, used alone or in combination with the layer 5078, may provide enhanced cushioning for those areas in which the thread 5108 is formed.

[0108] Figure 13E The diagram shows a cross-sectional view of a portion of an extruded polymer line 5110, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5111 of the upper 5030 using the extruder 26 of the manufacturing system 20 described above. The line 5110 may be located in any of the aforementioned areas of the shoe 5020 or in other areas of the upper 5030.

[0109] Line 5110 comprises an extruded polymer material line generated by a nozzle 28 moving along a path 5115, wherein the nozzle 28 translates over the outermost surface 5114 of the panel 5111, such that the extruded polymer material extends along the surface 5114 of the panel 5111 but does not penetrate it. At a specific location 5117, the nozzle 28 initially lowers or inserts into the surface 5114 during extrusion to form an anchor 5113, and rises during extrusion (without extensive translation along the surface 5114) to form a support 5119 substantially aligned with and vertically positioned above the substrate anchor 5113. After forming the corresponding or aligned anchor 5113 and support 5119, the nozzle continues to translate across the surface 5114 to the next location 5117 to form the next pair of corresponding anchors and supports. This process is repeated along the length of line 5110.

[0110] Similar to anchors 5073 and 5093, anchor 5113 provides discrete or different anchors that mechanically interlock with the substrate panel 5111 to securely hold the remainder of line 5110. Like pillar 5109, pillar 5119 is raised above the remainder of line 5110 (those portions of line 5110 between each pillar 5119), and additional protrusions or protrusions may be provided at spaced locations along line 5100 to improve abrasion resistance. Similar to line 5100, an additional layer 5078 may be provided on top of pillar 5109 (see discussion of pillar 5109 versus layer 5078).

[0111] Figure 13F This is a cross-sectional view showing a portion of an example extruded polymer line 5120, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5121 of the upper 5030, for example, using the extruder 26 of the manufacturing system 20 described above. The line 5120 can be located in any of the aforementioned areas of the shoe 5020 or other areas of the upper 5030. The line 5120 comprises a line of extruded polymer material generated by a nozzle 28 moving along a path 5125, wherein the nozzle 28 translates at a height above the outermost surface 5124 of the panel 5121 such that the extruded polymer material includes a surface-penetrating portion 5126, and is raised at position 5127 to form a surface-covering portion 5128 extending along the surface 5124 of the panel 5121 without penetrating the surface 5124. In some embodiments, the height of the nozzle 28 above the surface 5124 may be reduced such that a portion of the surface-covering portion 5128 penetrates below the surface 5124. Line 5120 provides a gradual change in the level of penetration relative to panel 5121, so as to provide a gradual change relative to those portions of the patterned filament overlay 5034 formed by line 5120.

[0112] Figure 13GThis is a cross-sectional view showing a portion of an example extruded polymer line 5130, which forms part of a patterned filament overlay 5034 and has been extruded or sprayed onto the substrate panel 5131 of the upper 5030, for example, using the extruder 26 of the manufacturing system 20 described above. The line 5130 may be located in any of the aforementioned areas of the shoe 5020 or other areas of the upper 5030. The line 5130 comprises a line of extruded polymer material generated by a nozzle 28 moving along a path 5135, wherein the nozzle 28 initially translates along the surface 5134 and is positioned at a certain height above the surface 5134 during extrusion, such that the extruded polymer forming the line 5130 forms a horizontal or flush portion 5139, which is flush with, located at, or below the surface 5134. At a specific location 5137, the nozzle 28 is gradually raised (in an oblique manner) relative to the surface 5136 to form a ramp portion 5138 of the line 5130. The ramp portion 5138 extends from one end completely below or flush with surface 5134 to the other end completely above or on top of surface 5134. The horizontal or flush portion 5139 provides a flat or smooth and horizontal surface for bonding or overlapping additional layers relative to panel 5131. The ramp portion 5138 provides a gradual increase in the height of line 5130 above surface 5134 to provide enhanced abrasion resistance without sharp changes that could create stress points.

[0113] Figures 14A-17 An example garment, in the form of a running vest 6020, is shown, comprising an example patterned filament overlay (PFO) 6034. The running vest 6020 includes one or more panels 6030 forming a back portion 6040, a shoulder portion 6042, a chest portion 6044, and an abdominal portion 6046. The back portion 6040 is configured to extend along the back of the person wearing the vest 6020 until reaching a back neck cover portion 6047, which is configured to extend along the back of the neck of the person wearing the vest 6020. The shoulder portion 6042 extends from the back portion 6040, close to the back neck cover portion 6047, wraps around the neck, and is positioned above the shoulders. The chest portion 6044 extends downward along the front of the person wearing the vest 6020, extending from the shoulder portion 6042 across the chest or pectoral muscles. The abdominal portion 6046 extends downward from the chest portion 6044 toward the waist of the person wearing the vest 6020.

[0114] In the illustrated example, the abdominal portion 6046 is connected to the back portion 6040 via a side portion 6051 extending below the armpit of the person wearing the vest 6020. The side portion 6051 includes a panel integrally formed with or connected to the back portion 6040 and the abdominal portion 6046. In other embodiments, the side portion 6051 may include cords, straps, or other connecting structures. Each of these side portions may consist of a single panel or multiple panels connected together.

[0115] In the illustrated example, the chest portion 6044 and the abdominal portion 6046 are interconnected by a connecting line 6048. The connecting line 6048 may include a rope, strap, or band. In some embodiments, the connecting line 6048 may be elastic. In other embodiments, the connecting line 6048 may be inelastic and its length may be adjustable via a buckle or the like. The connecting line 6048 may be permanently secured to the left and right portions of the chest portion 6044 and the abdominal portion 6046, or it may be detachable, allowing the left and right sides of the chest portion 6044 and the abdominal portion 6046 to be pulled apart. For example, in some embodiments, the connecting line 6048 may include left and right portions that can be detachably interconnected via a buckle, snap, or the like. In some embodiments, the connecting line 6048 may have end portions that are releasably connected to either or both of the left and right portions of the chest portion 6044 or the abdominal portion 6046.

[0116] In other embodiments, if the vest 6020 does not include a front vent (the left and right chest portions and / or left and right abdominal portions 6046 are integrally formed as part of a single, monolithic chest cover consisting of one or more panels), the connecting line 6048 can be omitted. In these embodiments, a head opening is formed between and defined by a single continuous chest cover, left and right shoulder portions 6042, and a neck and back cover 6047, and wherein, when a person wears the vest 6020, their head passes through the opening, the vest 6020 is pulled over their head, and it is slipped over their shoulders.

[0117] like Figure 14BAs shown, the running vest 6020 includes a rear side opening pocket 6049 disposed on a back portion 6040. The pocket 6049 may be constructed of an elastic or resiliently stretchable panel attached to the back portion 6040, thereby forming a side opening to a horizontally extending internal space configured to accommodate windproof clothing, liquid containers, or other devices or supplies. In other embodiments, the running vest 6020 may include additional mounting or carrying capabilities for equipment and / or supplies on the front or back. For example, the running vest 6020 may include elastic or non-elastic straps attached to opposite ends for securing equipment, supplies, or other attachment mechanisms, such as carabiners. The running vest 6020 may also, or alternatively, include a top opening pocket or pocket for accommodating hydration containers (water bottles, etc.), food / energy sources, or lightweight rain gear (ponchos, hats, etc.). Such pockets may include closure mechanisms, such as hook-and-loop fasteners, snaps, buttons, or zippers. In some embodiments, the running vest 6020 may also include a cable or conduit wiring sleeve built into the running vest 6020 for guiding wires or cables or for guiding water bladders.

[0118] PFO 6034 comprises a single continuous polymer thread, filament, or filament (these terms are used interchangeably) that is wound in a serpentine manner starting from the back neck cover portion 6047, crossing the left and right shoulder portions 6042, extending downward along the front of the vest 6020, crossing at least the chest portion 6044, and possibly extending to the abdominal portion 6046. In some embodiments, the polymer filament comprises a foam polymer. In some embodiments, the polymer filament comprises a thermoplastic polyurethane (TPU) material. Figure 15 This is an enlarged view of PFO 6034. The serpentine pattern of PFO 6034 provides a degree of flexibility because the undulations can spread out under load in a direction perpendicular to the back-and-forth direction of the undulations.

[0119] In the example shown, PFO 6034 has multiple sections between different areas of running vest 6020, each section having at least one varying property. PFO 6034 has a first back neck section 6050, a second shoulder section 6052, and a front section 6054. The back neck section 6050 extends over the back neck cover portion 6047, across the back and neck of running vest 6020. The shoulder section 6052 extends forward from the back neck section 6050 to above the top of the shoulder, located on shoulder portion 6042. The front section 6054 extends downward along the front of running vest 6020, extending from shoulder section 6052 to chest portion 6044 and abdominal portion 6046.

[0120] Sections 6050, 6052, and 6054 have different densities to provide varying degrees of reinforcement and breathability. The density (number of undulations per unit area) of the back neck section 6050 is greater than that of the shoulder section 6052. These different densities are achieved by controlling the path of the nozzles extruding the polymer along one or more panel surfaces of the running vest 6020. The density of the shoulder section 6052 is greater than that of the front section 6054. The higher density of the back neck section 6050 enhances the reinforcement of the back neck cover portion 6047, making it more load-bearing. The higher density of the shoulder section 6052 also enhances the reinforcement of the shoulder portion 6042, making it more load-bearing. The lower density of the front section 6050 provides a larger spacing between the undulations, thus reducing reinforcement and increasing flexibility and breathability.

[0121] In the example shown, intervals 6050, 6052, and 6054 also have different degrees of penetration. Figure 16A , Figure 16B , Figure 16C , Figure 16D and Figure 17 The diagram shows single filaments or lines 6035 forming PFO 6034, which have different penetration depths. The penetration depth of section 6050 is related to... Figure 16D Similarly, as shown, a single filament or wire 6035 has the greatest penetration depth, with most of the wire 6035 extending below the surface of the substrate or panel 6030. Greater penetration maintains reinforcement performance while altering surface properties to a lesser extent. Greater penetration enhances the anchoring of the PFO 6034, thereby making the attachment of the interval 6050 more secure.

[0122] The penetration distribution profiles of shoulder section 6052 and anterior section 6054 are similar to Figures 16A-16D and Figure 17 Similar to the example shown. Line 6035 from... Figure 16D The maximum penetration depth shown transitions along the 6050-degree cervical-dorsal region to... Figure 16A The minimum penetration depth of shoulder section 6052 is shown. Because line 6035 has the greatest height and smallest penetration depth in shoulder section 6052, line 6035 in section 6052 provides greater load cushioning. As line 6035 extends from shoulder section 6052 toward and along the front portion 6054, the penetration depth of line 6035 gradually increases, as... Figure 16B and 16C As shown, as line 6035 extends downward along the front of running vest 6020, the penetration depth of line 6035 gradually increases, thereby enhancing the anchoring or fixation of line 6035 while maintaining the reinforcement performance of line 6035 in these areas.

[0123] Although the line 6035 shown in the figure transitions gradually between different penetration depths, in other embodiments, the variation in penetration depth of line 6035 can also be achieved in other ways or variations. In some embodiments, line 6035 may have a shape similar to that described above. Figure 13A Figure 13B Figure 13C or Figure 13G The variation shown penetrates the distribution profile. In these embodiments, a portion of line 6035 may be provided with anchors 5113 as described above.

[0124] In the illustrated example, PFO 6034 extends along the outer running vest 6020, wherein those sections of PFO 6034 (shoulder section 6052) also have a very high level of abrasion resistance. In other embodiments, at least a portion of PFO 6034 may be covered by one or more additional layers extending to the top of PFO 6034, thereby concealing PFO 6034. In some embodiments, PFO 6034 may additionally include struts or posts 5109 or 5119 (as described above relative to...). Figure 13D and Figure 13E As shown in the figure, the upper panel is supported by or fixed to the support or column.

[0125] Figure 18A , Figure 18B and Figures 19-20 An example of a piece of equipment or personal carrying device in the form of a backpack 6120 is shown, which includes example patterned filament overlays (PFOs) 6234 and 6236. The backpack 6120 includes a wrapping section 6124 and a frame 6128 (as shown in the image). Figure 19 (as shown), shoulder straps 6132-L and 6132-R (collectively referred to as shoulder strap 1632), and waist belt 6136. The wrapping portion 6124 is made of a flexible material, such as canvas. In some embodiments, the wrapping portion 6124 may be made of a flexible material, such as woven fabric, textile, or fabric. In some embodiments, the fabric may be coated and / or laminated with at least one water-repellent, water-resistant, and / or waterproof material.

[0126] In the illustrated example, the package portion 6124 includes a top opening 6146 for access to an internal compartment. In the illustrated example, the top opening 6146 can be closed via a zipper 6147. In other embodiments, the top opening 6146 can be closed using a roll-top type closure mechanism or a hem-and-draw-cord type closure mechanism. In other embodiments, the backpack 6120 may use other closure mechanisms. It should be understood that the package portion 6124 can have a variety of different configurations and is not limited to an open-top backpack.

[0127] Frame 6128 (e.g.) Figure 19 The backpack 6124 (shown) is composed of at least one rigid or semi-rigid sheet or panel, wherein the rigidity of the sheet or panel is greater than the rigidity of the flexible material constituting the wrapping portion 6124. The frame 6128 stabilizes the shape of the wrapping portion 6124 along the back of the person wearing the backpack 6120. The frame 6128 also helps to transfer and distribute the load carried by the backpack 6120 to the person wearing it. The frame 6128 may be made of materials such as plastic, composite materials, or metal. The frame 6128 has an appropriate thickness to exhibit sufficient strength without increasing weight. In some cases, the frame 6128 may be omitted.

[0128] Shoulder straps 6132 serve as the load-bearing system for backpack 6120. The lower end 6154 of each shoulder strap 6132 is attached to the packing portion 6124, and the upper end 6158 is connected to the frame 6128 (if provided) and directly to the packing portion 6124. Shoulder straps 6132-L and 6132-R are detachably secured to each other along the front of the person wearing backpack 6120 via a front connector 6162 (shown as a side release buckle). In other embodiments, connector 6162 may be of other types. In the illustrated example, each shoulder strap 6132 includes a panel 6133 serving as the base of a PFO 6234.

[0129] Waist belt 6136 includes a strap configured to wrap around or extend around the waist region of a person wearing backpack 6120. Waist belt 6136 includes front adjusting straps 6160-L, 6160-R (collectively referred to as front adjusting strap 6160), a front connector 6162, and side panels 6164-L, 6164-R (collectively referred to as side panels 1806). Front adjusting strap 6160 extends from side panel 6164 to connector 6162. Front adjusting strap 6160 forms the front side of waist belt 6136 and mates with connector 6162 for adjusting the length of waist belt 6136. In the illustrated example, connector 6162 includes a side-release buckle. In other embodiments, connector 6162 may include other forms of buckles or other forms of connectors that releasably interconnect the front adjusting straps 6164-L and 6164-R along the front of the person wearing backpack 6120.

[0130] Side panels 6164 extend between the front adjustment strap 6160 and the angle retainer 6166. Each side panel 6164 wraps around the side of the person wearing the backpack 6120 and terminates near the back of the person wearing the backpack 6120, forming part of the rear side of the strap 6136. Side panels 6164-L form the left rear end portion 6168-L. Side panels 6164-R form the right rear end portion 6168-R.

[0131] Angle retainer 6166 facilitates adjusting the relative angle of side panels 6164 and their straps 6160, and holds these side panels 6164 at a selected relative angle. In the illustrated example, angle retainer 6166 includes a rotating rod 6169 and connector straps 6170-1 and 6170-2 (collectively referred to as straps 6170). The rotating rod 6169 includes a strap or strip whose end is attached to or formed into part of the rear end portion 6168-R. The rotating rod 6169 provides a structure around which the free end of the strap 6170 can rotate and wrap, thereby detachably connecting the rear end portion 6170-R to the rear end portion 6170-L.

[0132] The strap 6170 extends from the rear end portion 6168-L and wraps around the rotating rod 6169, then is detachably connected together. In this embodiment, the free end 6171 of the strap 6170 can pass through and wrap around the rotating rod 6169, and after passing around the rotating rod 6169, can be reversed and connected to itself, using two hook-and-loop fasteners (VELCRO). TM )6171 is connected. By changing the degree to which the two straps 6170 surround the rotating rod 6169 and the position of the self-connection, the length of the two straps 6170 between their respective end portions 6168 can be adjusted and changed, thereby holding the side panel 6164 at any of a number of relative angles to accommodate individuals with specific iliac crests.

[0133] In other embodiments, the waist belt 6136 may be configured differently. In some embodiments, the waist belt 6136 may not provide angle adjustment. For example, the waist belt 6136 may alternatively include a continuous belt, or a continuous, uninterrupted, or complete panel or panel assembly (without the swivel 6169 or strap 6170), the panel or panel assembly providing two sides 6164 and passing through a sleeve coupled to the frame 6128. In some embodiments, side panels 6164-R may be non-removably attached to the right side of the frame 6128 (if provided) or wrapping the rear of the portion 6124, while side panels 6164-L may be non-removably attached to the left side of the frame 6128 (if provided) or alternatively wrapping the back of the portion 6124.

[0134] PFO 6234 comprises a single, continuous polymer thread, filament, or strand (these terms are used interchangeably) 6235, which is wound back and forth in a serpentine manner along the length of each shoulder strap 6132. In some embodiments, the polymer filament 6235 comprises a foam polymer thread. In some embodiments, the polymer filament comprises thermoplastic polyurethane (TPU). The serpentine pattern of PFO 6234 provides a degree of flexibility because the undulating patterns can unfold under load in a direction perpendicular to the direction of the back-and-forth winding of the undulating patterns.

[0135] In the example shown, PFO 6234 has various intervals between different regions of shoulder strap 6132, these intervals having at least one varying property. Each PFO 6234 has a top shoulder interval 6252 and a front interval 6254. The top shoulder interval 6252 extends forward from the wrap portion 6124 above the top of the shoulder, located on shoulder strap 6132. The front interval 6254 extends downward from its corresponding top shoulder interval 6252 toward the lower end 6154. Both intervals 6252 and 6254 extend across a large portion of the width of their respective portions of shoulder strap 6132. Intervals 6252 and 6254 have varying densities to provide different levels of reinforcement and different levels of breathability. The density (number of undulations per unit area) of interval 6252 is greater than that of the front interval 6254. The variation in density is achieved by controlling the path of the nozzle extruding the polymer along the surface of one or more panels of shoulder strap 6132. The higher density of the top shoulder section 6252 enhances the reinforcement of specific parts of the shoulder strap 6132, thereby improving load-bearing capacity. The lower density of the front section 6254 increases the spacing between the undulations, thereby reducing reinforcement and improving flexibility and breathability.

[0136] In the example shown, intervals 6252 and 6254 also exhibit varying degrees of penetration. The penetration distribution profile of line 6235 in shoulder interval 6252 and front interval 6254 is similar to... Figures 16A-16D and Figure 17 The penetration distribution profile of line 6035 shown is similar. As line 6235 extends downward from the shoulder top region 6252, the penetration depth of line 6235 gradually increases, as... Figure 16B and Figure 16C As shown. The penetration depth gradually increases as line 6035 extends downward along shoulder strap 6132, enhancing the anchoring or fixation of line 6035 while maintaining the reinforcement performance of line 6235 in these intervals.

[0137] Although line 6235 is described as gradually transitioning between various penetration depths, in other embodiments, the variation in penetration depth of line 6235 may be implemented in other ways or variations. In some embodiments, line 6235 may have the same characteristics as described above. Figure 13A , Figure 13B , Figure 13C or Figure 13G The diagram illustrates a similar variation in the penetration distribution profile. In these embodiments, portions of line 6235 may be provided with anchors 5113 as described above. In some embodiments, line 6235 may be replaced by multiple polymer material lines or filaments that extend end-to-end (or are joined end-to-end) or are parallel to each other. In some embodiments, PFO 6234 may be formed from multiple individually extruded or deposited lines or filaments.

[0138] In the illustrated example, PFO 6234 extends along the outer edge of shoulder strap 6132 and along the shoulder surface of the person wearing backpack 6120 away from 6132, wherein the highest sections of PFO 6234 (shoulder top section 6252) also have the highest level of abrasion resistance. In other embodiments, at least a portion of PFO 6234 may be covered by one or more additional layers extending above the top of PFO 6034, thereby concealing PFO 6234. In some embodiments, PFO 6234 may also include a support or post 5109 or 5119 (as described above). Figure 13D and Figure 13E (as shown and described), wherein the upper cover panel is supported by or fixed to a support or post.

[0139] like Figure 18A , Figure 18B and Figure 20 As shown, PFO 6236 comprises a single, continuous polymer thread, filament, or strand (these terms are used interchangeably) 6237, which is wound back and forth in a serpentine manner along the length direction of axis 6139 of each side panel 6134, extending substantially from the top edge to the bottom edge of each side panel 6164. In some embodiments, PFO 6236, like PFO 6234, is made of a foam polymer. In some embodiments, PFO 6236, like PFO 6234, is made of thermoplastic polyurethane (TPU) material. In the illustrated example, PFO 6236 extends to a distance within the top and bottom edges no greater than 10% of the maximum width of the side panel 6164, and / or in some embodiments, PFO 6236 extends to a distance of no more than 1.5 cm from each of the top and bottom edges of the side panel 6164. The serpentine pattern of PFO 6236 along axis 6139 provides a degree of flexibility or stretchability. Meanwhile, the PFO 6236 formed by the line 6237 reinforces the side panel 6164 in a direction perpendicular to the axis 6139, thereby suppressing an effect known as "roping." The roping effect occurs when tension along the axis 6139 is concentrated on the axis 6139. This roping effect, along with the concentration of tension along the axis 6139, can cause discomfort to the person wearing the belt 6136. Conversely, the PFO 6236 distributes the tension or load in a direction perpendicular to the axis 6139 to suppress or reduce this roping effect.

[0140] While the line 6237 shown in the figure extends vertically and horizontally on opposite sides of axis 6139 in a zigzag / zigzag pattern to form PFO 6236, in other embodiments, line 6237 may extend across axis 6139 in a serpentine manner, or may otherwise extend above and below axis 6139. For example, line 6237 may alternatively undulate vertically across axis 6139 in a square wave pattern or a circular sine wave pattern. In some embodiments, PFO 6236 may be formed from multiple individual lines or filaments extruded or deposited onto side panel 6134. In some embodiments, line 6235 may be replaced by multiple polymer material lines or filaments extending end-to-end or parallel to each other.

[0141] In the example shown, line 6237 of PFO 6236 can have a maximum penetration depth into the substrate or panel 6134, similar to... Figure 16D As shown. Therefore, line 6237 does not alter the surface profile but provides a low-distribution and reinforcing effect. In other embodiments, line 6237 may have varying penetration depths along its length to provide anchorage for PFO 6236. In some embodiments, line 6237 may additionally include anchors similar to anchor 5073 (as described above). Figure 13A The anchors shown and described.

[0142] In the illustrated example, the line 6237 of the PFO 6236 extends along the outermost edge of the belt 6136, away from the waist of the person wearing the belt 6136. In other embodiments, at least a portion of the PFO 6236 may be covered by one or more additional layers extending to the top of the PFO 6236, thereby concealing the PFO 6236. In some embodiments, the PFO 6236 may also include a post or support 5109 or 5119 (as described above regarding...). Figure 13D and 13E (as shown and described), wherein the upper cover panel is supported or fixed to the column or support.

[0143] Figure 18CAn example backpack 6120' is shown. Backpack 6120' is similar to the backpack 6120 described above, except that the shoulder straps 6132 of backpack 6120' additionally include PFO 6284. PFO 6284 is formed from individual strands, filaments, or threads 6285, which are wound back and forth in a serpentine manner above or over PFO 6234 in the shoulder top section 6252. The layout or pattern of PFO 6284 differs from that of PFO 6234. PFO 6234 is zigzag-shaped, while PFO 6284 is more similar to a square wave. In other embodiments, patterns 6234 and 6284 may each have different patterns that are distinct from each other. In other embodiments, PFO 6234 and 6284 may have similar patterns but differ in density, thread thickness, or thread width.

[0144] In some embodiments, line 6285 may be fused to substrate line 6235. For example, in some embodiments, both lines 6235 and 6285 may be formed of a thermoplastic material, wherein line 6285 is extruded at a sufficiently high temperature such that the substrate portion of line 6235 melts and fuses with the material of line 6285. In some embodiments, lines 6235 and 6285 are formed of the same polymer material. In some embodiments, lines 6285 and 6235 are formed of different polymer materials. In some embodiments, line 6285 may be deposited directly on top of the substrate panel or substrate of shoulder strap 6132, wherein line 6285 intersects with and bridges the substrate portion of line 6235. In this embodiment, both lines 6235 and 6285 may be at least partially embedded in and beneath the surface of the substrate substrate provided by one or more panels of shoulder strap 6132.

[0145] Lines 6285 and PFO 6284 provide greater height to the top shoulder section 6252, thereby enhancing abrasion resistance. In some embodiments, PFOs 6234 and 6285 are formed on the bottom or underside of the shoulder strap 6132, extending between the top or outer side of the shoulder strap 6132 and the shoulder of the person wearing the backpack 6120'. The additional height provided by the stacking of PFOs 6234 and 6284 can provide additional cushioning for the person wearing the backpack 6120'. In some embodiments, to provide abrasion resistance and / or cushioning by adding PFO 6284, those portions of PFO 6234 on the top shoulder section 6252 may alternatively be extruded or deposited to penetrate the substrate or panel of the shoulder strap 6132 to a greater depth, thereby enhancing the retention and interlocking of PFO 6234 with the shoulder strap 6132.

[0146] Figures 21-23An example of equipment in the form of a harness 6320 is shown, which includes example patterned filament overlays (PFOs) 6334 and 6336. Overlays 6334 and 6336 may be formed from foamed or non-foamed polymers. In some embodiments, the polymer may include a thermoplastic polyurethane (TPU) material. The harness 6320 includes a waist belt 6324 (sometimes referred to as “swami” in the context of a harness), leg loops 6326-R and 6326-L (collectively referred to as leg loops 6326), a protective ring 6327, and a leg loop riser 6328. In some embodiments, the harness 6320 may include additional main components that wrap around or wrap around the shoulders and / or chest of the person wearing the harness 6320. Although the invention is shown as being incorporated into a climbing harness, the invention is also applicable to other harnesses and backpacks.

[0147] Waist belt 420 is configured to support the waist of a person wearing seatbelt 400 via leg loops 526. Waist belt 424 is also configured to connect to a tether, rope, cable, or other flexible line, via which waist belt 424 can be suspended from an upper support to limit the extent to which waist belt 424 and the person wearing seatbelt 400 may fall from the upper support. Waist belt 6324 includes upper waist strip 6340, connector 6342, upper connector 6344, and equipment loop 6346. Upper waist strip 6340 includes a strip configured to wrap around the waist of a person wearing seatbelt 6320. As described below, PFO 6334 is deposited on at least a portion of upper waist strip 6340 to reinforce upper waist strip 6340 (allowing for the use of lighter materials) and reduce rope pull effects.

[0148] Connector 6342 connects the opposite ends of the waistband 6340. In the illustrated example, connector 6342 provides length adjustment functionality, wherein the end portions of the waistband 6340 can be spaced apart or overlapped to varying degrees to accommodate different waist sizes. In the illustrated example, connector 6342 includes a buckle 6348 and an adjusting strap 6350. Buckle 6348 is secured to one end of the waistband 6340, while adjusting strap 6350 is connected to the other end of the waistband 6340 and wraps around a portion of buckle 6348. In other embodiments, connector 6342 may have other configurations. In some embodiments, connector 6342 may be omitted, in which case the size of waistband 6324 is not adjustable.

[0149] The upper connector 6344 includes a strip, strap, or cord, the opposite ends of which are sewn to or integrally formed with the upper waistband 6340 to create a loop or opening for receiving the belay loop 6327. In other embodiments, the upper connector 6344 may employ other structures. For example, the upper connector 6344 may include a loop or other structure secured to the upper waistband 6340.

[0150] Equipment loop 6346 includes loops formed at various locations along the length of the waist belt 6340. Equipment loop 6346 provides a loop for attaching supplies, equipment, or gear to the waist belt 6324. For example, equipment with an associated carabiner can be fastened to one of the equipment loops 6346 to suspend the equipment on the waist belt 6324. In some embodiments, equipment loop 6346 may be omitted.

[0151] Leg loops 6326-R and 6326-L extend and suspend from the right and left front sides of the waist belt 6324, respectively. Leg loops 6326-R and 6326-L are configured to wrap around the right and left thighs of the person wearing the seatbelt 6320, respectively. Leg loops 6326 are substantially identical to each other. In some embodiments, leg loops 6326 are secured or attached to the waist belt 6324 by means of stitching or the like. In some embodiments, leg loops 6326 are integrally formed with the waist belt 6324; for example, fibers or strands of the leg loop extend continuously through both the leg loop 6326 and portions of the upper waistband 6340. In some embodiments, leg loops 6326 have an adjustable length to provide an adjustable internal opening to accommodate different thigh sizes.

[0152] like Figure 21 As shown, leg rings 6326 are interconnected at a lower connector 6354, which forms a loop or ring for receiving a protective ring 6327. In some embodiments, each leg ring 6326 may have an associated ring through which the protective ring 6327 passes. In other embodiments, the lower connectors for connecting the protective ring 6327 to the two leg rings 6326 may have other configurations.

[0153] The protective ring 6327 includes a loop or ring extending around the upper connector 6344 and the lower connector 6354 for suspending the two leg loops 6326 onto the waist belt 6324. The protective ring 6327 also provides a connection point for a tether support line (e.g., rope, cable, strap, or the like) that can be suspended from the upper support. For example, in some embodiments, the tether support line may comprise a carabiner that snaps onto the protective ring 6327. In some embodiments, such a protective ring may be formed of materials such as nylon, polyester, ultra-high molecular weight yarn, liquid crystal polymer (e.g., VECTRAN), or other fibers.

[0154] The leg loop riser 6328 includes straps, ropes, or the like, with a first end of each strap, rope, or the like connected to the underside of the corresponding leg loop 6326 and a second end connected to the rear of the waist belt 420. The leg loop riser 6328 helps to support and suspend the leg loop 6326 on the waist belt 6324.

[0155] Figure 22 A portion of the example waistband 6340 is shown, its layout optimally representing the PFO 6334. (As shown) Figure 22 As shown, the waistband 6340 includes straps 6360-R, 6360-L (collectively referred to as straps 6360) and central panels (one or more) 6362. Each strap 6360 has an open end, wherein open fibers 6364 are spread or spread across the width of the central panel 6362. In some embodiments, the fibers 6364 are sandwiched between a pair of central panels 6362. In other embodiments, the fibers 6364 are sandwiched between folded portions of the central panels 6362. Multiple panels are secured to each other, or the folds of the folded panels are held in a folded state by adhesives, stitching, welding, etc. In some embodiments, straps 6360-R are secured to padding 6357 (e.g., Figure 21 (as shown), and further sewn to the upper connector 6344. In some embodiments, the strap 6360-R is sewn or otherwise attached to the strap 6360-L. In some embodiments, the strap 6360-R is detachably attached to the strap 6360-L by one or more buckles, thereby allowing the belt 6324 to open.

[0156] like Figure 22As further illustrated, PFO 6334 comprises a single, continuous polymer thread, wire, or filament (these terms are used interchangeably) 6535, which is wound back and forth in a serpentine manner along the length direction of axis 6339 of the central panel(s) 6362, substantially extending from the top edge to the bottom edge of the central panel(s). In the illustrated example, PFO 6334 extends within the top and bottom edges at a distance not exceeding 10% of the maximum width of the central panel 6362, and / or in some embodiments, PFO 6334 extends to a distance not exceeding 1.5 cm from each of the top and bottom edges of the central panel(s) 6362. The serpentine pattern of PFO 6334 along axis 6339 provides a degree of flexibility or stretchability. Meanwhile, the PFO 6334 formed by the line 6335 reinforces the central panel 6362 in a direction perpendicular to the axis 6339 to suppress an effect known as "pull cord," where tension along the axis 6339 can concentrate along the line axis 6339, and this "pull cord" and tension concentration along the axis 6339 can cause discomfort to the person wearing the belt 6324. Instead, the PFO 6334 distributes the tension or load in a direction approximately perpendicular to the axis 6339 to suppress or reduce this pull cord effect.

[0157] While the line 6335 shown in the figure extends vertically and horizontally on opposite sides of axis 6339 in a zigzag / zigzag pattern to form PFO 6334, in other embodiments, line 6335 may extend along and across axis 6339 in a serpentine manner, or may otherwise extend above and below axis 6339. For example, line 6335 may alternatively undulate vertically across axis 6339 in a square wave pattern or a circular sine wave pattern. In some embodiments, PFO 6334 may be formed from multiple individual lines or filaments extruded or deposited onto the central panel(s) 6362. In some embodiments, line 6235 may be replaced by multiple polymer material lines or filaments extending end-to-end or parallel to each other.

[0158] In the example shown, line 6335 of PFO 6334 can have a maximum penetration depth into the substrate or central panel 6362, similar to... Figure 16D As shown. Therefore, line 635 does not alter the surface profile but allows for load distribution and reinforcement. In other embodiments, line 6335 may have different penetration depths along its length to anchor PFO 6334. In some embodiments, line 6335 may also include anchors similar to anchor 5073 (as described above). Figure 13A The anchors shown and described.

[0159] In the illustrated example, line 6335 of PFO 6334 extends along the outermost edge of central panel 6362, facing away from the waist of the person wearing belt 6324. In other embodiments, at least a portion of PFO 6334 may be covered by one or more additional layers extending to the top or above PFO 6334, thereby concealing PFO 6334. In some embodiments, PFO 6334 may additionally include posts or supports 5109 or 5119 (as described above regarding...). Figure 13D and 13E As shown and described), wherein the upper cover panel is supported by or fixed to the column or support.

[0160] In the illustrated example, the thread 6335 of PFO 6334 may penetrate one or more central panels 6362 to further at least partially wrap around or secure the open fibers 6364, thereby providing enhanced fixation and load distribution. In other embodiments, PFO 6334 may be deposited on smaller portions of the central panels 6362 of the waistband 6340, such as those portions not covering the open fibers 6364. In some embodiments, the thread 6335 of PFO 6334 may be used on other configurations of the waistband 6340, such as in embodiments where the waistband 6340 does not contain open fibers 6364, for example, when the strap 6360 is sewn or otherwise attached to the ends of the central panels 6362 that do not have such open end fibers.

[0161] Figure 23 Leg loop 6326-R and PFO 6336 are shown. As described above, leg loop 6326-L is similar to leg loop 6326-R and also includes PFO 6336. Leg loop 6326-R includes straps 6460-R, 6460-L (collectively referred to as straps 6460), core 6462, and cover panel 6463. Each strap 6460 has an open end, wherein the open fibers 6464 are spread or spread across the width of core panel 6462.

[0162] The core panel 6462 comprises an elongated elliptical panel over which the open fibers 6464 extend, and PFO 6336 is deposited. The cover panel 6463 is larger than the core panel 6462, and its opposite edges are folded over the core panel 6462 to cover the open fibers 6464 and the distal portions of the PFO 6336. Multiple panels are secured to each other by adhesives, stitching, fusion / welding, etc. In the illustrated example, when folded, the cover panel 6463 forms a window 6467 to expose the central portion of the PFO 6336. In another embodiment, the size and shape of the cover panel 6463 can be designed to completely cover the PFO 6336. In other embodiments, the leg ring 6326 can have other structures. For example, the leg ring 6326 may omit the open fiber 6464; the folded cover panel 6463 may be omitted; or it may include an folded cover panel that is simply laminated onto the core panel 6462.

[0163] Similar to PFO 6334, PFO 6336 comprises a single continuous polymer thread, wire, or filament (these terms are used interchangeably) 6337 that is wound back and forth in a serpentine manner along the length of axis 6439 of core panel 6462, extending substantially from the top edge to the bottom edge of core panel 6462. In the illustrated example, PFO 6336 extends within the top and bottom edges at a distance not exceeding 10% of the maximum width of core panel 6462, and / or in some embodiments, PFO 6336 extends to a distance of 1.5 cm from each of the top and bottom edges of core panel 6462. The serpentine pattern of PFO 6336 along axis 6439 provides a degree of flexibility or stretchability. Meanwhile, the PFO 6336 formed by the line 6337 reinforces the core panel 6462 in a direction perpendicular to the axis 6439 to suppress an effect known as "tight cording," where tension along the axis 6439 can concentrate along the axis 6439, potentially causing discomfort to the person wearing the belt 6324. Instead, the PFO 6336 distributes the tension or load in a direction approximately perpendicular to the axis 6439 to suppress or reduce this tight cording effect.

[0164] While the line 6337 shown in the figure extends vertically and horizontally on opposite sides of axis 6439 in a zigzag / zigzag pattern to form PFO 6336, in other embodiments, line 6337 may extend along and across axis 6439 in a serpentine manner, or may otherwise extend above and below axis 6439. For example, line 6337 may alternatively undulate vertically across axis 6439 in a square wave or circular sine wave pattern. In some embodiments, PFO 6336 may be formed from multiple individual lines or filaments extruded or deposited onto core panel 6462. In some embodiments, line 6235 may be replaced by multiple polymer material lines or filaments extending end-to-end or parallel to each other.

[0165] In the example shown, line 6337 of PFO 6336 can have a maximum penetration depth into the substrate or core panel 6462, similar to... Figure 16D As shown. Therefore, line 6337 does not change the surface profile, but can serve to distribute and reinforce the load. In other embodiments, line 6337 may have different penetration depths along its length to anchor PFO6336. In some embodiments, line 6337 may also include anchors similar to anchor 5073 (as described above). Figure 13A The anchors shown and described.

[0166] In the illustrated example, line 6337 of PFO 6336 extends along the outermost edge of core panel 6462, facing away from the thigh of the person wearing the leg ring. In other embodiments, at least a portion of PFO 6336 may be covered by one or more additional layers extending above PFO 6336, thereby concealing PFO 6336. In some embodiments, PFO 6336 may also additionally include a support or post 5109 or 5119 (as described above). Figure 13D and Figure 13E As shown and described), wherein the upper cover panel is supported by or fixed to a support or post.

[0167] In the illustrated example, the thread 6337 of PFO 6336 can penetrate the core panel 6462 to further at least partially wrap around or secure the open fibers 6464, thereby providing enhanced fixation and load distribution. In other embodiments, PFO 6336 can be deposited on smaller portions of the core panel 6462, such as those portions not covering the open fibers 6464. In some embodiments, the thread 6337 of PFO 6336 can be used in other configurations of the leg loop, such as in embodiments where the leg loop does not contain open fibers 6464, for example, by stitching or otherwise attaching a strap 6460 to the end of the core panel 6462 that does not contain such open fibers.

[0168] Figure 24 and Figure 25 An example garment in the form of a pair of snow-protective leg covers 6520 comprising a PFO 6534 is shown. The snow-protective leg covers 6520 include an insulated leg portion 6523 and instep straps 6524, which are opposite each other along the lower inner portion of the leg covers 6520 and typically cover the shin and ankle of the person wearing the leg covers 6520. In the illustrated example, the instep straps 652 include panels 6525 sewn and attached to the inner surface of the insulated leg portion 6523. In the illustrated example, the snow-protective leg covers 6520 are in the form of ski pants or snowboard pants. In other embodiments, the snow-protective leg covers 6520 may be associated with shoulder straps or may be part of a snow or ski bib.

[0169] Figure 25 This is an enlarged view of a portion of one of the foot circumference bands 6524 of the leg cover 6520, showing the PFO 6534 in more detail. The PFO 6534 comprises a single, continuous line of polymeric material 6535, which has been extruded or otherwise deposited onto a substrate provided by the panel 6525 forming the foot circumference band 6524. In other embodiments, the line 6535 of the PFO 6534 may be deposited directly onto the isolated leg portion 6523 of the leg cover 6520. In some embodiments, the line 6535 may be replaced by multiple lines or filaments of polymeric material extending end-to-end or parallel to each other. In some embodiments, the PFO 6534 may be formed from multiple individual lines or filaments that have been individually extruded or deposited.

[0170] like Figure 25 As shown, line 6535 extends vertically along a zigzag path in a meandering / zigzag pattern. The vertical zigzag lines are arranged in pairs of closed lines 6540-1, 6540-2, with significant spacing between these lines and adjacent or consecutive pairs of closed lines. The zigzag path of each vertical line facilitates vertical stretching in the direction indicated by arrow 6543, while the horizontal spacing between the pairs of vertical zigzag lines facilitates horizontal stretching or flexibility in the direction indicated by arrow 6545. Horizontal flexibility enhances the deformability of the lower end of the leg cover 6520 (near the left and right feet) to accommodate different individuals wearing different snow boots or ski boots.

[0171] In the illustrated example, line 6535 protrudes above or beyond the surface of substrate panel 6525. In some embodiments, line 6535 is at least 0.1 mm above the outermost surface of substrate panel 6525. In other embodiments, this height is at least 0.2 mm. Because line 6535 protrudes above the outermost surface of substrate panel 6525, line 6535 and PFO 6534 form a protrusion that provides abrasion resistance. This is particularly beneficial for those parts of the instep of the instep band 652 that may come into contact with each other during snow activities such as snowboarding and skiing. In some embodiments, the penetration depth of line 6535 may fluctuate or vary, for example, alternatively penetrating at a first depth and alternating at a lower depth as shown in the figure. Figure 13B The smaller depth penetration shown refers to the larger depth intervals that form anchors for securing line 6535. For example, in some embodiments, line 6535 may have a similar depth to... Figure 13A The configuration shown is similar to that with anchor 5073, or has the same configuration. Figure 13C The configuration shown is similar to that with anchor 5093. In some embodiments, line 6535 may have the same configuration as... Figure 13D The configuration shown is similar to that in which the uprights or supports 5109 provide abrasion resistance.

[0172] Figure 26 This is a cross-sectional view of the inner portion of the example leg cover 6620. Leg cover 6620 is similar to leg cover 6520, except that line 6535 has varying height and varying penetration depth, as shown. Specifically, the portions of line 6535 at their directly facing apexes 6551 (i.e., the circumferential center of PFO 6534) have the greatest height and the smallest penetration depth. As line 6535 extends away from apexes 6551, the height above panel 6525 gradually decreases, while the penetration depth through panel 6525 gradually increases. Therefore, the outer end of PFO 6534 has the maximum amount of anchorage for securing PFO 6534, while the apex 6551, located at the point of greatest wear, has the greatest height above panel 6525.

[0173] Figure 27An alternative PFO 6734 formed on panel 6525 is shown for use as foot inner band 6524. PFO 6734 is similar to PFO 6534, except that PFO 6734 includes a second continuous polymer thread, namely threaded filament 6585. Thread 6585 has the same pattern as thread 6535, except that thread 6585 is horizontally offset relative to adjacent portions of thread 6535. Thread 6585 has different material properties than thread 6535. In the example shown, thread 6585 contains a softer, more flexible material (first hardness-measuring polymer), while thread 6735 contains a harder, more abrasion-resistant material (second, larger hardness-measuring polymer). Thread 6585 extends above (outside) thread 6535 to form the outermost surface of foot inner band 6524. The larger hardness or hardness of thread 6585 provides enhanced abrasion resistance. In some embodiments, line 6585 is extruded or deposited at a temperature that facilitates fusion or soldering with the substrate portion of line 6535. In other embodiments, the foot circumference strip 6524 (whether formed on panel 6525 or directly on the insulating outer panel of the insulated leg portion 6523) may have other PFO or other patterns. For example, the foot circumference strip 6524 may have any of the PFO patterns described above.

[0174] Figures 28-30 An example garment in the form of shorts 6620 is shown. Figure 28 This is a rear perspective view of the 6620 shorts. Figure 29 This is the left side view of shorts 6620, where the right side view of shorts 6620 is... Figure 29 A mirror image of the content shown. Figure 30 yes Figure 28 Window in (reference) Figure 30 (Part of the limited edition shorts 6620)

[0175] In some embodiments, the shorts 6620 may take the form of what is sometimes referred to as "climbing shorts." In such embodiments, the shorts 6620 may have a shorter, above-the-knee cut to provide all-around movement during training and competition. Such climbing shorts may incorporate features such as a double-layer design, with an inner Lycra fabric providing support and an outer layer providing comfort. In some embodiments, the shorts 6620 may be configured for outdoor recreational hiking / climbing / running, such as long-distance trails or mountaineering.

[0176] Shorts 6620 are formed from one or more panels 6623, which can be interconnected by stitching, welding / welding, or adhesive bonding to form the overall structure or shape of shorts 6620. The one or more panels 6623 may comprise textiles or fabrics, through which a flowable polymer can permeate. As described below, one or more panels 6623, or portions thereof, can serve as a substrate on which PFOs 6634, 6684, and 6694 can be deposited directly and may permeate. In other embodiments, separate additional panels supporting PFOs 6634, 6684, and 6694 can be attached to the top of the one or more panels 6623 by stitching, welding / welding, or adhesive bonding to form the overall shape or structure of shorts 6620.

[0177] Shorts 6620 typically include a waist opening 6622, a front crotch 6624, a back crotch 6626, leg portions 6628-L, 6628-R (collectively referred to as leg portions 6628), and PFOs 6634, 6684, 6694. The waist opening 6622 receives the waist of the person wearing the shorts 6620. The waist opening 6620 may be defined or restricted by a waistband 6630. The waistband 6630 may be elastic or non-elastic. In some embodiments, the waistband 6630 may be partially detachable, wherein the shorts 6620 may include a fly along the front crotch.

[0178] The front crotch typically extends downwards from the waist opening 6622 along the front of the shorts 6620 to the crotch 6631. Similarly, the back crotch 6626 extends downwards from the waist opening 6622 along the back surface or side of the shorts 6620 to the crotch 6631. The length of the leg portion 6628 extends downwards from the front crotch 6624 and the back crotch 6626 to below the crotch 6631. The length of the leg portion 6628 (the length of the inner seam) or the extent to which the leg portion 6628 covers the human leg can vary. In some embodiments, the leg portion 6628 extends and covers the human thigh, terminating above the human ankle. In some embodiments, the leg portion 6628 may be omitted, wherein the shorts 6634 terminates just below the crotch 6631, or may extend to or below the human knee. In some embodiments, the leg portion 6628 may be long enough that... Figures 28-30 The clothing shown can also be referred to as trousers.

[0179] PFOs 6634, 6684, and 6694 provide enhanced abrasion resistance to shorts 6620 across selected portions or sections. This abrasion resistance is particularly beneficial when shorts 6620 are used for outdoor recreational activities such as hiking / mountain climbing / running. For example, during such activities, hikers / mountains / runners may slide on their backs on lower terrain, where the abrasion resistance provided by PFOs 6634 and 6684 can improve the durability of shorts 6620 and reduce structural damage or chafing to the wearer. In certain embodiments, PFOs 6634, 6684, and 6694 may further reinforce selected portions of the panel 6623 forming shorts 6620 to increase the durability of shorts 6620, or potentially allow for the use of lighter and / or more breathable fabrics for the panel 6623 without significantly compromising the durability of shorts 6620.

[0180] PFO 6634 comprises a single, continuous polymer material line 6635, which is extruded or otherwise deposited directly onto a substrate provided by the one or more panels 6623. In other embodiments, the line 6535 of PFO 6634 may be deposited directly onto an additional panel or set of panels, which are themselves stitched, welded / bonded, or adhesively bonded or laminated over and on top of the one or more panels 6623, which are joined together to form the shape and structure of the shorts 6620. In the illustrated example, PFO 6634 extends across the rear surface of the crotch 6626 and the rear surface of each leg portion 6628, extending downward to the leg opening 6629. PFO 6634 extends along the side of the shorts 6620, crossing and extending past the midpoint between the crotch 6626 and the front crotch 6624. In some embodiments, the line 6635 may be multiple polymer material lines or filaments extending end-to-end or parallel to each other. In some embodiments, PFO 6634 may be formed from multiple individual lines or filaments, which are extruded or deposited separately.

[0181] In the example shown, line 6535 extends vertically in a zigzag pattern along a vertical serpentine path. The zigzag path of each vertical line facilitates vertical stretching in the direction indicated by arrow 6643, while the horizontal spacing between pairs of vertical zigzag lines facilitates horizontal stretching or horizontal flexibility in the direction indicated by arrow 6645.

[0182] In the illustrated example, line 6635 protrudes above or beyond the surface of substrate panel 6623. In some embodiments, line 6623 is at least 0.1 mm above the outermost surface of substrate panel 6625. In other embodiments, this height is at least 0.2 mm. Because line 6635 protrudes above the outermost surface of substrate panel 6623, line 6623 and PFO 6634 form a wear-resistant protrusion.

[0183] As shown in the shallower illustration in the diagram, in some embodiments, the penetration depth of line 6635 of PFO 6634 may vary. The shallower segments of line 6635 penetrate the substrate panel 6623 to a greater depth compared to the shallower segments of line 6635. This variation in penetration depth can be achieved by changing the vertical distance between the nozzle of the flowable polymer deposition or spraying process and the porous substrate panel 6623 (or the panel laminated to panel 6623). In the illustrated example, the depth of PFO 6634 on the side of shorts 6620 is greater than its depth at the rear of shorts 6620. In the illustrated example, the penetration depth of PFO 6634 gradually increases as it approaches the front of shorts 6620, and the height of PFO 6634 above the substrate panel 6623 gradually decreases along the side of shorts 6620. Therefore, the rear part of the shorts 6620, which may wear down when a person slides on the underlying terrain, provides greater abrasion resistance; and the penetration, interlocking and bonding of PFO 6634 can be arranged along the side of the shorts 6620, in which the shorts 6620 may be subjected to less wear during such sliding.

[0184] In some embodiments, the penetration depth of line 6635 may fluctuate or vary, for example, alternatively penetrating at a first depth and alternating between... Figure 13B The smaller depth penetration shown refers to the larger depth intervals that form anchors for securing line 6535. For example, in some embodiments, line 6635 may have a similar depth to... Figure 13A The configuration shown is similar to that with anchor 5073, or has the same configuration. Figure 13C The configuration shown is similar to that with anchor 5093. In some embodiments, line 6535 may have the same configuration as... Figure 13D The configuration shown is similar to that in which the upright post or column 5109 is abrasion resistant. In other embodiments, the line 6635 may have a uniform penetration depth along its length, such that the PFO 6634 has a uniform penetration range and uniform height within the area covered by the PFO 6634.

[0185] While the shorts 6620 shown in the figure employ the example pattern of PFO 6634, in other embodiments, PFO 6634 can employ any of the patterns formed by the patterned filaments described above. For example, the line segments of line 6635 between the turning points (where the direction of the line reverses) can be straight to omit the zigzag shape. Line 6635 can be more rounded at its end portions. Line 6635 can alternatively be wavy instead of zigzag. Line 6635 can also alternatively intersect itself within selected intervals.

[0186] PFO 6684 includes a second continuous polymer thread, filament, or strand 6685. Thread 6685 has the same pattern as thread 6635, except that thread 6685 extends horizontally over and across a portion of PFO 6634 on the rear side of the leg portion 6628. Thread 6685 has different material properties than thread 6635. In the example shown, thread 6635 comprises a softer, more flexible material (first hardness-measuring polymer), while thread 6637 comprises a harder, more abrasion-resistant material (second, greater hardness-measuring polymer). Thread 6685 extends above (outer) thread 6635 to form the outermost surface shorts 6620. The greater hardness or hardness of thread 6685 provides enhanced abrasion resistance.

[0187] like Figure 30 As shown, PFO 6684 intersects with PFO 6634. In some embodiments, line 6685 is extruded or deposited at a certain temperature to fuse or weld with the substrate portion of line 6635. In some embodiments, line 6685 may be deposited directly on top of the substrate or panel 6623 along a portion 6690 of line 6685, wherein a portion 6691 of line 6685 intersects with and bridges over the substrate portion of line 6635. In this embodiment, both lines 6635 and 6685 may be at least partially embedded within and below the surface of the substrate provided by one or more panels 6623.

[0188] PFO 6694 and its continuous thread or filament 6695 extend above the pattern 6634 on the area of ​​the crotch 6626, which is configured to face the buttocks of the person wearing the shorts 6620. Compared to thread 6635, thread 6695 can be made of a stiffer, more abrasion-resistant polymer to provide enhanced abrasion resistance and for use in areas where higher wear is expected. (As described above...) Figure 30In some embodiments, line 6985 may be deposited directly on top of the substrate or panel 6623, wherein a portion of line 6985 intersects with and bridges over the substrate portion of line 6635. In such embodiments, both lines 6635 and 6985 may be at least partially embedded within and below the surface of the substrate provided by one or more panels 6623.

[0189] In other embodiments, PFO 6684 (whether formed on an additional panel or directly on panel 6623 constituting the shape of shorts 6620) may have other patterns. For example, PFO 6684 may have any of the PFO patterns described above. In other embodiments, one or more PFOs 6634, 6684, and 6694 may cover different ranges of shorts 6620 or different portions of shorts 6620 (including the front and rear). In some embodiments, selected portions of shorts 6620 may contain additional PFOs, or some illustrated example PFOs may be omitted. As with all PFOs described in this disclosure, the filaments or threads of PFOs 6634, 6684, and 6694 are at least partially impregnated with or penetrate the substrate or panel. The threads of each PFO described in this disclosure may be formed of one or more polymeric materials compatible with the material of the substrate to facilitate or enhance adhesion and / or fusion / welding of the threads to the substrate.

[0190] Although this disclosure has been described with reference to exemplary embodiments, those skilled in the art will recognize that modifications can be made without departing from the scope of the claimed subject matter. For example, while different exemplary embodiments may be described as including features that provide benefits, it is conceivable that the described features may be interchanged or combined with each other in the exemplary embodiments or other alternative embodiments. Due to the relative technical complexity of this disclosure, not all technical changes are foreseeable. This disclosure, described with reference to exemplary embodiments and set forth in the following claims, is obviously intended to be as broad as possible. For example, unless expressly stated otherwise, a single particular element recited in the claims also covers multiple such particular elements. The terms “first,” “second,” “third,” etc., in the claims are used only to distinguish different elements and, unless otherwise stated, should not be specifically associated with a particular order or numbering of elements in this disclosure.

Claims

1. A wearable item comprising: At least one panel, which is formed as follows: The shoulder portion is positioned to extend across the top of the person's shoulder and sit on the top of the person's shoulder when the wearable item is worn; and Patterned filament overlay (PFO) on the shoulder portion, PFO comprising individually formed material lines that cross or extend side-by-side over a region.

2. The wearable article according to claim 1 further includes a back portion interconnected with the shoulder portion, wherein, PFO extends continuously from the shoulder section to the various sections located on the back.

3. The wearable article according to claim 2, wherein, PFO comprises a first part on the shoulder portion and a second part on the back portion, the first part having a first value for the PFO attribute and the second part having a second value for the PFO attribute different from the first value.

4. The wearable article according to claim 3, wherein, The PFO attribute is selected from a group consisting of the following attributes: layout; thickness; density; penetration; and layering.

5. The wearable article according to claim 3, wherein, The PFO property includes density, wherein a first portion has a first density, and wherein a second portion has a second density greater than the first density.

6. The wearable article according to claim 3, wherein, The attributes include penetration, wherein the PFO penetrates the shoulder portion to a first depth, and wherein the PFO penetrates the back portion to a second depth greater than the first depth.

7. The wearable article according to claim 3, wherein, The second part undulates horizontally along and across the vertical axis.

8. The wearable article of claim 1, further comprising a front portion extending from the shoulder portion, wherein, PFO comprises a first portion on the shoulder portion and a second portion on the front portion, the first portion having a first value for the PFO attribute and the second portion having a second value for the PFO attribute different from the first value.

9. The wearable article according to claim 8, wherein, The PFO attribute is selected from a group consisting of the following attributes: layout; thickness; density; penetration; and layering.

10. The wearable article according to claim 9, wherein, The PFO property includes density, wherein a first portion has a first density, and wherein a second portion has a second density less than the first density.

11. The wearable article according to claim 9, wherein, The attributes include penetration, wherein the PFO penetrates the first part at a first depth, and wherein the PFO penetrates the second part at a second depth less than the first depth.

12. The wearable article of claim 8, further comprising a second PFO on top of the PFO on the shoulder portion, wherein the second PFO is omitted from the front portion.

13. The wearable article according to claim 12, wherein, The first part of the PFO has a first pattern, and the second PFO has a second pattern different from the first pattern.

14. The wearable article of claim 8 further includes a belt, wherein the belt includes a second PFO extending along the length of the belt.

15. The wearable article according to claim 14, wherein, The second PFO crosses over and undulates vertically along the longitudinal axis of the belt.

16. The wearable article according to claim 14, wherein, The belt has its maximum width at a position along the belt, and the second PFO extends across most of the width at said position.

17. The wearable article according to claim 14, wherein, The second PFO includes undulating undulations that taper towards the opposite ends of the belt.

18. The wearable article according to claim 14, wherein, The second PFO extends at least most of the length of the belt.

19. The wearable article according to claim 1, wherein, PFO includes foam materials.

20. The wearable article according to claim 1, wherein, PFO consists of single, non-intersecting polymer material strands.

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