Fiber-bonded engineered materials formed using regional dunnings

Abstract

The invention relates to fiber-bonded engineered materials formed using regional dunnings. A fiber-bonded engineered material is provided that imparts desired characteristics at desired relative locations. The fibrous layer is entangled with additional fibers in a manner to form a non-uniform engineered material. The lack of uniformity of fiber-bonded engineered materials may be achieved by manipulating the fibers and / or by fiber-bonded dunnage. The fibrous layers are combined by entanglement with additional fibers such that a mechanical connection is provided between the entangled fibers. This entanglement allows the fibers to bind without supplemental adhesive, interlacing or joining. The change in the fibers and / or the inclusion of the dunnage material prior to entanglement allows for expected characteristics (e.g., functional characteristics) at expected relative locations (e.g., locations determined by the article from which it is to be formed).

Description

[0001] This application is a divisional application of the application filed on November 30, 2017, with application number 201780088704.0 and invention title "Fiber-bonded engineered material formed using regional padding material". Technical Field

[0002] This invention relates to engineered textiles with fiber bonding. It also relates to engineered textiles formed using zonal scrim. Background of the Invention

[0003] Raw materials, such as rolled goods, traditionally possess uniform functional properties throughout the material. To form engineered articles from raw materials, they can be cut into individual parts and layered and / or combined to construct the engineered articles. Layering and combining discrete parts increases cost, volume, and waste, and limits design choices for the final engineered articles. Invention Overview

[0004] Various aspects of the present invention provide a fiber-bonded engineered material and a method of manufacturing the material, the fiber-bonded engineered material providing desired properties at a desired relative position. Fiber layers are entangled with additional fibers in a manner that forms a non-uniform engineered material. That is, the fiber layers are entangled with additional fibers in a manner that produces an engineered material having at least one non-uniform functional property. The lack of uniformity in the fiber-bonded engineered material can be achieved by manipulating the fibers forming the fiber layers, manipulating additional fibers, and / or by using a fiber-bonded padding material. The fiber layers are bonded to additional fibers through entanglement, such that a mechanical connection is created between the entangled fibers. This entanglement allows the fibers to bond without additional adhesives, interlacing, or bonding. Variations in the fibers prior to entanglement and / or the inclusions in the padding material allow for desired properties (e.g., functional properties) at a desired relative position (e.g., the position determined by the article to be formed therefrom).

[0005] This overview is provided to present, in a simplified form, the essence of the concept that will be further described in the detailed description below. This overview is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to help determine the scope of the claimed subject matter. Brief description of the attached diagram

[0006] This article describes its illustrative aspects in detail with reference to the accompanying drawings, which are incorporated herein by reference and are shown in the drawings: Figure 1 It is a schematic diagram depicting exemplary footwear items according to various aspects of this article; Figure 2 Depicting various aspects based on this article Figure 1 A plan view of an exemplary footwear item; Figure 3A Exemplary fiber layers are depicted according to various aspects of this document; Figure 3B Depicting various aspects based on this article Figure 3A An exemplary cross-section of a fiber layer; Figure 3C An exemplary fiber layer formed of continuous fibers is depicted according to various aspects of this document; Figure 3D An exemplary continuous fiber layer roll having the outlines of multiple articles placed thereon is depicted according to various aspects of this document; Figure 4A The text describes the padding material placed on it, according to various aspects of this document. Figure 3A An exemplary fiber layer; Figure 4B Depicting various aspects based on this article Figure 4A A cross-section of an exemplary fiber layer / pad assembly; Figure 5A The text describes a structure with additional fiber layers placed thereon, according to various aspects of this paper. Figure 4A Exemplary fiber layer / pad assembly; Figure 5B Depicting various aspects based on this article Figure 5A A cross-section of an exemplary fiber layer / pad / fiber layer assembly; Figure 6A This describes the situation after entanglement, based on various aspects of this article. Figure 5A Exemplary fiber layer / pad / fiber layer assembly; Figure 6B Depicting various aspects based on this article Figure 6A A cross-section of an exemplary entangled component; Figure 7A Exemplary multifiber layer arrangements according to various aspects of this paper are described; Figure 7B Depicting the various aspects of this article Figure 7A Articles formed by an exemplary multifiber layer arrangement; Figure 8A A second exemplary multifiber layer arrangement is described according to various aspects of this document; Figure 8B Depicting the various aspects of this article Figure 8A A second exemplary article formed by a multifiber layer arrangement; Figure 8C Depicting various aspects based on this article Figure 8AA cross-section of a second exemplary multifiber layer arrangement; Figure 9A A third exemplary multifiber layer arrangement is described according to various aspects of this document; Figure 9B Depicting the various aspects of this article Figure 9A A third exemplary article formed by a multi-fiber layer arrangement; Figure 10A A fourth exemplary multifiber layer arrangement is described according to various aspects of this document; Figure 10B Depicting the various aspects of this article Figure 10A A side perspective view of an article formed by a fourth exemplary multifiber layer arrangement; Figure 10C Depicting the various aspects of this article Figure 10A A middle perspective view of an article formed by a fourth exemplary multifiber layer arrangement; Figure 11A Exemplary padding assemblies according to various aspects of this document are described; Figure 11B Depicting various aspects based on this article Figure 11A A cross-section of an exemplary padding assembly; Figure 12A A second exemplary padding assembly is described according to various aspects thereof; Figure 12B Depicting various aspects based on this article Figure 12A A cross-section of the second exemplary padding assembly; Figure 13A A third exemplary padding assembly is described according to various aspects of this document; Figure 13B Depicting various aspects based on this article Figure 13A A cross-section of a third exemplary padding assembly; Figure 14A A fourth exemplary padding assembly is described according to various aspects of this document; Figure 14B Depicting various aspects based on this article Figure 14A A cross-section of the fourth exemplary padding assembly; Figure 15 Exemplary engineering-element scrims are described according to various aspects of this document. Figure 16 A second exemplary engineered element pad is described according to various aspects of this document; Figure 17 A third exemplary engineered element pad is described according to various aspects of this document; Figure 18AExemplary padding constructions based on various aspects of this document are described; Figure 18B Depicting the various aspects of this article Figure 18A An intermediate perspective view of an article formed by an exemplary padding construction; Figure 18C Depicting various aspects based on this article Figure 18B A plan view of the item shown in the diagram; Figure 19A An exemplary scrim collection is described according to various aspects of this document. Figure 19B Depicting the various aspects of this article Figure 19A Articles formed from exemplary sets of padding materials; Figure 20A Exemplary perimeter scrims are described according to various aspects of this document. Figure 20B Depicting the various aspects of this article Figure 20A An example of an article formed from perimeter padding; Figure 21A Exemplary heel end padding materials according to various aspects of this article are described; Figure 21B Depicting the various aspects of this article Figure 21A An example article formed from shoe heel end padding; Figure 22A An assembly having multiple exemplary padding elements is described according to various aspects of this document; Figure 22B Depicting various aspects based on this article Figure 22A The cross-section of the components, each exemplary padding element is positioned between the first fiber layer and the second fiber layer; Figure 22C The entanglement following the first and second fiber layers is described according to various aspects of this paper. Figure 22B Components; Figure 22D A plan view of some exemplary tangled elements after modification operations according to various aspects of this article is depicted; Figure 22E Depicting various aspects based on this article Figure 22D A cross-section of an exemplary component; Figure 23A A schematic diagram of the zipper based on various aspects of this article is provided; Figure 23B The positioning between the first and second fiber layers is described according to various aspects of this paper. Figure 23A The cross-section of the zipper; Figure 23CThe initial entanglement of the first and second fiber layers is depicted according to various aspects of this paper. Figure 23B Exemplary components; Figure 23D The text describes the complete entanglement of the first and second fiber layers and the subsequent trimming operation, based on various aspects of this paper. Figure 23C Exemplary components; Figure 24A The hook-and-loop elements positioned between the corresponding first and second fiber layers according to various aspects of this paper are depicted. Figure 24B The entanglement following the first and second fiber layers is described according to various aspects of this paper. Figure 24A Exemplary components; Figure 24C The text describes the refining operations that can be performed according to various aspects of this document. Figure 24B Components; Figure 25A The exemplary dimensional offset padding is depicted according to various aspects of this article; Figure 25B Depicting various aspects based on this article Figure 25A An exemplary dimension offset of the cross-section of the padding; Figure 25C The positioning between the first and second fiber layers is described according to various aspects of this paper. Figure 25B The cross-section; Figure 25D The entanglement following the first and second fiber layers is described according to various aspects of this paper. Figure 25C Components; Figure 26 An exemplary footwear article is depicted, formed at least in part by fiber-bonded particles of a desired pattern between two fiber layers, according to aspects thereof; Figure 27 The embroidery padding material described in this article, which imparts the desired design to the manufactured footwear items; Figure 28 The laser or die-cut film padding, according to various aspects of this article, is described, which imparts the desired design to the manufactured footwear articles; Figure 29 The knitted shoe collar attached to the upper of footwear during entanglement is depicted according to various aspects of this article; Figure 30 Depicting various aspects based on this article Figure 29 A close-up view of the connection between the knitted collar and the upper; Figure 31 Various padding materials and elements are described according to various aspects of this article, which are bound together with fibers to produce footwear components to be manufactured; Figure 32 The construction of fiber-bonded engineered materials using individual, pre-sized cut fiber layers is described according to various aspects of this paper. Figure 33 The invention describes a construction for manufacturing fiber-bonded engineered materials using pre-sized cut fiber layers provided as a continuous roll, according to various aspects thereof; and Figure 34 The structure for manufacturing fiber-bonded engineered materials using loosely cut fibers is described according to various aspects of this paper. Detailed description of the invention

[0007] Fiber bonding is a process in which fibers from one or more fiber layers are entangled to form a complex composite material engineered for use in an article. The engineered material can have structures entangled within the fiber layers to achieve engineered properties for a specific article, such as a shoe or garment piece. In the case of athletic footwear, as an example only, fiber-bonded materials may include entangled high-tensile cable elements that transfer lacing loads from the throat to the sole, entangled foam structural elements that provide padding in the heel collar, entangled fusible material elements that form a waterproof membrane in a rigid heel stay and / or toe box, and / or entangled hardware elements that serve as lacing structures. All elements / components are integrated with the engineered material because they are entangled with and / or bound to one or more fiber layers without requiring additional cutting, fusing, or sewing operations.

[0008] One or more fiber layers serve as platforms and binders, to which additional materials are anchored to construct unique hybrid composite materials that are consolidated into a single material through entanglement. Entanglement results in the fibers of one or more fiber layers physically interacting with and locking into the additional material, producing a cohesive and complete material that can be formed into articles. The materials added to the fiber layers and the materials forming the fiber layers can be intentionally and / or strategically positioned to achieve desired functional properties at intended relative locations. This allows highly engineered materials to be formed as complex composite materials that are consolidated into a single material through entanglement.

[0009] The resulting fiber-bonded engineered materials are lightweight, comfortable, customizable, and highly efficient to manufacture. Fiber-bonded engineered materials can be applied to an unlimited number of industries and articles. For example, in sportswear, engineered bras with fiber-bonded clasps, loops, padding, and support elements can be formed from a single lightweight, breathable, and comfortable material. Fiber-bonded engineered materials can also be used, for example, in footwear or clothing to create outward-facing and inward-facing layers with different properties, for example, to create a moisture difference that allows moisture to be transferred away from the inward-facing layer. For example, the content and / or linear mass density (denier) of the polymer containing fibers on the outward-facing surface (first surface) and the inward-facing surface (second surface) of an article can be altered to change its relative moisture transfer properties. Fiber-bonded engineered materials can also be used to form shoes with integrally engineered properties, such as locking, elasticity, breathability, adhesion elements, and padding. Fiber-bonded engineered materials can also be processed into synthetic leather that retains the engineered properties, while being further classified as engineered synthetic leather. Therefore, this material, which is highly efficient to manufacture and has an unlimited degree of customizable engineering available, can be used to replicate synthetic leather in the form of engineered materials.

[0010] Fiber-bonded engineered materials possess a distinctive appearance derived from the fiber layers that form the fiber bonds. The fiber transitions between the integral components of the fiber-bonded engineered material contribute to this unique appearance. Regardless of the presence or absence of a top coating and post-treatment, fiber-bonded engineered materials are visually distinctive because the fiber bonds are formed or retained within the fiber-bonded engineered material as lattice-holding elements.

[0011] Engineered materials are those that provide desired properties for articles formed from them at intended relative positions. This contrasts with raw materials. Raw materials merely provide properties without considering the intended location of those properties within the article to be formed. Thus, manipulation will use the raw materials to form an article to obtain selected properties at the article's intended relative positions. This manipulation can include combining parts of the raw materials in different orientations and positions to achieve a desired overall property configuration (e.g., a unique functional fingerprint for the set of components and the relative positions of those components). Combining parts of raw materials introduces waste from forming the parts (e.g., cutting scrap), which is accompanied by inefficiencies (e.g., additional manufacturing steps such as sewing and joining, and / or more chances of manufacturing errors leading to higher scrap rates), embeds unintended properties into the article (e.g., the joining between combined materials disrupts the transition between material properties), limits article design options, and restricts the comfort and fit of the resulting article.

[0012] Engineered materials can include at least knitted, woven, braided, custom-laid fiber materials, deposition-formed, molded, injection-formed, pressure-formed, expansion-formed, and reduction-formed (e.g., cut-off, dissolved, or milled) materials. Each of these engineered materials can be formed using different technologies, processes, materials, and / or machines, which can impart different properties, uses, and costs. In all use cases, one engineered material may not be a substitute for another. This is partly a result of article design, requirements, and usage. Therefore, while engineered materials are well-known, each engineered material offers its own advantages for a particular implementation.

[0013] This paper envisions fiber-bonded engineered materials. Fiber-bonded engineered materials are engineered materials that, at intended relative positions, provide the desired properties to the article to be formed from them.

[0014] Fiber-bound (or fiber-bind) refers to holding material in a defined relative position through fiber bonding. Fiber bonding is the physical entanglement of fibers that creates a mechanical connection. Fiber bonding can hold material in a defined relative position by entanglement of the fibers of a fiber layer with the fibers of the material to be held. Fiber bonding can also hold material in a defined relative position by entanglement of the fibers of a first fiber layer on a first side of the material to be held with the fibers of a second fiber layer on a second side of the material to be held (e.g., wrapping or trapping the material to be held). Fiber bonding can also hold material in a defined relative position by entanglement of the fibers of a first fiber layer on a first side of the material to be held with the fibers of both the material to be held and the second fiber layer on a second side of the material to be held. Similarly, fiber bonding envisions multidimensional entanglement of fibers. Thus, for the example provided above where the fibers of the first fiber layer are entangled with another set of fibers, it is envisioned that another set of fibers is also entangled with the fibers of the first fiber layer.

[0015] Fiber entanglement can be achieved using various techniques; fiber entanglement is the physical interaction of fibers that results in a mechanical connection between them. Fiber entanglement can be achieved through physical movement of a first fiber into contact with a second fiber, causing friction and / or intertwinement. Physical movement can be achieved using one or more barbs of a hook, one or more sharp tips of a structured needle (e.g., in nonwovens), and / or a focused flow of fluid (e.g., liquid and / or gas).

[0016] Crochet entanglement has a needle-like element comprising one or more barbs that enter or pass through an assembly of fibers to cause interlocking of the fibers. For example, a technique commonly referred to as needle felting relies on entanglement with a crochet needle. In this example, a crochet needle (or multiple crochet needles) moves up and down over an assembly of fibers, where the barbs of the needle grip the fibers and cause physical interactions between them. The up-and-down movement of the crochet needle effectively moves the fibers upward and downward within the fiber assembly, causing fibers located at or near a first surface to move toward fibers located at or near the opposite surface of the assembly, and vice versa. A conventional sewing needle, lacking barbs to intentionally cause fiber movement, merely causes piercing of the fibers and does not cause entanglement as envisioned herein. For example, sewing fiber layers with a conventional sewing needle connects them by stitching, not by entanglement.

[0017] Structured needle entanglement includes a needle element having one or more sharp tips that, when the tips enter or pass through an assembly of fibers, create a specific structure. For example, structured needles can create rhomboid or ring-shaped structures under entanglement. In structured needle entanglement, the profile of the needle element is such that, as the needle element passes through the assembly of fibers, a structure is also created whose shape is based on the profile of the needle tip. By way of example only, a structured needle may include a forked structure having two forks with a gap between them, wherein, upon passing through the assembly of fibers, at least a portion of the assembly of fibers aligns with the gap, thereby allowing the formation of a structure consistent with the profile of the needle element.

[0018] Fluid entanglement relies on a high-pressure jet (e.g., flow) of a liquid (e.g., water) to enter or pass through an assembly of fibers, physically moving portions of one or more fibers. The liquid jet may pass through in a single direction or in multiple directions to achieve different types of entanglement. Furthermore, the conditions and parameters of the fluid flow can be varied to alter the resulting entanglement. For example, pressure, flow size, direction, velocity, number of interactions, flow shape, etc., can be modulated to change the resulting entangled fibers. For instance, an increase in flow pressure can cause one or more fibers to split during the entanglement process, which can produce a larger entangled surface and changes in fiber properties. Moreover, fluid entanglement can effectively incorporate one or more structures or textures into the entangled fiber layer. For example, a roller around which entanglement may occur may have one or more textures or structures that help define the resulting texture or structure produced by entanglement around the roller. The roller may include multiple holes that form pores in the fiber layer during entanglement. Furthermore, as part of the entanglement process, the roller may include a variable surface that imparts texture to the fiber layer. In an exemplary aspect, fluid entanglement can also be referred to as spunlacing. One exemplary form of fluid entanglement that typically utilizes water flow is called hydraulic entanglement.

[0019] The entanglement process can be performed uniformly or it can be performed in sections. In a first exemplary aspect, entanglement applies common entanglement conditions throughout the entire fiber assembly. This uniformity can provide a simplified entanglement process. As will be described below, it is envisioned that other variables (e.g., material, material location, relative position of materials, and material size, thickness, weight, and / or density) can be adjusted to obtain engineered materials while still achieving a uniform entanglement process.

[0020] Variable entanglement processes can include zone-controlled entanglement. For example, a first region of an assembly of fibers may receive entanglement with a first set of parameters (e.g., duration, pressure, and / or cycles), while a second region of the same fiber assembly may receive entanglement with a second set of parameters. The resulting engineered material may have properties different from those formed by fiber entanglement in the first region compared to those formed by fiber entanglement in the second region. For example, in the first region of the fiber assembly, the hydraulic entanglement properties may be at the high pressure and duration required to effectively split the fibers, while in the second region of the fiber assembly, the pressure and duration may be reduced to prevent fiber splitting. In this example, for instance, the first region may have higher tear strength, greater fineness, and lower bulk compared to the second region.

[0021] The variability of entanglement characteristics can be manually controlled by the operator of the entanglement machine and / or can be automated based on computer-controlled entanglement equipment. For example, it is envisioned that a vision system or other identification device can be used to identify parts and determine the appropriate variable entanglement to be provided. In this example, positional orientation, size, and article type can be determined by the vision system or other identification device and used to control the characteristics of the entanglement and the position of the entanglement relative to the article. The computer can store one or more programs with predetermined instructions for implementing the variable entanglement process based on the determined article and / or the position of the article.

[0022] Another variable that can be adjusted to achieve differences in entanglement characteristics is the hook used for entanglement. The number of hooks, the size of the hooks, the shape of the hooks, and the size / shape / number of barbs on a particular hook can also be adjusted for different materials and / or locations. For example, different hook types / sizes / shapes can be used on a common set of fibers to obtain different entanglement results. For example, the choice of hooks can depend at least in part on the material, construction, and / or size of the padding material (i.e., the element held in relative position by one or more layers of fibers as a fiber binding element, as described more fully below) placed at a given location in the set of fibers. Thus, in a first location of the set of fibers, the first location includes a first padding material with first characteristics, and a first hook can be selected. In a second location of the set of fibers, the second location includes a second padding material with second characteristics, and a second hook can be selected. The difference between the first and second hooks can be to achieve different entanglements to improve entanglement efficiency and / or to improve manufacturability (e.g., limiting hook breakage while still minimizing hook size). Furthermore, it is envisioned that the set of hooks can be bundled together as a common entanglement tool. The way the crochet hook is tied and the combination of ties can also help to regionally manipulate the fibers through entanglement.

[0023] In a specific example, a needle-wrapping machine is envisioned to have a collection of hooks extending along the width of the material. The hooks can vary in one or more characteristics (e.g., diameter, barb size, barb direction, and / or number of barbs) depending on their relative position along the width of the material. For example, a repeating pattern of needle characteristics can be used to form repeating stripes of a wrapping pattern along the width of the material. In practice, this can be used to make the stripes in each width direction reflect areas of the article to be formed. For example, along a single stripe, the toe-end on the right side of the stripe and the heel end on the left side of the stripe can have different wrapping characteristics based on the choice of padding and / or fiber at their relative positions. Thus, a roll of goods can be formed with regional properties resulting from the wrapping along the roll width by varying hook characteristics.

[0024] Another variable that can be adjusted to achieve differences in entanglement properties is the configuration of the needle elements used for structured needle entanglement. The number of needles, the configuration of the needle elements, and the size / shape / number of needle elements on a particular needle can also be adjusted for different materials and / or locations. For example, different needle elements / sizes / shapes can be used on a common set of fibers to obtain different entanglement results. For example, the selection of structured needles (and therefore their structured needle elements) can depend at least in part on the material, construction, and / or size of the padding material (i.e., the element held in relative position by one or more fiber layers as a fiber bonding element, as described more fully below) placed at a given location in the set of fibers. Thus, in a first location of the set of fibers, the first location includes a first padding material with first characteristics, and a first structured needle can be selected. In a second location of the set of fibers, the second location includes a second padding material with second characteristics, and a second structured needle can be selected. The difference between the first and second structured needles can be to achieve different entanglements to improve entanglement efficiency and / or to improve manufacturability (e.g., limiting needle breakage while still minimizing needle size). Furthermore, it is conceivable that an assembly of structured needles could be bundled into a common entanglement tool. The manner in which the structured needles are bundled and in what combination they are bundled could also facilitate the regional manipulation of fibers through entanglement.

[0025] Fiber layer A fiber is a long and significantly elongated natural or synthetic flexible material. In an exemplary aspect, a fiber has a length that is at least 100 times its width / diameter. However, it is contemplated that the diameter / length ratio may be less than 1:100. For example, in some cases, fibers may be formed from cut segments where a length-to-diameter ratio of at least 100 is met before cutting, but a smaller multiple is measured after cutting the original fiber. One example could be protein-based chain materials, such as animal hide / skin, which may have a smaller ratio but can still be considered fibers. Other natural or biosynthetic fibers are contemplated, such as polymeric fibers derived from plant, animal, and / or microbial sources. Peptide polymers are protein-based fibers. Examples of peptides include, but are not limited to, collagen, keratin, silk, wool, cashmere, and soybean-based fibers. Other contemplated natural fibers include, but are not limited to, polysaccharide polymers, such as cotton, rayon, ramie, and other cellulose-derived compounds. In additional examples, the fiber is an extruded composition comprising a hydrocarbon-based polymer. For example, for the purposes of this application, thermoplastics can be extruded into continuous filaments, which are fibers. The composition forming the fiber can consist substantially of any of the following non-limiting examples: thermoplastic polyurethane (TPU), polyurethane, polyester, polyamide, polyolefin, polycarbonate, and / or copolymers thereof. Other materials, such as aromatic polyamides, glass, cellulose materials, carbon, metals, minerals, polyacrylonitrile, etc., are also contemplated. Furthermore, it is contemplated that the fiber can consist substantially of any of the contemplated materials, or the fiber can be a composition comprising the contemplated material combined with other materials (e.g., protein-based materials with a polymer coating), such as additives, fillers, coatings, treatments, etc. An additional list of suitable “polymers” is included below, from which fibers, fiber layers, padding, padding elements, etc., can be formed.

[0026] Fibers can be interpreted as including filaments, yarns, threads, ropes, cords, strands, etc. In other words, a “fiber layer” can be formed from yarns, threads, cords, strands, etc., and for the purposes of this application, it is still a fiber layer. Fibers can be continuous fibers or staple fibers. Furthermore, it is envisioned that fibers can be macroscopic or microscopic fibers. For example, fibers can have a linear mass density measurement expressed as denier per filament (“dpf”) of 1 to 9 dpf. Alternatively, fibers can have a linear mass density measurement expressed as denier (or denier per filament) of 0.001 to 0.999 dpf. In some examples, fibers may have a first dpf when formed as an aggregate of fibers (e.g., a flocculent layer), and a much smaller dpf after entanglement (e.g., chemical or mechanical fibrillation). For example, during entanglement, fibers may break into a greater number of fibers. Fibers can have an island-in-the-sea construction that allows for the application of triggers (e.g., chemical, thermal, light, and / or water) to dissolve the sea portion or otherwise disrupt the original fiber. For example, in some examples, short fibers may begin with a size between 1 dpf and 9 dpf and end with a size between 0.005 dpf and 0.1 dpf. This reduction can be achieved by solvent reduction or by dissolving the sea portion (such as polyvinyl alcohol dissolved in water). Furthermore, fiber size reduction can be achieved using segmented pie construction. It is envisioned that fibers can be reduced from 3 dpf to 0.05 dpf. This can also be achieved using techniques like solvent reduction. Such variations in fiber number and / or dpf can be useful for altering one or more characteristics of the fiber assembly. For example, microfibers that are too fragile to form flocs may be caused by a reduction in the desired dpf in the final article (e.g., through splitting and / or reaction).

[0027] Furthermore, it is envisioned that the fiber can be measured at a cross-section in the transverse direction relative to its longitudinal length. The width of the cross-section in the transverse direction is referred to hereinafter as the "fiber width". Suitable fibers are envisioned to have any range of fiber widths, but in an exemplary embodiment, the fiber has a fiber width of 200 micrometers to 100 nanometers. Another envisioned fiber width range includes 100 micrometers to 100 nanometers. Yet another envisioned range for fiber width is 25 micrometers to 0.01 micrometers. Another envisioned fiber width range is 10 micrometers to 0.01 micrometers. Macroscopic fibers have a fiber width range of 10 micrometers to 200 micrometers. Microscopic fibers have a fiber width range of 10 micrometers to 1 micrometer. Nanofibers have a fiber width of less than 1 micrometer (e.g., 0.9999 micrometers to 100 nanometers). Envisioned exemplary materials can have fiber widths such as cotton fibers of about 20 micrometers, wool fibers between 10 and 25 micrometers, nylon fibers between 12 and 16 micrometers, apparel polyester fibers between 12 and 25 micrometers, and glass fibers of about 150 micrometers.

[0028] An assembly of fibers can be composed of a variety of fibers. These fibers can vary based on any properties, such as material composition, dpf (durability per unit area), fiber width, size, cross-sectional shape in the transverse direction (e.g., circular, oval, triangular, straight, leaf-like, dog-bone, or hollow), longitudinal profile (e.g., flat, straight, wavy, crimped, smooth, proportional, branched, or irregular), and / or length. The assembly of fibers can be a non-uniform distribution of different fibers (e.g., a regional distribution of the assembly) or a relatively uniform distribution (e.g., a homogeneous assembly of different fibers). Furthermore, the assembly of fibers can vary based on their position in the XY plane and / or in the Z direction. For example, it is envisioned that a first fiber can be positioned at a first location in the flocculent layer by the thickness of the flocculent layer, and a second fiber, different from the first fiber, can be positioned at a second location in the flocculent layer by the thickness of the flocculent layer. In an alternative example, it is envisioned that a first layer of flocculent material comprises the first fiber, and a second layer of flocculent material comprises second fibers, different from the first fiber. It is envisioned that engineered materials can be obtained by applying both the XY positional variations in fiber type and the layering variations.

[0029] Fibers can be constructed in various forms, such as nonwoven materials. In some examples, nonwoven fiber materials can be referred to as flocculents. Nonwoven materials are materials that are neither woven nor knitted. Instead, the aggregate of fibers is held together by mechanical and / or chemical interactions. Examples of nonwoven materials include felt. Felt is neither woven nor knitted. Instead, felt is a material in which an aggregate of fibers is mechanically manipulated to form a mat-like material. However, felt is not an engineered material because conventional felt has uniform properties and it cannot provide the desired properties for the article to be formed from it at the intended relative positions. For example, when forming an article with felt, the orientation, position, or other functional properties of a portion of the felt from the larger aggregate of felt are not considered when forming the article, because the felt is substantially constant in its properties.

[0030] As described above, multiple fibers can be homogeneous or heterogeneous and can be formed into a nonwoven material, sometimes referred to as batting. The batting can be formed from multiple strata. Each strata can have a different or similar fiber composition. The batting can be formed as a continuous material (e.g., a rolled product) or as discrete elements (e.g., a batched product). Therefore, as described throughout this application, fiber layers can comprise continuous materials (e.g., rolled batting layers) or discrete materials (e.g., cut batting layers).

[0031] A continuous flocculent layer formed from fiber layers can have different properties in its width direction (e.g., transverse to the longitudinal direction of the continuous flocculent layer). The continuous flocculent layer can also, or alternatively, have varying properties in the longitudinal direction. For example, a repeating pattern of properties in the longitudinal direction is envisioned for forming multiple similar articles in a non-batch process. Alternatively, gradient variations in properties in both the transverse and longitudinal directions are envisioned. Such transitional changes in properties can avoid binary transitions in the properties of the resulting product. Similarly, variations are envisioned to occur at any layer in the longitudinal and / or transverse directions (e.g., in the Z-direction). The properties of the continuous flocculent layer can include, but are not limited to, fiber composition, fiber properties, flocculent thickness, etc.

[0032] Batch-sized flocculent layers formed from fiber layers can have different properties in the X, Y, and / or Z directions. The property variations of the batch-sized flocculent layers can be binary (e.g., a identifiable change from a first property to a second property) or progressive. The properties of the batch-sized flocculent layers can be, but are not limited to, fiber composition, fiber characteristics, floc thickness, fiber density in the layer, etc.

[0033] Another fiber layer concept is the mesh fiber layer. A mesh fiber layer is a fiber layer that substantially constitutes the perimeter of the entire article to be formed, generating minimal waste. Therefore, after tangling, trimming and cutting operations can be minimized, thereby minimizing waste generation. A mesh fiber layer may include one or more fabrication sections. Fabrication sections are elements beyond a true mesh but provide handling and material movement capabilities to manipulate parts. For example, tags or other elements may be included to allow for positioning, picking, identification, and / or sorting. In various aspects, as referenced below… Figures 32 to 34 More comprehensively, the mesh fiber layer can be used together with a reusable carrier mesh during manufacturing.

[0034] Fiber selection also envisions including reflective materials. For example, polyester films (mylar) or other materials with reflective surfaces can be combined to provide heating and / or cooling properties. The reflectivity of the material can be incorporated into any level of fiber-bonded engineered material (e.g., fiber level, flocculent level, padding level, or topcoat level).

[0035] One or more macroscopic additives are also envisioned that can be incorporated into the fiber layers. For example, any material provided herein in particulate or powder form can be incorporated into one or more fiber layers. For example, expandable acrylic polymers can be incorporated into fiber layers before or after entanglement. The combination of particulate / powder materials can be used to complement the properties of the fibers. For example, a lower-cost fiber can be used, which can be reinforced by particle integration relative to a higher-cost fiber with similar properties without supplemental particles. The envisioned particles include at least the polymers listed herein.

[0036] It is envisioned that engineered materials can be formed by varying the properties of fiber layers. These variations can be determined, at least in part, by fiber selection and placement, entanglement properties, and / or combinations thereof. Furthermore, as will be described in more detail below, additional treatment of the engineered fiber layer can produce desired properties for the article to be formed from it at the intended relative positions of the fiber layer. For example, applying triggers (e.g., heat, light (UV, IR, or visible light), sound waves, plasma, electron beams (E beams), radio frequency, chemicals, and / or water) to specific portions of the fiber layer can produce engineered materials. Alternatively, applying triggers to substantially the entire fiber layer can result in variations in specific fibers (or other additives) that are already non-uniformly (e.g., intentionally) placed relative to the fiber layer. An example of the former involves selectively applying one or more liquid chemicals (e.g., hardeners) to achieve different properties in the fiber layer at application positions relative to where no liquid chemicals were applied. An example of the latter involves selectively placing fibers capable of melting (or softening) at a given temperature in a first region and fibers that do not melt (or soften) at the same temperature in a second region. In this example, when the entire fiber layer is exposed to a given temperature, only those locations containing fibers that melt (or soften) at that temperature exhibit the different properties resulting from the melting (or softening) of the fibers. Additional triggers, materials, placements, and combinations will be described as provided throughout this document, and these additional triggers, materials, placements, and combinations apply to all aspects of this document.

[0037] Fusible fibers, such as thermoplastic polymer fibers having a melting temperature and softening temperature lower than at least one of the melting temperature, softening temperature, and decomposition temperature of other materials forming fiber-bonded engineered materials, can be used to modulate the properties of fiber layers. The application of fusible fibers can be achieved through integral bonding with the fiber layer (e.g., fiber mixing), or it can be achieved by layering a portion of the fiber layer with fusible fibers, followed by entanglement of the fusible fibers with the layer. Fusible fibers can be used to form transparent or translucent portions of fiber-bonded engineered materials. For example, after entanglement, heat can be applied to the fiber layer to form translucent or transparent window portions that can visually expose padding (e.g., with a specific color and / or structure) or other underlying elements while still binding the underlying elements. Fusible fibers can also be varied to provide different measurements of flexibility. For example, the type of fusible fiber can be selected based on location. Fusible nylon can remain flexible during molding or activation, while polyester can become rigid when melted. Therefore, base fibers such as microfibers can be combined with fusible nylon in a first region (e.g., the toe area of ​​a shoe) to form a flexible portion, and with fusible polyester in a second region (e.g., the heel area of ​​a shoe) to form a relatively rigid portion.

[0038] Once the fusible fibers are activated (e.g., melted), their distribution can be determined to allow for variations in total porosity (e.g., the thickness throughout the fiber layer) or only surface porosity. This determination of the fusible fiber distribution allows for the formation of sections that are water-resistant, waterproof, windproof, abrasion-resistant, etc. For example, fusible fibers near the first surface of the fiber layer can be linked together to form a continuous, less permeable fusion to increase resistance to water penetration, or the first layer can have a fusible fiber distribution that forms a discontinuous, more porous fusion that is more sensitive to air and water permeability.

[0039] Fiber properties (such as elastic modulus) are measured before entanglement. Once entangled, measurements of individual fibers are affected by the entanglement process and / or mechanical connections with adjacent fibers.

[0040] bedding A padding material is an element held in relative position by one or more fiber layers as a fibrous binding element. Padding materials can be textiles (e.g., knitted, woven, braided, embroidered, nonwoven, or directly laid-out structures), non-fibrous materials (e.g., films, sheets, extruded elements, molded elements, deposition-molded, expansion-molded, or compression-molded materials), and / or components (e.g., zippers, fasteners, loops, hooks, rings, sensors, wires, optical fibers, pouches, tubes, ropes, or cable components). Padding materials can be formed from a variety of materials, as detailed below and indicated by the examples immediately following. Contemplated materials include organic and synthetic materials. For example, padding materials can be formed from any of the following non-limiting materials, including polypeptide-based materials (e.g., animal skin, wool, or feathers), plant or cellulose-based materials (e.g., cotton or linen), carbon, minerals, aromatic polyamides, glass, metals, TPU, PU, ​​polyesters, polyamides, polyolefins, polyphenylene oxide, polystyrene, polyethylene, ABS, and / or polycarbonate, as well as copolymers of polymers. The padding material can be formed from recycled or reused waste, for example, sheets that can be used to form the padding material. Furthermore, the padding material can be in the form of strips or strips (strips are generally more continuous than strips of similar or different materials).

[0041] The padding material can be a discrete element or a collection of elements. For example, the first padding material can be a homogeneous material (e.g., a polymer film) that, when bonded to at least one fiber layer, forms an engineered material as described below. Alternatively, the second padding material can be an engineered textile (e.g., a knitted material having at least one desired property at a desired location in a knitted material) that forms an engineered material when entangled and / or wrapped with or by one or more fiber layers. Furthermore, it is envisioned that multiple (and potentially different) padding materials can be used in combination to form an engineered material when entangled, trapped, and / or wrapped with or by one or more fiber layers.

[0042] As will be described in more detail below, any combination of fibers, fiber layers, and padding can be manipulated to produce engineered materials. Exemplary manipulations may include, but are not limited to, the selection of materials, locations, constructions, sequences, secondary processes, etc. Therefore, aspects of this document contemplate the use of any number, location, and / or combination of fiber layers and padding to form fiber-bonded engineered materials. Furthermore, fiber-bonded engineered materials can be used to form any article. For example, the manipulations contemplated herein can be applied to form clothing articles (e.g., shirts, trousers, shorts, undergarment pants, bras, or socks), outerwear articles (e.g., coats, hats, or gloves), equipment articles (e.g., grappling gloves, padding, protective gear, or footwear inserts), footwear articles (e.g., shoes, sandals, boots, slides, mules, or loafers), etc. Similarly, fiber-bonded engineered materials can be used in other industries (e.g., automotive, aerospace, medical, security, packaging, furniture, etc.). The specific aspects described below will be for footwear items, but it should be understood that the ideas presented herein are not limited to footwear, but can be applied to the entire product and industry.

[0043] Padding materials can be described as continuous padding, localized padding, regional padding, engineered padding, base padding, or component padding. Specific padding materials incorporated into fiber-bonded engineered materials can be classified as one or more different types of padding materials. For example, continuous padding can also be engineered padding.

[0044] Continuous padding can have a shape, size, and / or construction that extends between two or more parts of an article to be formed. For example, in an exemplary aspect, continuous padding, such as that used in a component forming a footwear article, can extend from the inside to the outside of the footwear article.

[0045] Local padding can have the shape, size, and / or construction of discrete portions of an article to be formed. For example, local padding used in components forming footwear articles can be positioned in the toe box, heel stabilizer, medial waist area, lateral waist area, tongue, etc.

[0046] Regional padding is a combination of padding materials, such as the overlap or stacking of multiple padding materials. For example, a padding material with specific properties in a single direction can be stacked on top of another padding material that has properties in a single direction but in different directions to achieve one or more multidirectional properties. As used herein, stacked padding includes adjacent padding materials, allowing one or more layers to be interposed, but sharing a common X and Y location regardless of Z-direction offset. However, stacking does not require all X and Y locations to be shared between the stacked materials (e.g., they can be of different sizes and / or shapes). By way of example and not limitation, macro-mesh padding can be overlapped with fine-mesh padding, allowing the first side of the fiber-bonded engineered material to have a macro-texture and the opposite side associated with the fine mesh to have a more uniform texture. It is also envisioned that different padding materials of different materials can be stacked. For example, a high-toughness material for limiting tension can be stacked with a foam material for providing cushioning.

[0047] Engineered padding is padding that provides desired properties at a intended location. For example, engineered padding can be constructed using knitting, weaving, braiding, nonwoven, extrusion, molding, casting, deposition, expansion, reductions-formed, embroidery, custom fiber placement, 3D printing, film, sheet, etc., and has variable properties based on the location of the padding and the location where the padding is bonded or will be bonded to a fiber-bonded engineered material or article. For instance, engineered padding can modify the material and / or construction based on location to achieve desired properties at the intended location.

[0048] A base padding material is a non-regional padding material that exhibits uniformity in one or more properties of the padding material. Examples may include non-engineered textiles, non-engineered films / sheets, extrusions (e.g., thermoplastic or adhesive webs), or cast filament matrices, which are not specific to the location and / or orientation where the padding material will be bonded to the fiber-bonded engineered material. Exemplary base padding materials may be formed from a composition comprising a thermoplastic material having at least one of a melting temperature and a softening temperature lower than at least one of a melting temperature, a softening temperature, and a decomposition temperature of the base padding material to which it is entangled.

[0049] Component padding is a component or collection of components that is traditionally bonded to textiles using bonding mechanisms other than fiber bonding (such as sewing, chemical bonding, or melting). Examples include, but are not limited to, zippers, hooks and / or loops, snaps, rings, electrical sensors, electrical components, lamps, wires, optical fibers, fluid bladders, tubes, reinforcements, etc.

[0050] Padding can also be used as a structural carrier. For example, when used in the manufacture of footwear, padding may include one or more lace holes extending through it, such that the resulting fibrous manufactured article will have reinforced structural support around the hole locations.

[0051] The padding material can also be used as a non-structural carrier. For example, the padding material can be used as a carrier for various particles such as foam beads. In some aspects, an adhesive (e.g., a temporary adhesive) can be applied to the padding material uniformly or in a desired pattern, shape, or configuration. Multiple foam beads can be placed on the adhesive (strategically or randomly). Excess foam beads can be removed (e.g., by blowing air, etc.). The padding material can then be entangled with one or more fiber layers, such that the foam beads remaining on the adhesive are trapped or encapsulated by the fiber bonds. When viewed relative to the surrounding surface, the resulting manufactured article will have a “bumpy” appearance, with its surface raised at the locations where the encapsulated or trapped foam beads were.

[0052] In some aspects, the carrier padding material may include indentations or wells at the locations where the fibers of the particles are desired to bond. In such aspects, the Z-direction offset caused by the fiber bonding of the particles can be controlled. Such Z-direction offset can also be controlled by the size of the particles used. For example, in some aspects, foam beads with a diameter of approximately three to five millimeters can be used, while in others, foam beads with a diameter of 0.5 mm or less can be used. Any and all such variations and any combinations thereof are contemplated to fall within the scope of the various aspects herein.

[0053] It should be understood that particles formed from materials other than foam (e.g., solid polymeric materials) can be used. It should also be understood that foam beads can be applied in a pre-foamed state and activated during pre-entanglement or post-entanglement, or can be applied while already foamed. Furthermore, it should be understood that although the particles described herein are discussed as having a diameter, particles having shapes other than spherical (e.g., elliptical, disc-shaped) can also be used.

[0054] In some cases, instead of using a carrier pad, particles can be applied directly to the fiber layer to entangle with the pad or other fiber layers. Figure 26 An exemplary footwear article 2600 is illustrated, which is at least partially formed from fiber-bonded particles in a desired pattern 2610 between two fiber layers. A similar result can be obtained using a carrier padding material.

[0055] Padding can also be used as a non-structural element. For example, padding (such as sheets of foam material) can be die-cut or laser-cut into specific patterns (such as lattice patterns) and strategically placed and entangled with one or more fiber layers, such that the resulting fiber-bonded articles will at least tactilely exhibit the padding pattern. Figure 28 Footwear articles formed from a first mesh padding material and a colored second mesh padding material (these padding materials may differ in color, for example) and a laser- or die-cut film padding material are depicted. As illustrated, the film padding material imparts the desired pattern to the footwear articles formed from the fiber-bonded components.

[0056] The padding material can be formed from various materials and / or technologies. Different padding materials, as described below, can be combined in an overlapping manner to achieve desired properties. For example, a macro-mesh padding material can be overlapped with a fine-mesh padding material, allowing the first side of the fiber-bonded engineered material to have a macro-texture, and the opposite side associated with the fine mesh to have a more uniform texture. It is also envisioned that different padding materials of different materials can be layered. For example, a high-toughness material for limiting tension can be layered with a foam material for providing cushioning.

[0057] Coloring can be integrated with fiber-bonded engineered materials. For example, the fibers of one or more fiber layers can have a color profile imparted to the material when the fibers are entangled and consolidated. The padding can also have a color profile. The padding can influence the perceived coloring of the fiber-bonded engineered material, as shown by the padding through the fiber bond. In some examples, the fiber bond can form a transparent or translucent structure by using low-melt fibers that become transparent or translucent to depict the underlying coloring. Similarly, one or more colored fibers having a melting temperature, softening temperature, or degradation temperature higher than that of the low-melt fibers can become encapsulated / trapped or suspended within the low-melt fiber fusion. Furthermore, it is envisioned that when trimming or unmasking operations occur, one or more underlying materials can be exposed along with their associated coloring. Moreover, because different materials can be formed as continuous and cohesive composites, some materials can be colored using coloring techniques, while others may not be. This difference in the tendency to accept coloring can lead to mixed coloring from uniformly applied coloring. As can be understood, various color variations can be achieved through material selection, placement, and / or processing.

[0058] In some respects, padding can be attached to another component of the article to be manufactured before entanglement. For example, padding intended for forming the upper of a footwear article can be adhered (e.g., sewn) to a secondary element (e.g., a knit ankle collar) before entanglement. In this case, the padding will no longer be planar but will extend in the Z direction at the location of the secondary element. In some respects, the knit collar (secondary element) can then be masked (e.g., with a band) and a fiber layer is placed on the masked padding / secondary element assembly, and the assembly and the fiber layer become entangled. Depending on the location of the masking, the fiber entanglement can effectively conceal the seams, making it difficult to determine from appearance alone how the secondary element is attached. The seams can also be reinforced by entanglement, making the connection stronger and less prone to damage.

[0059] In some respects, secondary elements formed by processes other than fiber entanglement can be interconnected with each other and / or connected to fiber-bonded elements via fiber bonding. For example, Figure 29 An exemplary footwear article 2900 is illustrated, having an upper 2916 formed using laser- or die-cut foam padding 2910 and mesh padding 2912. A knitted collar component 2914 has been attached to the remainder of the upper 2916 during tangling, rather than by sewing. Figure 30 The illustration shows a close-up view of the connection between the upper 2916 and the knitted collar 2914.

[0060] Various padding materials and fiber layers can be strategically placed relative to each other to produce a variety of desired effects, the boundaries of which are limited only by imagination. For example, Figure 31 The illustration depicts a fiber-bonded flat upper component 3100 for footwear, which has not yet been cut and assembled to form a three-dimensional upper. The fiber-bonded component 3100 includes mesh padding entangled with a region 3110 of first fibers, a region 3112 of second fibers, a region 3114 of third fibers, and a region 3116 of a mixture of the first and second fibers on a surface that will be the outward-facing surface of the three-dimensional footwear. Fly-wire cables 3118 are entangled along portions that will become the inner and outer sides of the upper. The left side of the loop 3120, used as a lacing support, is not yet entangled, nor is the area of ​​the mesh padding. In the illustrated upper component, silicone material 3122 has been screen-printed onto portions of the upper, for example, to provide abrasion resistance.

[0061] In some respects, entanglement can occur in two directions (e.g., fibers of the first fiber layer extend into (i.e., not completely through) or through the fibers of the second fiber layer and become entangled with them, and fibers of the second fiber layer extend through the fibers of the first fiber layer and become entangled with them). Such bidirectional entanglement can result in a relatively uniform appearance of the resulting fiber-bonded article (assuming the fiber layers and padding are substantially uniform, if present). In other respects, entanglement can occur in only one direction, for example, fibers of the first fiber layer extend through and become entangled with the fibers of the second fiber layer, wherein fibers of the second fiber layer do not extend through the fibers of the first fiber layer to become entangled with them. Such unidirectional entanglement can result in a relatively uniform appearance of the resulting fiber-bonded article (assuming the fiber layers and padding are substantially uniform, if present). However, in cases where the fiber layers exhibit properties different from each other (e.g., different coloring), the strategic use of unidirectional and bidirectional entanglement for a single fiber-bonded article can result in the formation of a desired pattern on the resulting fiber-bonded article. For example, in Figure 29 and Figure 30 In the items shown, some portions of the mesh padding have become entangled in only one direction, causing the fibers of the first fiber layer to appear as dotted patterns through certain areas of the shoe upper.

[0062] Overview Fiber-bonded engineered materials provide desired properties (e.g., elasticity, cushioning, stiffness, breathability, moisture control, toughness, feel, or insulation) at a predetermined relative position, for use in articles formed therefrom to retain or produce the desired properties at a predetermined position. For example, a first fiber layer composed of a first plurality of fibers, a padding material, and a second fiber layer composed of a second plurality of fibers can be formed as a component of a footwear article. This component is formed at least by entanglement of the first plurality of fibers with the second plurality of fibers. This entanglement holds the padding material in a predetermined relative position with respect to the first and second fiber layers.

[0063] In some examples, the padding material itself is formed of a material that allows mechanical engagement with one or more fibers from at least one of the first and second plurality of fibers. Mechanical engagement can be entanglement, where fibers forming at least a portion of the padding are entangled with fibers from the first and / or second plurality of fibers. Mechanical engagement can include one or more fibers from the first and / or second plurality of fibers entering (i.e., not completely penetrating) or passing through a portion of the padding material. For example, if the padding includes pores (e.g., negative spaces), fibers from the first and second plurality of fibers may wrap around the pores and pass through them. Mechanical engagement can include one or more fibers from the first and / or second plurality of fibers extending into the padding and physically interacting with it. For example, the padding material can be composed of a foam material that allows penetration or mechanical engagement of one or more fibers from the first and / or second plurality of fibers during entanglement operations. The gaps between adjacent fibers can provide additional or alternative locations for the interlocking of fibers and padding.

[0064] In some examples, the padding material is held in a position where it is not entangled with fibers. For example, in a first aspect, the padding material may be impervious, and multiple fibers may be entangled around the padding material but not through it. If the padding material is of a suitable shape (e.g., tubular or circular), the padding element may be able to rotate or move within a defined position enclosing the padding material. Alternatively, if the padding material is of a suitable shape (e.g., asymmetrical or discrete elements), the padding element may be held in a designated position and may be immovable within the enclosing position.

[0065] After one or more fiber layers are entangled to retain cushioning, a fiber-bonded engineered material is formed by wrapping and / or mechanical bonding, which provides desired properties at a intended relative location on a component of a footwear article. This component can be a discrete element of the footwear article or it can be an integral part of the footwear article (e.g., the upper of a shoe). In the example where the component is the upper of a shoe, the location of the desired feature can be relative to the upper of the shoe. Therefore, specific properties can be formed at the location on the upper of the shoe to be formed by the fiber-bonded engineered material.

[0066] Additional materials can be integrated or incorporated. For example, films such as metal films can be applied to one or more parts of fiber-bonded engineered materials. Metal coatings can provide reflective characteristics, such as heat retention or heat reflection relative to articles formed with metal coatings. Additional coatings are envisioned to achieve complementary engineered properties, such as water resistance, abrasion resistance, coloring, etc. Coatings can be applied generally to materials or applied in sections.

[0067] Footwear Go to Figure 1The illustration depicts an exemplary footwear article, shoe 100, according to various aspects thereof; for simplicity, the footwear article is referred to herein as a shoe, but it should be understood that footwear articles may include sandals, slippers, dress shoes, cleats, running shoes, tennis shoes, loafers, boots, skate boots, mules, etc. Shoe 100 is exemplary in nature to illustrate relative terminology and is not intended to be limited to the scope of the concepts provided herein. It should be understood that components of a footwear article may or may not include the elements illustrated with shoe 100. Furthermore, it should be understood that alternative constructions, styles, and relative dimensions from those combined with the shoe 100 illustration may be implemented in the components used for footwear articles.

[0068] Shoe 100 includes an upper 102 and a sole structure 104. The upper 102 is the foot-retaining portion of the shoe 100. The upper 102 conventionally forms a foot receiving cavity into which the wearer inserts his / her foot to be secured to the sole 104. The sole 104 is the surface of the shoe 100 that contacts the ground. The sole may include an outsole, a midsole, and / or an insole. When an outsole is present, it forms the ground-contacting portion of the sole 104 and is typically abrasion-resistant or suitable for use on which the shoe 100 is intended to be worn. In one exemplary aspect, when a midsole is present, it can provide impact damping for the shoe 100. When an insole is present, it provides the foot-facing portion of the sole 104. It should be understood that one or more portions of the sole 104 may be combined indiscriminately. Furthermore, in some aspects, it is contemplated that specific portions of the sole 104 may be omitted together.

[0069] Shoe 100 has a toe cap 106, a heel end 108, a forefoot opening 110, an ankle opening 112, and a tongue 114. (See the plan view depicting shoe 100.) Figure 2 As best seen in the view, the shoe 100 also includes an inner side 109 and an outer side 107. In addition, the shoe 100 includes a toe portion 118, a quarter portion 120, a throat edge 122, and an inner surface 116.

[0070] Shoe 100 can be described based on the relative positions of several parts. For example, a midsole portion 120 typically extends downward from the throat edge 122 toward the sole 104 on the outer side 107. Similarly, shoe 100 includes opposing midsole portions on the inner side 109. Furthermore, a heel portion extends around the heel end 108 between the inner side 109 and the outer side 107. Shoe 100 has a toe cap region that extends from the toe cap 118 toward the toe tip 106 between the inner side 109 and the outer side 107. In this example, the throat edge 122 passes through the toe cap 118 and surrounds the forefoot opening 110 on both the inner and outer sides 107. Figure 1The lacing system can extend through the opening at the front of the shoe (110). Figure 1 ), to tighten the upper 102 around the wearer's foot ( Figure 1 In an exemplary aspect, the tongue 114 can pass through the toe 118 and the forefoot opening 110 ( Figure 1 It extends toward the ankle opening 112 and provides support and / or cushioning to the wearer as the lacing mechanism extends over the wearer's forefoot.

[0071] Construction of fiber-bonded engineered materials Figures 3A to 6B The sequence for constructing exemplary fiber-bonded engineered materials, according to various aspects of this document, is described. (Furthermore, a more comprehensive discussion follows.) Figures 32 to 34 Constructions for building exemplary fiber-bonded engineered materials using a carrier network, according to various aspects of the present invention, are described.

[0072] Figure 3A A cut fiber layer 300, consisting of multiple fibers 302, is depicted as a nonwoven structure. The fibers 302 are depicted for illustrative purposes; however, it should be understood that the fibers 302 may have a concentration, density, size, interaction, and form different from those schematically illustrated in Figure 3 and other figures below. Furthermore, while the cut fiber layer 300 is depicted as a batch-style element, it is essentially representative and could alternatively be depicted as a continuous element (e.g., a roll of goods). Therefore, the cut fiber layer 300 is merely exemplary in nature and does not limit the size, shape, or construction for the purposes of this document.

[0073] Figure 3B Depicting along the various aspects of this article Figure 3A A cross-sectional view of the cut fiber layer 300 along cut line 3B; the cut fiber layer 300 has a first side surface 304 and a second side surface 306. Although depicted as a single layer formed of fibers 302, it is contemplated that, as described above, the cut fiber layer 300 may consist of multiple discrete or transitional layers. The cut fiber layer 300 is depicted having a thickness extending between the first side surface 304 and the second side surface 306. However, the thickness is depicted for illustrative purposes and is not limiting in nature.

[0074] Figure 3C It depicts something very similar to Figure 3B The fiber layer 301; however, according to this aspect, the fibers 303 of the fiber layer 301 are "continuous" fibers. A continuous fiber is a fiber having a length that is 200 times greater than its transverse width. This aspect contemplates fiber layers having cut fibers and / or continuous fibers.

[0075] Figure 3D A continuous fiber layer 305 according to various aspects of the present invention is depicted, which forms a fiber layer as a rolled product. As described herein, the fiber layer may be a batched layer with discrete dimensions, or the fiber layer may be a continuous textile, such as... Figure 3D As depicted, one or more article outlines 307, such as shoe upper pattern outlines, can be formed on a continuous fiber layer 305. It is envisioned that a single padding material can span multiple articles to be formed. For example, padding material can be applied to a roll of good fiber layer such that the padding material extends through the lateral or longitudinal direction to be incorporated into multiple footwear uppers. For example, the depicted article outlines 307 include uppers of multiple shoes in the longitudinal direction. A common padding material can be placed in the longitudinal direction such that when the uppers of multiple shoes are removed from a continuous roll, one padding material is incorporated into the uppers of multiple shoes.

[0076] Figure 4A A padding material 400 positioned on a fiber layer 300 according to various aspects of the invention is depicted. The padding material 400 is exemplary in nature and not limiting. The padding material 400 is a continuous and engineered design. The padding material 400 partially forms the upper for footwear articles having a toe cap 406 and a heel cap 408. The padding material 400 also includes a midshoe engineered element 402 of a high-strength (e.g., low-tensile) material that, when formed as the upper of a shoe, effectively transfers lacing loads from the throat opening toward the sole structure. The padding material 400 also includes a heel cap engineered element 404. In some aspects of the invention, the heel cap engineered element 404 may be a reinforcing member to strengthen the heel area when formed as the upper of a shoe.

[0077] Padding material 400 can be formed into knitted, woven, nonwoven, braided, embroidered, custom fiber lay-up, deposition molding, film, sheet, casting, extrusion, molding, expansion, shrink molding, 3D printing, and other materials, as previously described. Padding material 400 can be formed from synthetic and / or organic materials, such as, for example, peptide-based materials, cellulose-based materials, protein-based materials, aromatic polyamides, glass, minerals, carbon, metals, and / or polymers. As provided throughout, any material and / or forming technique can be implemented as envisioned herein for other padding materials.

[0078] Figure 4B The following are depictions of various aspects of the present invention. Figure 4A A cross-sectional view of the cutting line 4B. The relative positions of the heel end 408 of the padding and the heel end engineered element 404 are shown.

[0079] Figure 5A A second diced fiber layer 500 is depicted according to various aspects of the present invention, which is composed of stacked... Figure 4AThe component depicted herein consists of a second plurality of fibers 502. The second cut fiber layer 500 may be similar to or different from [the other component]. Figure 3A The second diced fiber layer 500. For example, different fiber properties may be associated with the second diced fiber 502 compared to the multiple fibers 302 (e.g., the second diced fiber 502 may have a melting temperature (or softening temperature or decomposition temperature) lower than that of the multiple fibers 302). Although the second diced fiber layer 500 is depicted, it is contemplated that a single fiber layer may be used in exemplary aspects to form the fiber-bonded engineered material. As will be described in more detail below, although the second diced fiber layer 500 is depicted as stacked on top of the entire diced fiber layer 300, it is contemplated that only a portion of the diced fiber layer 300 may have a corresponding second diced fiber layer 500. Instead, two or more different fiber layers may be positioned corresponding to the diced fiber layer 300 to provide engineered properties to the fiber-bonded engineered component by means of alternative fiber layers and the positions of multiple fiber layers.

[0080] Figure 5B It describes the various aspects of this article. Figure 5A A cross-sectional view of the cutting line 5B. The relative positions of the heel end 408 of the padding 400 and the heel end engineered element 404 are shown.

[0081] Figure 6A Depicting the entanglement based on various aspects of this text Figure 5A The components. Entanglement results in mixing and mechanical bonding between multiple fibers 302 and a second multiple fibers 502. As previously described, entanglement can be achieved through various mechanisms, such as needle entanglement (e.g., hook needle or structured needle entanglement) or fluid entanglement (e.g., hydraulic entanglement). One or more portions of the padding 400 (such as...) are also envisioned. Figure 6B (The best view in the middle) can also be entangled with one or more of the multiple fibers 302 and the second multiple fibers 502.

[0082] Figure 6B Depicting along the cutting line 6B according to various aspects of this text Figure 6A A cross-sectional view of the components. As depicted, the multiple fibers 302 and the second multiple fibers 502 are not limited to their respective fiber layers. Instead, entanglement has moved one or more fibers from each fiber layer to another fiber layer to cause entanglement and the resulting bonding. Entanglement leads to fiber consolidation. Fiber consolidation can be from fibers from different fiber layers and / or padding, forming a cohesive composite material, which is a complex composite material. As a result, padding 400 is fiber-bonded and forms a fiber-bonded engineered material that can be used to form articles (e.g., shoe uppers) with minimal additional processing (e.g., cutting, sewing, and / or gluing).

[0083] The pad 400 can be removed from the entangled fiber layer at the periphery of the pad 400, where fibers are entangled around and / or through the pad 400. Depending on the variety of fibers forming the now entangled fiber layer, the waste from the removal process can be recycled. For example, if multiple fibers 302 and a second multiple fiber 502 have similar compositions, they can be recycled to form another fiber layer. In some examples, the ease of fiber recycling can drive manufacturing efficiency.

[0084] The idea comes from Figure 6A The resulting fiber-bonded engineered material can then be formed into a shoe. For example, from Figure 6A The resulting components can be attached at the heel and along the toe. The attached portion can then be placed on a cobbler's last, where the foot portion can be attached to form a receiving cavity in which the foot can ultimately be received. Furthermore, one or more processes can be performed at any point, such as before removing components from excess fibers, after lasting, after closing, etc. As an example and not limiting, these processes can include preparing for market by placing orders according to customer requirements, applying energy (e.g., heat, light, radio waves, sound waves, plasma, electron beams, or vibrational energy), applying liquid chemicals, cutting, sewing, welding, pressing, heating, expanding, shrinking, printing, impregnating, spraying, rolling, perforating, filling, purging, painting, and / or applying a sole.

[0085] Figures 7A to 10C An exemplary fiber layer structure for forming fiber-bonded engineered materials is illustrated according to various aspects of this document. Figure 7A A first fiber layer 700, a perimeter 702 of the shoe upper, and a second fiber layer 704 are depicted according to various aspects herein. As used throughout this document, unless explicitly stated otherwise, the first fiber layer 700 and any other fiber layer (e.g., the second fiber layer 704) may consist of any fiber or combination of fibers. As previously described, fibers may be organic (e.g., wool, cotton, protein-based, or cellulose-based), synthetic (e.g., polymers or aramids), and / or engineered (e.g., carbon fiber or glass). Additionally, unless explicitly stated otherwise, the first fiber layer 700 and any other fiber layer (e.g., the second fiber layer 704) described herein may consist of other materials. For example, by way of example only, other materials may include binders, colorants, reactive chemicals, fillers, primers, foaming materials, granules, powders, etc. All listed materials related to fibers are contemplated as provided herein.

[0086] The upper perimeter 702 may represent a different material, such as padding, and / or it may represent the perimeter defining the portion to be removed from the assembly. In the latter case, the upper perimeter 702 may be representative for illustrative purposes only and to provide context for the drawings (e.g., the upper perimeter 702 may not be a visible physical boundary), or the upper perimeter 702 may be a visible indication / marking (and / or may include one or more visible markings for sizing, alignment, and / or registration). In the former case, where the upper perimeter 702 is a different material, it is contemplated that certain aspects (e.g., engineered materials) have been omitted for illustrative purposes. However, it is contemplated that when the upper perimeter 702 is a different material, the upper perimeter 702 may include one or more elements provided herein. Furthermore, regarding the aspect of the upper perimeter 702 being made of different materials, like other padding materials described herein, the upper perimeter 702 can be formed by various techniques (e.g., knitting, weaving, nonwoven, braiding, embroidery, custom fiber placement, deposition molding, reduction molding, casting, extrusion, expansion, 3D printing, or film technology), and it can be formed from various materials or combinations of materials. Throughout this application, other upper perimeters will be described in a similar manner to the upper perimeter 702; however, it should be understood that they are also described in a simplified manner for illustrative purposes only, and the above description of the upper perimeter 702 applies equally.

[0087] Figure 7B Depicting the various aspects of this article Figure 7A The upper is formed by the components. Specifically, a first fiber layer 700 forms part of the toe section and the midfoot section. A second fiber layer 704 forms part of the heel section and the midfoot section. In this example, two concepts are explored and depicted.

[0088] First, it is envisioned that a single fiber layer can be used to form part of an article. For example, if the upper perimeter 702 is padding, the first fiber layer 700 can be entangled with the upper perimeter 702 and / or the first fiber layer 700 can trap a portion of the upper perimeter 702 when the first fiber layer 700 self-entangles. In this example, the padding can be located on the inner or outer surface relative to the single fiber layer. The inner or outer choice can be adjusted depending on the purpose of the padding. For example, if the padding provides structural integrity but is not ideal from a tactile perspective relative to the fiber layer, then the padding can be positioned on the outer surface of the fiber layer. Alternatively, if the padding material has better moisture mobility properties relative to the fiber layer, the padding can be positioned on the inner surface of the fiber layer to more effectively position itself, for example, near the wearer's body. Therefore, while the upper perimeter 702 is... Figure 7B It is depicted on the outer surface of the shaped object, but alternative locations are also envisioned.

[0089] Figure 7A and Figure 7B The second aspect explored is the generation of engineered materials through the layering of fiber layers. As will be explored throughout the text, the layering of fiber layers can effectively impart engineered properties to fiber-bonded materials. For example, additional fiber layers forming the layers of a component can be composed of various materials in various relative orientations and / or in specific relative positions to achieve desired properties at non-uniform, desired relative positions throughout the component. For example, the second fiber layer 704 may comprise a composition having a melting temperature or softening temperature lower than that of the first fiber layer 700. Thus, it is possible to... Figure 7B The components in the process apply energy to melt (or at least induce a change in the state of the composite), causing the entangled fibers to flow and / or bond at the location of the second fiber layer 704. In this example, such a change in state can provide increased elasticity, rigidity, moisture resistance, visual properties (e.g., transforming the second fiber layer into transparent or translucent) and / or similar properties in the part of the article incorporating the second fiber layer 704.

[0090] Figure 8A The first fiber layer 800, the perimeter 802 of the shoe upper, the second fiber layer 804, and the third fiber layer 806 are depicted according to various aspects of this document. As previously described, Figure 8A The elements depicted are merely exemplary and not limiting in nature. It should be understood that any element can be formed from various techniques and materials, as described above. Figure 7A As described.

[0091] Figure 8B The invention describes the components of various aspects thereof. Figure 8A The upper component is formed by the components. In this example, the layering of the fiber layers is further emphasized, wherein a first fiber layer 800 forms the toe portion, a second fiber layer 804 forms the outer surface of the heel portion, and a third fiber layer 806 forms the outer surface of the midfoot portion. However, as... Figure 8C The description in Figure 8C It is along Figure 8A A cross-sectional view of the cut line 8C shows that the component includes overlapping layers forming a composite structure with a tapered profile. The tapered profile can provide a transition or gradient from a first region to a second region. For example, the heel portion includes a first fiber layer 800, an upper perimeter 802 (e.g., padding in this example), a second fiber layer 804, and a third fiber layer 806. (See also...) Figure 8CAs depicted, multiple fiber layers entangle to form a bonded assembly. For example, fibers from a first fiber layer 800 extend into (and potentially through) a third fiber layer 806, forming a bond between the first and third fiber layers 800. Similarly, fibers from the third fiber layer 806 extend into and entangle with the fibers of the first fiber layer 800. Fibers from the first fiber layer 800 may also extend into a second fiber layer 804. In some examples, entanglement through multiple layers can occur depending on entanglement characteristics (e.g., availability and degrees of freedom of fiber movement, technique, duration and / or pressure) and fiber characteristics (e.g., longitudinal length, longitudinal shape, transverse dimensions, transverse shape, fiber length, strength, and flexural modulus). Reciprocating movement can also be present. Fibers forming the second fiber layer 804 may extend into (and potentially through) the third fiber layer 806 to form a fiber-bonded assembly. The upper perimeter 802 may be entangled with one or more fibers of different fiber layers 800, 804, 806 (as depicted). For example, if the upper perimeter 802 is formed of a fiber-based structure, the fibers of the upper perimeter 802 and the fibers of the fiber layers 800, 804, 806 may interact to entangle and bond. Alternatively or additionally, the upper perimeter 802 may be wrapped with the fibers of various fiber layers 800, 804, 806. For example, in one exemplary aspect, if the upper perimeter 802 is formed of a material unaffected by entanglement (e.g., a polymer sheet with hydroentanglement), the fiber layers 800, 804, 806 may entangle around but not through the upper perimeter 802.

[0092] Figure 9A Alternative multi-fiber layer assemblies according to various aspects of this document are depicted. A first fiber layer 900 is stacked with a second fiber layer 902 and a third fiber layer 904 to form the assembly. In this example, the second fiber layer 902 and the third fiber layer 904 are coplanar and do not overlap. Therefore, as Figure 9B The illustration depicts, in the text, the diagram of, by Figure 9A An article formed from components may have an inner surface formed by a second fiber layer 902 and an outer surface formed by a third fiber layer 904. Therefore, it is contemplated that a first portion of the formed article can be designed in a first manner with a first fiber structure, and a second portion of the formed article can be designed in a second manner with a second fiber structure, such that the first and second fiber structures do not interact (except at their boundary, if present). Although Figure 9AThe fiber layup depicts a centerline crack between the second fiber layer 902 and the third fiber layer 904, but it is envisioned that the crack could appear in any location, in any orientation (e.g., lateral or offset), and / or in any shape (e.g., organic shape, linear shape, or island that does not share a boundary with adjacent coplanar materials). As can be understood, different parts of an article can have different functional requirements. For example, footwear articles can be designed to have variability in their inner and outer portions in response to the greater shear forces experienced by the outer portion during cutting movements.

[0093] Figure 10A Another coplanar fiber assembly according to various aspects of this document is depicted. A first fiber layer 1000 has multiple superimposed fiber layers. Thus, the first fiber layer 1000 can be a carrier fiber layer on which engineered aspects are formed. In some aspects, it is envisioned that the carrier fiber layer can be formed from a material with relatively neutral properties, which, when formed, will impart minimal engineered properties to the article as a whole. In other aspects, in an exemplary aspect, the carrier fiber layer is envisioned to be a relatively inexpensive material, such that it can be formed into rolls for use in continuous manufacturing processes. Furthermore, it is envisioned that the carrier fiber layer can be formed from a material capable of recycling. Further still, it is envisioned that the carrier fiber layer can be formed from a material with suitable properties. For example, footwear articles can be formed such that the carrier material is an insole, foot portion, and / or the inner surface of the footwear article. In this example, the carrier fiber layer can be formed from a soft, non-abrasive fiber composition having, for example, higher abrasion resistance, higher anti-pilling properties, or higher melting, softening, or decomposition temperatures than typically experienced during manufacturing or wear. In other words, it is envisioned that fiber-bonded engineered materials could be used for the footwear portion of footwear. These materials could also have an internal surface that functions as an insole, allowing for the omission of the typically additional material layers used in insoles. Therefore, fiber-bonded engineered materials could be used to create shoes that are lighter and fit better than those made with conventional materials.

[0094] The second fiber layer 1002, the third fiber layer 1004, and the fourth fiber layer 1006 are all depicted as coplanar fiber layers superimposed on the periphery of the shoe upper. In this exemplary arrangement, as... Figure 10B and Figure 10C As depicted, a second fiber layer is formed at the heel end on both the inner and outer sides. The inner side, including the toe portion, is formed by a third fiber layer 1004 (e.g., Figure 10C (As depicted in the text). The outer surface, including the toe portion, is formed of a fourth fiber layer 1006 (as shown in the text). Figure 10B (As depicted in the text). Therefore, it is proven that in Figures 10A to 10C Various coplanar arrangements can be implemented in the material to achieve engineered properties by manipulating the fiber layers.

[0095] Figures 11A to 14B Examples of various padding materials and their relative positions and / or characteristics are provided based on various aspects of this document. Specifically, Figures 11A to 14B Various configurations are described based on the interaction of the fiber layer with one or more padding materials, material selection and the resulting entanglement and / or trapping / encapsulation of the padding materials, as well as the relative positions of the various padding materials with respect to each other.

[0096] Figure 11A A first fiber layer 1100 comprising a plurality of fibers 1102 is depicted according to various aspects thereof. As previously provided, it is contemplated that the first fiber layer 1100 (or any fiber layer, unless explicitly indicated otherwise) may be formed from any combination of fibers. The first fiber layer 1100 may be homogeneous or variable in fiber composition. Thus, it is contemplated that, in exemplary aspects, the first fiber layer 1100 may be engineered or made of raw materials. Figure 11A The figure also depicts a first padding material 1104 and a second padding material 1106. The first padding material 1104 and the second padding material 1106 can be any material or construction (e.g., knitted, woven, nonwoven, braided, custom fiber lay-up, embroidered, deposition molding, shrink molding, molding, casting, expansion, 3D printing, sheet, film, etc.); however, in some respects, they are contemplated as materials similar to textiles as depicted. As previously provided, unless otherwise indicated, the exemplary padding materials depicted in the figures can consist of any material composition, forming technique, size, shape, and / or orientation.

[0097] Figure 11B It describes the various aspects of this article. Figure 11AA cross-sectional view of the cut line 11B. As depicted, multiple fibers 1102 extend through and entangle with the first padding material 1104 and the second padding material 1106. In this example, the first fiber layer 1100 serves as the sole fiber binder for the first padding material 1104 and the second padding material 1106. For example, no active binder other than the fibers 1102 can be used to join one or more padding materials together or to bind one or more padding materials to the fiber layer 1100. For example, adhesives, mechanical fasteners, etc., can be omitted. Omitting these alternative binders prevents the binder from inserting properties or limitations into the component. For example, adhesives can restrict tensile strength, increase rigidity, reduce air permeability, etc., which are not desired for that property in one or more parts. Furthermore, non-fiber bonding options can increase thickness, weight, cost, and / or manufacturing process. Therefore, aspects of this document envision the complete omission of alternative binders or their limitation in other aspects. Fiber bonding is an effective bonding solution that works to form engineered materials. It is also envisioned that the fiber layer can be formed from fibers of a material (e.g., a fusible material) that can be bonded to the padding material by means other than entanglement. For example, the fiber layer can be formed from a first fusible material having one or more fusible fibers, and the padding can also be formed to include at least a portion having the first fusible material. In an exemplary aspect, after (or before) entanglement, the first fusible material can be activated (e.g., energy can be applied to it) such that the bond between the fiber layer and the padding is enhanced relative to a bond achieved solely by entanglement.

[0098] The first padding material 1104 partially overlaps with a portion of the second padding material 1106. This provides an example of how multiple padding materials (engineered or raw materials) can be combined and bonded in relative positions through fiber entanglement. Thus, if the first padding material has a first property and the second padding material has a second property, a combination of the first and second properties can be achieved through fiber bonding to produce an engineered textile. Depending on the entanglement technique implemented, entanglement can occur only from a first side of the assembly or from both sides of the assembly. In this example, since the fiber layer is only on a single side, an entanglement process capable of allowing fibers to pass through the padding material can be utilized. One example may include hook entanglement, where the barbs of the needle effectively push and pull the fibers to facilitate entanglement. Furthermore, fluid entanglement from at least the rear side of the assembly is envisioned. Fluid entanglement from the rear and front sides of the assembly is effective for achieving different (e.g., potentially stronger) bonds between the padding materials as the fibers are pushed forward and backward.

[0099] Figure 12A A fiber layer 1200 composed of multiple fibers 1202 is depicted according to various aspects thereof. A first padding material 1204 and a second padding material 1206 are also depicted. As best seen in the cross-sectional view along the cutting line 12B and as in Figure 12BAs shown, the first padding material 1204 and the second padding material 1206 are enclosed within a fiber layer 1200. Enclosure can be achieved by starting with at least a first fiber layer on a first side of the padding materials 1204, 1206 and at least a second fiber layer on the opposite second side of the padding materials 1204, 1206, and then entangled the first and second fiber layers to form the fiber layer 1200. Figure 12B As depicted, one or more of the multiple fibers 1202 also extend through and entangle with the first pad 1204 and the second pad 1206. The first pad 1204 and the second pad 1206 are bonded together by at least a portion of the multiple fibers 1202 to form a fiber-bonded engineered material, wherein the pads 1204, 1206 are enclosed within fibers.

[0100] Figure 13A A fiber layer 1300 composed of multiple fibers 1302 is depicted according to various aspects thereof. A first padding material 1304 and a second padding material 1306 are arranged in a manner similar to... Figure 12A and Figure 12B The material is encased within the fiber layer 1300. However, the first padding material 1304 and the second padding material 1306 are formed of an unaffected material. An unaffected material is one through which the entanglement process does not cause the fibers to extend. A generally unaffected material is one in which the strength of the resulting fiber bonds is insufficient to resist minor disturbances when entanglement occurs. For purposes throughout the text, unless otherwise indicated, an unaffected material may also include a generally unaffected material. Examples may include films or sheets.

[0101] like Figure 13B The description in Figure 13B It is along Figure 13A A cross-sectional view of the cut line 13B shows that the multiple fibers 1302 do not extend through either the first padding 1304 or the second padding 1306. In this example, the padding is held in place by perimeter entanglement between the multiple fibers 1302, rather than by entanglement between the multiple fibers 1302 and the padding 1304, 1306 themselves. Therefore, as will be described below, if the fiber layer 1300 is manipulated (e.g., ruptured) near one of the paddings, the padding can be removed or dissolved, and the volume previously filled with padding will remain as a pocket within the fiber layer 1300. Thus, in an exemplary aspect, the use of an unaffected material allows for the creation of voids or other cavities within the fiber layer. As will be described below with respect to truncated padding or components, an unaffected material can allow for bonding while still allowing movement within the formed fiber wrapping.

[0102] Figure 14AA fiber layer 1400 having multiple fibers 1402 is depicted according to various aspects thereof. A first padding material 1404 is formed of an entangleable material (e.g., textiles), and a second padding material 1406 is formed of an unaffected material (relative to the fibers) (e.g., polymer sheets or films). Furthermore, for illustrative purposes, the first padding material 1404 and the second padding material 1406 are non-overlapping padding materials. Figure 14B As depicted, the first pad 1404 and the second pad 1406 are coplanar pads; however, it is contemplated that, alternatively, they could be offset in the Z-direction (non-coplanar). For example, one or more fiber layers could be positioned between the pads in the Z-direction before the entangled fiber layers are formed. In this example, the assembly would consist of multiple non-coplanar pads. It is also contemplated in this example that the Z-direction offset pads could overlap wholly or partially in the X or Y direction.

[0103] Back Figure 14B Multiple fibers 1402 pass through and become entangled with the first padding material 1404. However, the multiple fibers 1402 do not pass through or become directly entangled with the second padding material 1406. Instead, as previously described, the multiple fibers 1402 self-entangle and form a wrapping portion that traps (encloses) the second padding material 1406.

[0104] Figures 15 to 17 The text describes a padding material with directional engineering accomplished by one or more engineered elements, such as high tensile strength (e.g., low tensile strength) relative to the associated fiber layers.

[0105] Figure 15An article 1500 is depicted, including an article perimeter 1502 and a first engineered element 1504. The first engineered element 1504 can be (or can be made to be by subsequent processing) a high-toughness, high-tensile-strength, low-stretch material, such as rope, wire, molding matrix, deposition matrix, filament, thread, roving, etc. Measured properties (tensile strength, toughness, and tensile strength) can be related to the associated fiber layer used as the fiber binder of the first engineered element 1504. The illustrated article perimeter 1502 represents the upper construction of a shoe. As described earlier herein, an article perimeter such as article perimeter 1502 can be visually present on the fiber layer, theoretically for illustrative purposes, or as a physical element (e.g., as padding having that shape). The direction from toe to heel is indicated by arrow 1508. The offset inward-to-outward direction is indicated by arrow 1506. With the arrangement of the first engineered element 1504, stretching is limited in the direction of arrow 1506 because this direction is generally parallel to the placement direction of the first engineered element 1504. However, stretching is minimal in the direction of arrow 1508 if fundamentally influenced by the first engineered element 1504. Thus, article 1500 demonstrates how the orientation of an engineered material used as padding can impart engineered properties to the fiber layer, thereby becoming a fiber-bonded engineered material. In this example, the first engineered element 1504 can be a custom fiber layup that may have locking stitches, such as embroidery stitches, to hold the fibers in designated positions in the underlying material. The locking stitches can be formed from any material, even removable materials that are later dissolved. Alternatively, it is contemplated that locking stitches with discrete lines be omitted. Instead, an entanglement process can be used when the element (e.g., roving) is applied to the underlying substrate (e.g., padding). For example, when placing the element, one or more crochet hooks may entangle the element with the fiber layer. Other entanglement methods can be implemented (e.g., fluid entanglement and / or structured needle entanglement).

[0106] Figure 16An article 1600 is depicted, comprising an article perimeter 1602, a first engineered element 1604, and a second engineered element 1606. The first engineered element 1604 and the second engineered element 1606 can each be (or can be made to be by subsequent processing) a material with high toughness, high tensile strength, and low elongation, such as rope, wire, roving, etc. The article perimeter 1602 represents the upper construction of a shoe. The first engineered element 1604 is restricted to stretching in the direction indicated by arrow 1608, and the second engineered element 1606 is restricted to stretching in the direction indicated by arrow 1610. Furthermore, in an exemplary aspect, after the entanglement process, it is envisioned that the first engineered element 1604 and the second engineered element 1606 work together by forming a common bonding point at the intersection of the elements 1604 and 1606. Therefore, the properties obtained from the padding formed by the first engineered element 1604 and the second engineered element 1606 may differ from the properties measured individually of each of the engineered elements 1604 and 1606.

[0107] Figure 17 An article 1700 is depicted, comprising an article perimeter 1702, a first engineered element 1704, a second engineered element 1706, and a third engineered element 1708. Each of the first engineered element 1704, the second engineered element 1706, and the third engineered element 1708 can be (or can be made to be) a high-toughness, high-tensile-strength, low-strength material, such as rope, wire, or roving. The illustrated article perimeter 1702 represents the upper construction of a shoe. It is envisioned that engineered elements 1704, 1706, and 1708 can be the same, similar, or different. Engineered elements 1704, 1706, and 1708 can differ in material, construction, and size. Figure 17 The provided design envisions the formation of regional structures for engineered elements 1704, 1706, and 1708. For example, at the heel end of the article perimeter 1702, the third engineered element 1708 restricts the stretching of the article perimeter 1702 in the heel-to-toe direction. When constructed as a three-dimensional shoe upper, the third engineered element 1708 effectively restricts the stretching around the heel end in the inward-to-outward direction. Therefore, Figure 17 The placement of engineered elements in specific areas was envisioned and explored to achieve variable (e.g., regionally applied) engineered properties. While depicted in the heel area, it is envisioned that one or more alternative or additional areas could have engineered elements. Furthermore, although the engineered elements are described with reference to tensile constraints, additional (or alternative) properties can also be achieved through engineered elements. For example, an engineered element could be an elongated portion of foam integrated to provide impact damping or other cushioning properties.

[0108] Figures 18A to 21BDifferent upper constructions and potential padding locations are depicted according to various aspects of this paper. While some upper constructions are depicted as having specific padding arrangements, it is envisioned that upper constructions can be combined with the intended results of the depicted padding. For example, for a first upper construction, the padding configured to add engineered properties to the heel section can be of a first shape, and for different upper constructions, the padding can be of different shapes (or can consist of multiple paddings). Therefore, for similar purposes regarding alternative upper constructions, the envisioned padding locations allow for effective conversion between padding shapes, sizes, and positions. In other words, the discrete elements described and depicted herein demonstrate implementable and non-limiting principles. Rather, the provided principles guide combinations that can be formed.

[0109] Figure 18A A planar upper 1800 having a base portion 1802 and padding 1804 is depicted according to various aspects thereof. The base portion may be a fiber layer and / or padding. As provided herein, the base portion and padding may be formed from various materials (e.g., organic or synthetic materials) using various techniques (e.g., knitting, weaving, nonwoven, embroidery, custom fiber placement, deposition molding, shrink molding, expansion, 3D printing, molding, or extrusion). Figure 18B and Figure 18C As seen in the image, padding 1804 provides engineered properties for the midfoot region on the medial and lateral surfaces extending around the throat portion toward the sole connection location. In this example, continuous padding extends through multiple portions of the article and can be effectively used for various engineered properties. In one exemplary aspect, continuous padding is a continuous, uninterrupted whole. For example, padding 1804 transfers lacing loads from the throat region toward the sole more effectively than the base portion 1802 alone. For example, padding 1804 may have a lower modulus of elasticity than the base portion 1802.

[0110] In another example, padding material 1804 (or any padding material provided herein) can be formed with multiple openings, such as a large knitted mesh. In this example, texture is created when the fiber layers become entangled around the multiple openings. Depending on the size of the openings and the properties of the fibers, the fibers may not block the openings and instead become entangled around the positive portion of the padding, making the negative space generally negative. Therefore, in Figures 18A to 18C In the example, a highly permeable portion can be formed in the padding 1804. At this point, the padding can effectively form a macroscopic texture partially exposed through the entanglement process. This concept can be applied to any padding provided herein.

[0111] Figure 19AA planar upper 1900 is depicted according to various aspects thereof, the planar upper 1900 having a base portion 1902, a first padding material 1904, a second padding material 1906, a third padding material 1908, and a fourth padding material 1910. While a specific combination of padding materials is depicted and will be described, in combination... Figure 19A As can be understood from other figures, one or more of the depicted elements may be omitted or changed. Furthermore, it is conceivable that one or more types of padding materials may be added.

[0112] When the first pad 1904 is in its dimensional forming state (see...) Figure 19B The first padding material 1904 is on the outer portion of the heel area of ​​the flat upper 1900. The second padding material 1906 is on the inner portion of the heel area. The third padding material 1908 is formed around the throat on the inner and outer surfaces, and across the toe area. The fourth padding material 1910 extends from the inner and outer surfaces through the toe box. The fifth padding material 1912 is depicted in the subfoot area. The fifth padding material 1912 can provide stability, cushioning, fit, and / or similar properties. Although the fifth padding material 1912 is depicted as filling most of the subfoot area, in various aspects herein, it may alternatively be concentrated in the heel area, arch area, forefoot area, or toe area. The fifth padding material 1912 can provide subfoot engineering designs such as arch support, cushioning, foot alignment, etc. Each of the padding materials 1904, 1906, 1908, 1910, and 1912 can be formed from different materials, using different techniques, and / or have different properties.

[0113] For example, the first padding material 1904 and the second padding material 1906 can be used to reinforce the heel area and provide additional rigidity. Alternatively or additionally, the first padding material 1904 and the second padding material 1906 can be used as cushioning in the heel area, such as by forming the respective padding materials with a loose or foamy material. The third padding material 1908 can be formed of a material with greater tear resistance than the base portion 1902. This greater tear resistance is combined around the lacing eyelets, which expose the throat portion to concentrated tension, thereby securing the item to the wearer. The fourth padding material 1910 can be formed of a material and / or technology that provides greater abrasion resistance than the base portion 1902. Shoes may experience abrasions and scratches at the toe edge, which is not commonly experienced elsewhere on the shoe. As a result, the fourth padding material 1910 effectively engineers abrasion resistance properties into the flat upper 1900.

[0114] Figure 19B Depicting the state of size formation according to various aspects of this article. Figure 19A The flat upper is 1900. Figure 19B include Figure 19AThe tongue portion is not depicted; however, it is envisioned that the tongue portion could be formed as part of the upper pattern, or it could be formed separately and subsequently attached.

[0115] Figure 20A A planar upper 2000 having a base portion 2002 and padding 2004 is depicted according to various aspects thereof. Although depicted as a single padding, padding 2004 can actually be formed from two or more portions. Padding 2004 is formed along the connecting perimeter of the planar upper 2000. Perimeter padding can extend along any perimeter, such as the ankle collar, the forefoot opening, etc. Perimeter padding can be continuous and / or discrete, such that the connecting perimeter and / or the finished edge perimeter can be common or discrete padding.

[0116] The flat upper 2000 can be lasted, and a Stellar sock and / or plate (sometimes called a lasting board) can be attached to the flat upper 2000 to form a three-dimensional shoe. Attachment can be achieved through stitching (e.g., Stellar stitching), adhesives, and / or other joining techniques. Attachment at the perimeter exposes the perimeter to concentrated tension that, when used alone as the base portion 2002, could cause the upper material to tear, split, or otherwise deform. Therefore, padding 2004 effectively resists the negative consequences of perimeter attachment, such as increased dimensional stability and greater tear resistance. Padding 2004 can extend from the perimeter of the base portion 2002 to a point inside the interlocking line to prevent padding exposure in the finished article. The interlocking line is the line formed at the transition between the upper and the sole.

[0117] Figure 20B A bottom view of a planar upper 2002 with a Stellar plate attached at the perimeter is shown. It should be understood that the padding material can be used alone or in combination with one or more other properties as a connecting reinforcement. For example, discrete padding material can be used as a connecting reinforcement, or the padding material may include portions for use as a connecting reinforcement.

[0118] Figure 21A A planar upper 2100 with a base portion 2102 and a padding 2104, according to various aspects herein, is depicted. The padding 2104 extends from the medial and lateral sides through the heel portion. In this example, the padding 2104 also extends toward the throat to the first lacing eyelets on both the medial and lateral sides. The padding 2104 can provide the transmission of tensile force from the lacing eyelets toward the heel and into the sole portion to help secure the shoe to the wearer. The padding 2104 can also provide rigidity and / or cushioning in the heel area. As provided herein, the padding can provide one or more of the engineered properties described herein. Figure 21B The planar upper 2100, which is in a three-dimensional structure according to various aspects of this paper, is depicted. Figure 21B Depicting what was originally not in Figure 21A The image depicts the tongue portion of the shoe. However, it is envisioned that the tongue portion could be formed as... Figure 21A A portion of the flat upper 2100, or it may be formed separately and incorporated into footwear items.

[0119] Component pads As previously explained, a pad is an element held in relative position by one or more fiber layers as a fiber-bonded element. Figures 22A to 25D Component padding has been explored in this paper. As provided above, component padding can include one or more components traditionally used in textiles with different coupling mechanisms, and these components can have functions beyond the functional purpose of the textile. Non-limiting examples of components can include snaps, buttons, zippers, hook and loop structures, tubes, rings, grommets, electrical sensors, electrical transmission elements, optical fibers, airbags, tread / adhesion elements, etc. Component padding can also include components forming raised surface embossings that provide a visual, cognitive, and / or tactile perception of the presence and / or absence of entrapment or encapsulation. Component padding with raised surface embossings may not have functions beyond the functional purpose of the textile and may provide, in whole or in part, the visual appearance they offer.

[0120] Figures 22A to 22E Exemplary elements are depicted in various views and in tangled states. Figure 22A A plan view of an assembly 2200 of elements according to various aspects thereof is depicted. The assembly 2200 of elements includes an unaffected general-purpose element 2210, a second unaffected general-purpose element 2212, a snap fastener with a flange 2214, a snap fastener with a first entangled flange 2216, a snap fastener with a second entangled flange 2218, an electrical element with an entangled flange 2220, a first solid channel 2222, a second solid channel 2224, a first deformable channel 2226, a first hollow channel 2228, a second hollow channel 2230, and a D-ring 2232. It should be understood that the assembly 2200 of elements is exemplary in nature and not limiting.

[0121] Some elements may simply be encased within a fiber layer, while others may be entangled with the fibers. As will be explained in more detail below, mere encapsulation allows the element to move (e.g., rotate) within a defined encapsulated volume. Furthermore, as will be explained in more detail below, encapsulated elements can be readily removed from the entangled fiber layer to create a volume (e.g., a pocket, channel, window, or opening), wherein the encapsulated element is positioned during entanglement and prior to removal. Entangled elements may be firmly fiber-bonded to at least one fiber layer (and potentially also to one or more padding layers) to prevent movement of the element, such as rotational movement. Elements may be formed from any material or combination of materials, such as, but not limited to, polymers, metals, and / or organic materials. Elements may be formed using any technique, such as molding, deposition molding, reduction molding, extrusion, etc. Elements may have any size, shape, or construction.

[0122] The unaffected general-purpose component 2210 can be any component encased within a fiber layer. For example... Figure 22E As best seen, a portion of the fiber-encasing layer can be removed to expose the unaffected general-purpose element 2210. This is partly possible because the fibers removed from the fiber layer are not entangled with the unaffected general-purpose element 2210. Therefore, the unaffected general-purpose element 2210 can provide a mask, window, or other feature, which will be described below. In some aspects, a portion of the fibers forming the fiber-encasing layer can be manually or forcibly separated or detached to expose a portion of the unaffected general-purpose element 2210. For example, the unaffected general-purpose element 2210 may include pointed or protruding portions or other suitable protrusions that can be exposed when the fibers are forcibly or manually separated.

[0123] The second unaffected general-purpose component 2212 is similar to the unaffected general-purpose component 2210, but as Figure 22E As best seen in the diagram, a hole is formed through the fiber layer and the post-entanglement of the second unaffected general-purpose element 2212. Therefore, the second unaffected general-purpose element 2212 provides an example of post-processing that can be performed on the padding to further engineer the fiber-bonded engineered material. In all respects herein, the second unaffected general-purpose element 2212 can provide reinforcement, lace holes, or other purposes. The hole formed through the second unaffected general-purpose element 2212 and the fiber layer can be formed by, but is not limited to, punches, drills, CNC machines, lasers, water jets, cutting, slits, dissolution, etc.

[0124] The snap fastener with flange 2214, although called a "snap fastener," can be a grommets or other ring-shaped elements. The snap fastener with flange 2214 can be made of, for example... Figure 22CThe unaffected material formation described herein ensures that the fibers from the fiber layer do not entangle with the snap fastener having flange 2214; instead, the fibers entangle with each other, binding the snap fastener and flange 2214 within a volume to enclose the snap fastener with flange 2214. Because the snap fastener with flange 2214 has a symmetrical shape within the volume enclosing it, and because it does not contain entanglement structures, it can rotate freely within the volume while remaining fixed to the fiber layer. A reciprocating snap fastener element intended to mechanically engage the snap fastener with flange 2214 is also envisioned, but not depicted.

[0125] It is envisioned that a pad, such as a component pad, can be sufficiently enclosed within a fiber bonding layer to at least temporarily position and hold the pad. Subsequent operations, such as applying pressure, heat, or adhesives, can be used to ultimately secure the trapped pad to the fiber layer. In other words, trapping and / or entanglement can serve as a temporary bonding process to hold the pad in place, and subsequent processes can be implemented to reinforce the bonding and firmly retain the pad relative to the fiber layer.

[0126] The snap fastener with the first entanglement flange 2216 is similar to the snap fastener with flange 2214, but the flange portion includes multiple holes through which fibers from the fiber layer can extend. The fibers extending through the holes in the flange prevent rotational movement within the fiber volume provided by the snap fastener with flange 2214. Therefore, it is contemplated that the element could be adapted to wrap or entangle fibers using only one or more structural variations, such as the holes through the flange in this example.

[0127] The snap fastener with a second entanglement flange 2218 provides an alternative flange concept that can offer different entanglement characteristics than the snap fastener with a first entanglement flange 2216. The snap fasteners with the first entanglement flange 2216 and the snap fastener with the second entanglement flange 2218 provide examples of how the entanglement characteristics of an element can be adjusted through structural changes. For example, instead of holes extending through an existing structure, the structure itself can be modified to enhance entanglement characteristics, as depicted by the snap fastener with the second entanglement flange 2218. Therefore, it is envisioned that the entangled structure can be co-produced or post-produced from materials similar to or different from the padding portion to which the entangled structure is attached.

[0128] An electrical element with entanglement flange 2220 represents any electrical component (e.g., a sensor, lamp, integrated circuit, battery, or antenna) that can be fiber-bonded to engineered materials. While depicted with an entanglement flange, it is envisioned that in some respects, the electrical element could simply be wrapped rather than entangled. It is envisioned that one or more electrical conductors could extend to the electrical element with entanglement flange 2220 (or any electrical element secured with fiber bonding). The electrical conductors can be padding or part of individual components, also composed of fibers bonded together from fiber layers. For example, an electrical harness with selected components having electrical connections could be inserted as one or more paddings entangled with one or more fiber layers.

[0129] The first solid channel 2222 is conceptually similar to the unaffected general-purpose element 2210; however, the first solid channel 2222 is envisioned to have an extended longitudinal length relative to a transverse cross-sectional measurement (e.g., diameter). The first solid channel 2222 may represent an optical fiber, a conductive element, or another unaffected element.

[0130] The second solid channel 2224 is similar to the first solid channel 2222; however, from Figure 22E As can be seen, the second solid channel 2224 can be removed to form a channel within the entangled fiber layer in the volume previously filled by the second solid channel 2224. Because the second solid channel 2224 is unaffected, the fibers do not become entangled with it, and the second solid channel 2224 can be removed without significantly damaging the entangled fiber layer.

[0131] The first deformable channel 2226 is conceived to have an extended longitudinal length relative to a transverse cross-sectional measurement (e.g., diameter), and possesses elasticity that allows for temporary or permanent deformation within the transverse cross-section. Deformation in Figure 22C As depicted in the figure. In an exemplary aspect, it is envisioned that the first deformable channel 2226 can provide shock attenuation capabilities or other buffering functions.

[0132] The first hollow channel 2228 can be a tubular structure with any transverse cross-sectional shape (e.g., circular, oval, triangular, straight, leaf-shaped, dog-bone shaped, or hollow). The tubular structure can effectively conduct fluids, such as liquids or gases, or retain foamable, flowable, expandable, or state-changing materials. Furthermore, the tubular structure can serve as a conduit through which entangled components (e.g., optical fibers, microfibers, or electrical components) can pass. For example, by using the first hollow channel 2228 as a conduit, components that may not be suitable for entanglement treatment (e.g., due to the increased risk of breakage) can still be integrated into fiber-bonded engineered materials.

[0133] The second hollow channel 2230 can be similar to the first hollow channel 2228; however, as Figure 22C As shown, it may be relatively indeformable in cross-section.

[0134] like Figure 22D As seen, the D-ring 2232 represents an element that can be wrapped, but can be partially repositioned from the outside of the fiber layer using rotational movement. For example, the entire D-ring 2232 can be wrapped in the fiber layer, but a masking or trimming operation can release the curved portion, leaving the wrapped linear portion. After releasing the curved portion of the D-ring 2232, the curved portion can rotate about an axis defined by the longitudinal direction of the still-wrapped linear portion. While a “D”-shaped ring is depicted, it is contemplated that any ring or clasp can be fiber-bonded. In an exemplary aspect, the clasp or ring can have a linear portion that can rotate freely when wrapped. However, it is contemplated that rotation can be avoided, and a portion of the fibers wrapping the ring or clasp can be trimmed to allow at least a portion of the ring or clasp to be accessible outside the fiber layer. Rotation can be inhibited or encouraged by the structural design of the wrapped element (e.g., an asymmetric design or incorporating entangled structures) and / or post-processing (e.g., applying energy, heat, pressure, or adhesives).

[0135] Figure 22B Depicting from various aspects of this article Figure 22A A cross-sectional view of an element having a first fiber layer 2234 on top and a second fiber layer 2236 on the bottom. While two fiber layers are depicted, it is envisioned that some elements could be sufficiently entangled with a single fiber layer. However, in one exemplary aspect, only those elements that are wrapped may benefit from at least the second fiber layer to form a wrapped fiber structure to be entangled. The cross-section also illustrates fibers entangled with the element, such as entanglement flanges 2216 and 2218 via snap fasteners.

[0136] Figure 22C The following describes the entanglement of the first fiber layer 2234 and the second fiber layer 2236 according to various aspects of this paper. Figure 22B A cross-sectional view. Entangled fibers bind the element. Entanglement results in the element at least partially enclosing and / or becoming entangled with the fibers.

[0137] Figure 22D It describes the result after modifications were performed on it according to various aspects of this article. Figure 22C A plan view of some of the components. Figure 22E It describes the various aspects of this article. Figure 22D The cross-section of the cutting line 22E. For example... Figure 22D and Figure 22EAs can be seen, the post-entanglement trimming operation can remove portions of the fibers to expose one or more portions of the element enclosed therein and / or entangled with them. The trimming operation can also extract a portion of the element itself, such as for a second unaffected general-purpose element 2212. Furthermore, it is envisioned that post-entangled elements can be partially exposed to allow access, such as element 2238. Additionally, as depicted by 2240, elements can be extracted together, leaving fiber cavities in the gaps formed around the element during entanglement.

[0138] It is envisioned that the fiber cavity can be filled with one or more materials. For example, foamable and / or flowable materials, such as granules or powders, can be inserted into the fiber cavity. The cavity can be sealed with the foamable and / or flowable materials contained therein by further entanglement or other closure methods. The foamable material can be foamed (e.g., triggered by heat or other catalysts) such that the fiber cavity is filled with the foamable material. Other materials, such as curable materials (e.g., silicone resin), are also envisioned, which can be inserted in a first state (e.g., liquid, dispersion, or paste) and formed into another state (e.g., elastic solid). In one exemplary aspect, the channel provides a container containing the added material. Furthermore, the fiber cavity can serve as a channel through which a tension rope or other tightenable element can extend. It is also envisioned that locking elements (e.g., rope locks) can be fiber-bonded into the material to hold the rope at a set tension. Furthermore, it is envisioned that a low-friction surface coating can be applied or formed along the fiber-formed cavity / volume. The low-friction surface coating can be low-friction relative to the untreated portion of the same fiber material. The low-friction property can be used for threading elements through the fiber volume or for moving an article once within the fiber volume.

[0139] As previously described, fiber-encased elements include those forming raised surface embossings. Raised surface embossings provide a visual, cognitive, and / or tactile perception of the presence and / or absence of entrapment in the padding and padding elements, including transitions that provide a distinctive “fiber-bonded” appearance. One aspect of this characteristic appearance is that it suggests alternative manufacturing techniques due to the lack of obvious traditional construction or attachment mechanisms, such as stitched or melted sheet-like plastic polymer films. Examples may include, but are not limited to, padding and fibers (e.g., molded parts, foams, support cables, fusible fiber bundles, and textiles (such as those with openings)) having physical properties that produce perceptible differences, such as pattern, texture, color difference, Z-dimensional differentiation, density, and / or other physical properties where variability can be detected. In some aspects, the padding may undergo one or more manufacturing processes (e.g., dyeing, screen printing, embroidery, etc.) prior to fiber bonding, such that one or more visual properties of the padding become visible on the surface of the resulting manufactured article upon fiber bonding. For example, a portion of the pretreated padding may extend through the fibers (e.g., to create color differences), and / or may be wrapped or trapped by the fibers (e.g., to create raised surface reliefs of the desired shape or structure).

[0140] Figure 27 A footwear article 2700 is depicted formed using mesh padding and padding with a pattern embroidered on it using high-tenacity thread (which can be of any color or reflectivity, as needed). When the fibers are bonded, the embroidered pattern 2710 is visible on the surface of the manufactured article. Figure 27 In the article, a separate skin layer 2712 is also applied to the surface of the fiber-bonded article, which will form the outward-facing surface of the resulting manufactured footwear article 2700.

[0141] Compared to the appearance, weight, and less supple feel of components traditionally bonded with adhesives or fused together with sheet-like plastic polymer films, the tactile characteristics of fiber-bonded wrapping components in a shoe's upper can include softness, lightness, suppleness, permeability, and non-moldeability.

[0142] The above phenomena can be observed or experienced when the trapped element has enhanced visual, cognitive and / or tactile perception due to changes in the surrounding medium, such as production to be translucent / transparent, and / or through textural cues of fibers, additives, treatments, polymer encapsulation, shape transformation (such as by bending or molding), and / or the addition of temporary or permanent luminescent elements within or outside a structure that provides backlighting to reveal the internal layering and / or transition between the trapped padding and fibrous elements.

[0143] Now go to Figure 23A This document depicts a zipper 2300 according to various aspects thereof. The zipper 2300 includes a first belt 2302 and a second belt 2304. A first plurality of teeth 2306 are engaged with the first belt 2302. A second plurality of teeth 2308 are engaged with the second belt 2304. Although not depicted, it is contemplated that the zipper 2300 may include a top stop, a bottom stop, an insert pin, a box pin, and / or a retaining box, which is conventional for zippers. A slider is included to engage and / or disengage the first plurality of teeth 2306 and the second plurality of teeth 2308. Optional holes 2310 on the first belt 2302 and optional holes 2312 on the second belt 2304 are also depicted. However, the holes engaging with belts 2302, 2304 are exemplary in nature. They can be of any size, shape, order, position, sequence, etc. Alternatively, each tooth may have an integrally formed or interconnected entangled structure, which may allow direct entanglement of the teeth without regional structures. For example, each tooth (or set of teeth) can be formed (e.g., molded) to have one or more entangled structures. Thus, the entanglement process is an effective process of maintaining the set position of one or more teeth with or without supplemental tape. Furthermore, in addition to extending through the holes in the tape or as an alternative to extending through the holes in the tape, the tape itself can be an entangled structure (e.g., a fiber-forming material susceptible to fiber entanglement).

[0144] In an exemplary aspect, zipper 2300 is an element padding material with fibers bonded to a fiber layer. The fibers of the fiber layer are entangled with a first strip 2302 and a second strip 2304. Entanglement with strips 2302 and 2304 can occur via piercing the strip, such as through needle entanglement (crochet entanglement or structured needle entanglement), or through a modified strip (or an integral entanglement structure) having one or more structures suitable for inducing entanglement. An example of the entanglement structure includes holes 2310 and 2312. Alternative structures are also contemplated, such as nonlinear edges (e.g., fan-shaped edges), slits, and / or flange portions on the strip, such as... Figure 22A The flange element on the snap fastener having a second entangled flange 2218 is depicted in the figure.

[0145] In an exemplary aspect, preventing the fibers from interacting with the first plurality of teeth 2306 and the second plurality of teeth 2308 can attempt to prevent malfunctions of the zipper 2300 caused by fiber interference. Thus, and as... Figure 23B As depicted, during entanglement, zipper 2300 may include one or more masks. Figure 23B Depicting from various aspects of this article Figure 23AThe zipper 2300 and the cross-section of the first fiber layer 2314 and the second fiber layer 2316 are described. A first mask 2318 and a second mask 2320 are positioned between the fiber layers (2314 and 2316, respectively) and the zipper 2300 in a location where fiber entanglement is not intended to occur. A mask is a temporarily (or permanently) contained, unaffected (e.g., not prone to fiber entanglement) element to prevent fibers from becoming entangled with the underlying element / pad material when entanglement occurs. The mask can be formed of any material, such as a polymer composition, a metal composition, or an organic composition. In one exemplary aspect, the mask can be formed of a plastic sheet material and sized to correspond to a portion of the zipper 2300, primarily at the intersection of the first teeth 2306 and the second teeth 2308. Masks 2318 and 2320 can extend along the longitudinal length of the zipper 2300. In an exemplary aspect, it is contemplated that the mask can be removed or that the mask can be disintegratable (e.g., soluble or disintegratable). Furthermore, in one aspect, it is envisioned that the mask can be retained relative to the padding and / or fiber layer after entanglement. For example, in one exemplary aspect, the mask can prevent contamination or other damage through the fibers during the actual use of the article.

[0146] According to this article, Figure 23C The first fiber layer 2314 and the second fiber layer 2316 are depicted as being combined. Figure 23B The entangled fibers of the zipper 2300. As can be seen, fibers from the first fiber layer 2314 and fibers from the second fiber layer 2316 extend through the holes 2310, 2312 of the zipper tape to bond the zipper 2300 to the fiber layers 2314, 2316. Similarly, as depicted, masks 2318, 2320 prevent the fibers from entangled with the teeth of the zipper 2300. The use of masks 2318, 2320 allows the entanglement process to be applied uniformly, rather than preventing entanglement up to the teeth 2306, 2308.

[0147] Figure 23D This describes the various aspects of the text from... Figure 23C The finishing operation of fibers after the components are completely entangled. As can be seen, the first plurality of fibers 2322 and the second plurality of fibers 2324 are entangled and the fibers are bonded to the zipper 2300. It is envisioned that through one or more holes or entanglement structures (e.g., holes 2310, 2312) of the zipper 2300, one or more fibers may be entangled with the tape of the zipper 2300 and / or one or more fibers may be entangled with other fibers of the fiber layers 2314, 2316.

[0148] Material reduction / trimming operations can then be performed, such as via laser, water jet, knife, die, etc., to remove fibers near one or more masks. In this example, a slit through the entangled fiber layer can be formed along mask 2318 to allow removal of mask 2318 and access to zipper 2300 for operation. Alternatively, as Figure 23D As depicted, trimming operations can be performed to remove fibers covering mask 2318, such as cutting along the perimeter of mask 2318. In an exemplary aspect, removing fibers near the mask can reduce unintentional interference of fibers from entangled fiber layers with zipper operation. A similar operation can be performed on the second mask 2320.

[0149] Zippers can be incorporated into articles with a fiber-bonded structure. For example, a zipper can be envisioned as a closure mechanism formed in the upper of a shoe. Fiber-bonded zippers can also be formed into clothing items (e.g., shirts, shorts, trousers, or bras). Fiber-bonded zippers can also be incorporated into outerwear (e.g., jackets, gloves, or hats). Fiber-bonded zippers can be incorporated into equipment (e.g., protective gear). The fiber bonding of zippers reduces or eliminates stitching or other bonding mechanisms that could increase manufacturing costs and time. Furthermore, the fiber bonding of zippers allows for seamless constructions that provide the wearer / user with alternative tactile sensations, different force distributions on the items they are bonded to, and / or different appearances.

[0150] Fiber bonding can also be used as an anti-interference construction. For example, a fiber-bonded element with or without a mask can secure an article or volume. This volume or gap can maintain a verifiable seal until the fibers are trimmed, allowing access to a padding material, which can be a closing / opening element (such as a zipper or hook). In other words, a delayed trimming process provides functional proof for the fiber-bonded element (e.g., proof that the element has not yet been adjusted, such as zipping up or unzipping a zipper).

[0151] Figures 24A to 24C Fiber-bonded hook-and-loop fasteners as element padding materials according to various aspects of this document are depicted. Although the hook-and-loop structure is depicted, it is envisioned that any fastener construction (e.g., mushroom caps and containers) can be implemented. Figure 24A A hook assembly 2402 is depicted, comprising a hook fastener 2408 positioned between a first fiber layer 2404 and a second fiber layer 2406. A mask 2410 is also depicted to cover the hook of the hook fastener 2408. The mask 2410 restricts entanglement of fibers from the first fiber layer 2404 with the hook of the hook fastener 2408. As previously described, the mask may be formed of an unaffected material or technique that restricts fiber penetration and / or entanglement beneath the mask.

[0152] Still Figure 24AThe image depicts a ring assembly 2420. The ring assembly 2420 includes a first fiber layer 2412, a second fiber layer 2414, and a ring fastener 2416. A mask 2418 covering the ring fastener 2416 is also depicted. In one exemplary aspect, the hook fastener 2408 and the ring fastener 2416 effectively cooperate to form a hook-and-loop fastening mechanism that can engage and disengage to open and close connected articles.

[0153] Figure 24B The entanglement of the first and second fiber layers of the corresponding hook and loop assemblies is depicted. However, as depicted, masks 2410 and 2418 restrict the entanglement of the fibers with the hooks or loops of the corresponding assemblies. As previously described... Figure 23A As described in zipper 2300, it is envisioned that hook fasteners 2408 and / or loop fasteners 2416 can be modified to provide entanglement structures. For example, one or more holes may be integrally formed with or through the element in locations that will not be obscured by a mask, such as perimeters. Furthermore, it is envisioned that entanglement structures, such as non-linear edges, and additional structures may be combined with hook fasteners 2408 and / or loop fasteners 2416 to aid in achieving fiber bonding of these elements to the fiber layer. It is also envisioned that simply wrapping may be sufficient to hold hook fasteners 2408 and / or loop fasteners 2416 in a defined position within the fibrous material. Additionally, wrapping can be used to temporarily hold the element until post-processing (e.g., energy, heat, pressure, or adhesives) can be applied. It is envisioned that elements such as hook assemblies may include masks or unaffected backing / materials to prevent contamination of the functional portions of the element. For example, fibers extending through the rear portion of the hook assembly into the hook may reduce the hook's gripping ability. Therefore, masks or unaffected materials may be used relative to the element to prevent fiber entanglement, which could limit the functional intent of the element.

[0154] Figure 24C Depicting from various aspects of this article Figure 24B The trimming operation of the components. Even after trimming allows the removal of mask 2410 and associated fibers, hook fastener 2408 is still fiber-bonded. This trimming operation exposes the hook of hook fastener 2408 for use as a hook-and-loop fastener. The trimming operation associated with loop fastener 2416 allows the removal of mask 2418 and associated fibers. Once removed, the loop of loop fastener 2416 is exposed for effective use as a hook-and-loop fastener.

[0155] Imagine that hooks and / or loops of any size, shape, or type can be fiber-bonded. Hook and / or loop assemblies can be incorporated into articles with fiber-bonded structures. For example, imagine hook and / or loop assemblies forming as closure mechanisms in the upper of a shoe. Fiber-bonded hook and / or loop assemblies can also be formed in clothing items (e.g., shirts, shorts, trousers, or bras). Fiber-bonded hook and / or loop assemblies can also be incorporated into outerwear (e.g., jackets, gloves, or hats). Fiber-bonded hook and / or loop assemblies can also be incorporated into equipment (e.g., protective gear). Fiber-bonded hook and / or loop assemblies reduce or eliminate stitching or other bonding mechanisms that can increase manufacturing costs and time. Furthermore, the fiber bonding of hook and / or loop assemblies allows for seamless constructions that provide the wearer / user with alternative tactile sensations, different force distributions on the bound items, and / or different appearances. Another advantage of fiber-bonded hook and loop assemblies is that, traditionally, sewing hook assemblies can cause the thread to become tangled and break during use because the hooks interact and move relative to the thread used to secure them by stitching. By utilizing fiber bonding, more mechanical interactions (e.g., discrete fiber entanglement) can be used to secure hook assemblies (and / or loop assemblies).

[0156] Figures 25A to 25D The fiber-bonded elements that provide dimensional offsets according to various aspects of this paper are described. Figure 25A An exemplary dimension offset element 2500 according to various aspects herein is depicted. In a particular example, the dimension offset element is envisioned to be used as a shoe outsole, protective padding element, etc. The dimension offset element 2500 includes a plurality of protruding elements 2502 and a lattice structure 2504. The lattice structure 2504 may also be referred to as a structurally two-dimensional and / or three-dimensional matrix. It should be understood that the features of the dimension offset element 2500 are merely exemplary in nature and not limiting. It is envisioned that different sizes, shapes, and constructions can be implemented for these features. For example, when used as a tread pattern for footwear, the dimension offset element 2500 may have different patterns to accommodate different parts of the footwear (e.g., the toe box, heel, or midfoot). The plurality of protrusions 2502 may have different cross-sectional shapes and / or sizes. The plurality of protrusions 2502 may have variable offset heights (e.g., protrusion heights). The lattice structure 2504 can be nonlinear, dimensionally variable, and / or structurally different (e.g., it can have size gradients, spacing gradients, transverse cross-sectional shape variations, longitudinal shape variations, wavy or curled shapes).

[0157] The dimension shifting element 2500 can be formed from various materials. In an exemplary aspect, the dimension shifting element 2500 is formed from a molding polymer, such as polyurethane, vinyl acetate, silicone rubber, etc. An exemplary material may be an elastic polymer. It is contemplated that the plurality of protrusions 2502 may be formed together with or independently of the lattice structure 2504. It is also contemplated that the plurality of protrusions 2502 may be made of a material different from or similar to the lattice structure 2504. Furthermore, in an exemplary aspect, it is contemplated that the lattice structure 2504 may be completely omitted, and one or more of the plurality of protrusions 2502 may be discrete elements. When the protrusions of the plurality of protrusions 2502 are discrete elements, it is contemplated that the protrusions may have flanges or other entangled structures, as described throughout this document. Thus, the lattice structure 2504 may be integral with and / or formed from the same material as one or more of the plurality of protrusions 2502, or the lattice structure 2504 may be separate from and different from one or more of the plurality of protrusions 2502 as an entangled structure.

[0158] Figure 25B Based on the various aspects of this article Figure 25A A cross-sectional view of the cutting line 25B. As depicted, a plurality of protrusions 2502 extend from the lattice structure 2504 to extend a greater distance in the Z direction (e.g., in...). Figure 25B (Upward). In one exemplary aspect, when entangled, the fiber layer of the fiber bonding dimension offset element 2500 may have a height in the Z direction smaller than that of the plurality of protrusions 2502, starting from the lattice structure 2504. In other words, the plurality of protrusions 2502 may extend beyond the fiber layer forming the fiber bond, such that they are exposed and not covered / obscured by the fibers.

[0159] Figure 25C The first fiber layer 2506 and the second fiber layer 2508 are described according to various aspects of this document. Figure 25B The dimension shifting element 2500. As with other padding and fiber layer combinations described herein, it is envisioned that one or more fibers in the first or second fiber layers 2506, 2508 may have variable properties. For example, a low-melting polymer composition may form at least a portion of the fibers, such as those in the first fiber layer 2506. For example, it is envisioned that post-entangled low-melting fibers may be exposed to energy, resulting in fiber flow or bonding, which creates a plate or sole structure through which the dimension shifting element 2500 protrudes to form an adhesion element. The formed plate or sole structure may have different permeability (e.g., breathability or water permeability), rigidity, flexibility, and / or abrasion resistance relative to the unmelted fiber layers. It is also envisioned that one or more fibers can be bonded to one or more materials to form the dimension shifting element. For example, fibers may be bonded to dimension shifting through pressure, energy, chemicals, and / or other techniques.

[0160] Figure 25D Depicting the entanglement based on various aspects of this text Figure 25C The component. The dimension shifting element 2500 is fiber-bonded by an entanglement process performed by being enclosed by the lattice structure 2504. Additionally, it is contemplated that the dimension shifting element 2500 may include a fiber-based lattice structure entangled with one or more fibers from the fiber layers. It is also contemplated that one or more masks may be used to prevent entanglement of one or more portions of the dimension shifting element. Additionally or alternatively, masks may not be used, as one or more portions may be formed of a fiber-independent material (e.g., a robust polymer or rubber) serving as a self-masking portion. Trimming operations may also be performed in various aspects to expose or otherwise remove one or more fibers from a portion. As depicted, one or more of the plurality of protrusions 2502 extend beyond the fiber layer 2510 formed by the entanglement of the first fiber layer 2506 and the second fiber layer 2508. As a result, the dimension offset element 2500 can provide dimension offset with the entangled fiber layer, such as for the tread of a shoe, protective filling (e.g., elastomer or foam), enhanced durability, breathability, reduced surface contact and / or similar properties.

[0161] As explored in conjunction with the above-described component padding, masks are envisioned for use with any padding material. For example, masks are envisioned for use with padding to prevent fibers from becoming entangled with the padding at one or more locations. When fibers from the fiber layer become entangled with the padding, the properties of the padding may change. In some cases, it may not be desirable to change the properties of the padding at specific locations. Therefore, masks such as fiber-unaffected materials (e.g., polymer sheets) are envisioned to be positioned between the padding and the fiber layer. After entanglement, a trimming process can be performed to remove fibers adjacent to the mask and the mask itself. Thus, preventing fiber entanglement at the location of the mask allows the original properties of the padding to be retained. Furthermore, trimming operations and / or masks are envisioned to be used to form windows where the underlying engineered components can be more visible or identifiable because they are not obscured by the fiber layer.

[0162] As previously described, self-masks are also envisioned. Self-masks envision materials and / or structures that alter entanglement properties, such as preventing entanglement, limiting entanglement, and / or changing the location of entanglement. Examples include the choice of materials that are unaffected by fiber entanglement. Generally, rigid or non-porous materials can resist fiber entanglement. Another example of fiber-unaffected structures are those with sharp distal ends. For example, conical or tapered structures can cause fibers around a portion of the structure to split or separate during entanglement. The forces applied during entanglement act as a means to move fibers around the structure when they are entangled. Thus, in an exemplary aspect, self-mask elements with specific shapes and / or materials can be formed to limit the use of a dissociated mask while obtaining a masking result.

[0163] Fiber bonding can also be used to bond fibrous materials, such as fiber-bonded engineered materials, to different materials at the periphery of the fibrous material. For example, the upper of a shoe can be formed by the fiber bonding process described herein. The upper can then be attached to the sole, such as a foam sole, by entanglement of the fibers of the upper into and with the sole. For example, needles can pressure-form one or more parts of the sole by pushing fibers from the fibrous material into the sole. Fluid entanglement can alternatively be used to entangle fibrous layers with a sole structure (or any structure). Furthermore, it is envisioned that sole structures (or any structures for articles composed of foam or other fiber-unaffected or at least fiber-resistant materials) include entangled structures. For example, the sole (or any component) can be formed using co-molding, co-forming, or post-processing attachment lattices. The lattice can be fiber-based or any entanglement structure / material described herein. The entangled structure serves as a fiber bonding interface for a component (e.g., the sole) and one or more fibrous layers (such as fiber-bonded engineered materials).

[0164] Additional advantages provided by fiber bonding can include edge finishing. In conventional textiles, such as weft knitting or weaving, individual elements (e.g., yarns or cords) can fray or fraying. Fraying in conventional materials can be prevented by edge finishing, such as seams, bonding agents, and other techniques. However, edge finishing techniques may introduce additional materials, weight, cost, and processes. Fiber-bonded engineered materials are self-finishing. Due to the entanglement of multiple fibers, edges formed during or as a result of cutting operations on fiber-entangled engineered materials are self-finishing without the need for additional materials. Furthermore, it is envisioned that the fiber layers may include one or more reactive fibers that melt at the edges or otherwise attach to other fibers to reinforce the self-finishing edges. Fiber-bonded engineered materials resist edge failures, such as fraying. Furthermore, fiber bonding in materials susceptible to edge failure can also prevent these failures. For example, if cut before fiber entanglement, a pad formed from a knitted material can fray along the cut. However, if the knitted material is fiber-bonded before being cut, the fiber-bonded knitted pad resists edge failure. Therefore, the cut edges of fiber-bonded engineered materials can resist edge failure and eliminate the need for edge finishing techniques.

[0165] Synthetic leather The fiber-bonded engineered materials presented in this article can be processed into synthetic leather that retains the engineered properties, and are further classified as engineered synthetic leather. This material is highly efficient to manufacture and offers an unlimited degree of customizable engineering, allowing it to mimic synthetic leather in engineered form. At least two types of synthetic leather can be formed from fiber-bonded engineered materials.

[0166] The first type of engineered synthetic leather material includes a shaped fiber-bonded engineered material, at least a portion of which is impregnated with a polymer, such as silicone or polyurethane, such that the polymer at least partially encapsulates the fibers. If padding is present, the polymer can also coat the padding and at least partially encapsulate it. In other words, the polymer can fill the interstitial volume of the fiber-bonded engineered material. The polymer-coated material can then be treated to form a porous structure, such as by solvent or mechanical processes. Further processing can occur to form the fiber-bonded engineered material into synthetic (e.g., imitation) leather. For example, colorants, dyes, textures, top coats (e.g., polyurethane, silicone, or ethylene-vinyl acetate) can be applied at different stages to achieve a leather-like feel and appearance.

[0167] The second type of synthetic leather engineered materials includes shaped fiber-bonded engineered materials as presented herein, wherein at least a portion of the fibers are protein-based fibers. Examples of protein-based fibers are cut, shredded, or ground animal materials, such as hides, or protein-based materials that have been dissolved and reformed into fibers. Protein-based fibers can be formed into compositions also consisting of low-melting-point polymer fibers, wherein the low-melting-point polymer fibers have a melting or softening temperature lower than the softening or decomposition temperature of the protein-based fibers.

[0168] Compositions consisting of low-melting-point polymer fibers and protein-based fibers may also include base fibers. Base fibers are fibers having a melting temperature, softening temperature, or decomposition temperature higher than that of the low-melting-point polymer fibers. Base fibers can be any material, such as synthetic, organic, or metallic materials. The composition of this material can at least partially form a fiber layer for constructing fiber-bonded engineered materials.

[0169] Prior to entanglement of the fiber layers containing protein-based fibers, a low-melting-point fiber mixed with the protein-based fibers can be melted to at least temporarily fix the protein-based fibers and the base fibers. The webbing formed from the base fibers and protein-based fibers can then undergo an entanglement process. It is envisioned that in the above compositions, the low-melting-point polymer may be in a non-fibrous form and / or part of a bicomponent fiber having a base fiber. Furthermore, it is envisioned that a temporary backing material may be applied to the fiber layers prior to entanglement. In an exemplary aspect, the backing material may help maintain the bond between the protein-based fibers and the base fibers during the entanglement process. Alternatively, it is envisioned that the backing material may be omitted, and a padding material forming at least a portion of the fiber-bonded engineered material may be used to maintain the bond between the protein-based fibers and the base fibers. The resulting fiber-bonded engineered material containing protein-based fibers can provide a material with a leather-like feel and appearance, but with the functional properties of an engineered material.

[0170] A topcoat for engineered synthetic leather materials is also envisioned. The topcoat may include one or more polymeric materials. These polymeric materials can be thermoplastic or thermosetting. They may include polyurethanes, polyesters, polyethers, polyamides, polyolefins including polypropylene and polyethylene, polycarbonates, polyacrylates including polyacrylonitrile, vinyl polymers including polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA), aromatic polyamides, any copolymers thereof, and any combinations thereof. The coating may be applied to the surface of the engineered synthetic leather material. The topcoat may be applied regionally to provide another potential level of the engineered material. For example, a first material may be applied as a topcoat to increase abrasion resistance in a desired location (e.g., the toe box of a shoe). A second material may be applied in another location to achieve UV resistance. Thus, surface coatings can be used to achieve engineered properties with the desired function at the intended location.

[0171] Engineered synthetic leather materials can be further processed to achieve different results. For example, some treatments can be performed to form suede leather. Regardless of the technology used to form synthetic leather from fiber-bonded engineered materials, the resulting products can be implemented in a variety of articles as an alternative to conventional leather or monolithic (e.g., uniform) synthetic leather. Seams, volume, and number of layers can be reduced with engineered synthetic leather formed from fiber-bonded engineered materials.

[0172] Synthetic leather can be further processed to achieve different results. For example, some treatments can be performed to create suede.

[0173] Regardless of the technique used to form synthetic leather from fiber-bonded engineered materials, the resulting products can be implemented in a variety of articles as an alternative to conventional leather or monolithic (e.g., uniform) synthetic leather. Seams, volume, and number of layers can be reduced using engineered synthetic leather formed from fiber-bonded engineered materials.

[0174] thing While this application generally provides for fiber-bonded engineered materials, many examples are directed toward footwear articles. It should be understood that the introduced concepts can be applied to a variety of articles across various industries. For example, it is envisioned that the clothing and apparel industry can utilize fiber-bonded engineered materials. For instance, bras can be formed using the materials and techniques described herein to provide support, padding, integrated clasps, hooks, buckles, loops, adjusters, underwire bras, and / or support while minimizing volume. Outerwear, such as jackets, can be formed to have functional properties at intended locations (e.g., abrasion resistance from padding at joints, water resistance from fusible fibers at the top of the shoulders, breathability from macrotextured and / or exposed padding elements in the chest and back sections, pockets created by regionally preventable tangling, and closure systems from fiber-bonded padding elements such as zippers and buckles). In the interior decoration industry, fiber-bonded engineered materials can be used to form integrated conduits for fluid or electrical components for heating and / or cooling, and to provide abrasion resistance at interior decoration edges through padding or fiber selection. Thermal overlays, such as heating blankets, can be formed from one or more fiber-bonded engineered materials. Fiber-bonded engineered materials can be utilized in the medical and / or safety fields, for example, to enable component padding to position and retain support elements relative to a patient (human or animal), integral fastening mechanisms, sensors, and / or transmission materials, such as those integrated with splints, casts, sleeves, belts, wraps, masks, or others. In the automotive, aerospace, and construction industries, fiber-bonded engineered materials can be used to form engineered components, such as laminates, composite materials, or other combinations of fiber-bonded engineered materials encapsulated in polymers (like resins). The sporting goods industry can utilize fiber-bonded engineered materials for equipment such as gloves, hats, face shields, bats, sticks, handles, padding, etc. Therefore, while specific examples are made throughout footwear, it should be understood that fiber-bonded engineered materials can be implemented in a wide variety of industries and articles.

[0175] Manufacturing System The formation of fiber-bonded engineered materials can be accomplished in automated and / or manual environments. It is envisioned that the fiber-bonded engineered materials can be formed continuously from any point, but as early as possible during fiber production. For example, fibers can be formed, such as by extrusion, to be laid as a nonwoven flocculent layer. One or more padding elements can be formed independently or in-line. For example, engineered knitted padding can be formed at an automated loom on a production line that converges with the production line forming the fiber-bonded engineered material. This convergence concept can be used for all elements bonded to the fiber-bonded engineered material. As provided herein, after the padding has been positioned by a person or a pick-and-place machine, an optional fiber layer can be placed on the assembly. The assembly can be conveyed to an entanglement machine, such as a hydraulic entanglement machine, which entangles the assembly into the fiber-bonded engineered material. The fiber-bonded engineered material can then pass through one or more manufacturing stations where one or more post-processing operations (e.g., cutting, trimming, energy application, molding, selective and / or strategic ablation, or tumbling) can occur. Then, fiber-bonded engineered materials can be incorporated into article-forming processes, such as automated shoe manufacturing processes, to form articles (e.g., shoes) of various sizes from fiber-bonded engineered materials.

[0176] Throughout the process, one or more computer-aided machines are envisioned to operate based on input and one or more instructions stored in a computer-readable memory (such as a non-transitory computer-readable medium). For example, at least one vision system with a capture device such as a CCD sensor is envisioned to capture data for effectively identifying one or more features to determine the size, type, orientation, and / or nature of an article. Input from the vision system can be used by a computing device to control one or more devices, such as pick-up tools (e.g., vacuum, adhesive, or clamps), or tools constructed for cutting, trimming, spraying, conveying, sewing, joining, cleaning, heating, molding, quality control, or blow molding machines. For example, fiber-bonded engineered material can travel along a conveyor captured by the vision system. The vision system can capture an image of the fiber-bonded engineered material. This image is processed by a computing device to determine the size, style, and orientation of the fiber-bonded engineered material as a specific footwear upper. This information can generate one or more instructions to be retrieved from the data storage to control the pick-up tool. The pick-up tool picks up the fiber-bonded engineered material and places it at a defined location and orientation for subsequent processing. Subsequent processing can be post-processing operations such as cutting, stitching, shaping, joining, cleaning, or similar processes. At least one vision system can always be implemented to ensure alignment, orientation, position, and / or properties.

[0177] It is also envisioned that one or more automated or manual operations can be performed during the formation of fiber-bonded engineered materials. For example, a vision system and a pickup tool can be used in combination to pick up one or more pads and place them on the fiber layer. One or more pads can be selected based on feedback from the vision system or other identification systems, such as RFID systems, optical scanners, laser scanners, etc. The pickup tool can also determine the position or relative position of the pad to be picked up on the fiber layer. Computer equipment can determine the toolpath to be followed by the pickup tool to pick up the pads and place them on the fiber layer (or anywhere else), thus achieving proper orientation and position.

[0178] Automated processing machines can be used. For example, a computer-controlled cutting machine using molds, lasers, water jets, blades, etc., can cut one or more sections from a fiber-bonded engineered material. As previously described, the fiber-bonded engineered material can have self-cleaning edges, which allow such operations to occur without taking preventative measures to limit wear or fraying. In this example, a vision system can determine the location where the fiber-bonded engineered material is positioned relative to the cutting tool. This information can then be provided to a computing device so that a known tool path can be adjusted to compensate for the determined position / orientation of the fiber-bonded engineered material. Similar processes can be used for other operations to be performed on the fiber-bonded engineered material.

[0179] Manufacturing allows for the creation of customized items. For example, consumers can choose specific attributes (e.g., size, color, fit, or function). In response, unique fiber-bonded engineered materials can be manufactured. This enables customized orders, parts, and items. It also allows for the timely manufacturing of fiber-bonded engineered materials specific to consumer choices.

[0180] Post-processing Fiber-bonded engineered materials can undergo post-processing. Post-processing can further enhance the engineered aspects of the material, such as the zoned application of post-processing. Post-processing can include, but is not limited to, tumbling, shearing, grinding (which can be selective and / or strategic to produce areas that are thinner or more translucent than others), wrinkling, flocking, molding, and energy application. Each of these post-processing techniques can modulate the state of one or more materials used to form the engineered material. For example, surface appearance / texture can be manipulated through post-processing techniques. Texture, feel, appearance, flexibility, and response can all be tuned through post-processing.

[0181] As an example, Figure 28Footwear articles formed from mesh padding 2810 and laser- or die-cut film padding 2812 are depicted. The outer layer of fibers used to form the articles has a lower melting point than the padding material and has melted during post-entanglement to form a transparent surface layer on the exterior of the shoe upper.

[0182] Post-processing may also include assembling the fiber-bonded components with one or more additional components to be included in the resulting manufactured article. For example, Figure 26 An exemplary footwear article 2600 is illustrated, which is at least partially formed from fiber-bonded particles in a desired pattern 2610 between two fiber layers. The fiber-bonded portion of the footwear article (i.e., the upper 2612) is sewn to a knitted component (i.e., the collar 2614) to form the resulting article 2600.

[0183] Material As mentioned above, examples of suitable polymers for various components, such as fibers, padding materials, etc., may include one or more polyesters, one or more polyamides, one or more polyurethanes, one or more polyolefins, copolymers thereof, and blends thereof.

[0184] On one hand, the fiber / pad composition includes one or more polyesters. The polyester can be derived from the polyesterification of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol-1,5, diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanediol and combinations thereof) with one or more dicarboxylic acids (e.g., adipic acid, succinic acid, sebacic acid, octanoic acid, methyl adipic acid, glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid and citralic acid and combinations thereof).

[0185] Polyesters can also be derived from polycarbonate prepolymers, such as poly(hexamethylene carbonate) glycol, poly(propylene carbonate) glycol, poly(tetramethylene carbonate) glycol, and poly(nonanethylene carbonate) glycol. Suitable polyesters may include, by way of example and not limited to, polyethylene adipate (PEA), poly(1,4-butanediol adipate), poly(tetramethylene adipate), poly(hexamethylene adipate), polycaprolactone, polyhexamethylene carbonate, poly(propylene carbonate), poly(tetramethylene carbonate), poly(nonamethylene carbonate), and combinations thereof.

[0186] On the other hand, the fiber / pad composition includes one or more polyamides (nylons). In some embodiments, the polyamide may be derived from a polyamide prepolymer, such as a condensation of lactams, amino acids, and / or diamino compounds with dicarboxylic acids or their activated forms. The resulting polyamide comprises amide bonds (—(CO)NH—). Examples of suitable polyamides include, but are not limited to, polycaprolactam (PA6), polyhexamethylene isopamil (PA6,6), polyhexamethylene monoamide (PA6,9), polyhexamethylene monoamide (PA6,10), polyamide 6 / 12 (PA6,12), polyundecyl lactam (PA7), polyundecyl lactam (PA11), polylaurolactam (PA12), and combinations thereof. In a further embodiment, the polyamide may include one or more thermoplastic polyamide copolymers, such as those under the trade name “PEBAX” from Arkema, Inc., Clear Lake, TX; and the “SERENE” coating from Sumedics, Eden Prairie, MN.

[0187] On the other hand, the fiber / pad composition includes one or more polyurethanes, each polyurethane having one or more polyurethane copolymer chains (e.g., thermoplastic polyurethane, thermosetting polyurethane, ionomer polyurethane elastomer, etc.). In some embodiments, at least a portion of the polyurethane copolymer chain each includes a plurality of hard segments forming crystalline regions with other hard segments of the polyurethane copolymer chain, and a plurality of soft segments covalently bonded to the hard segments.

[0188] Polyurethane can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having urethane bonds (-N(CO)O-), wherein each isocyanate molecule preferably comprises two or more isocyanate (-NCO) groups, such as 2, 3 or 4 isocyanate groups per molecule (although monofunctional isocyanates may also be optionally included, for example as chain termination units).

[0189] Examples of suitable aliphatic diisocyanates for the production of polyurethane copolymer chains include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), butene diisocyanate (BDI), cyclohexylmethane diisocyanate (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), methylcyclohexane diisocyanate, methyltricyclodecane diisocyanate, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4'-dicyclohexylmethane diisocyanate (H12MDI), dodecane diisocyanate, lysine diisocyanate, and combinations thereof.

[0190] Examples of suitable aromatic diisocyanates for producing polyurethane copolymer chains include toluene diisocyanate (TDI), TDI adducts with trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chain is substantially free of aromatic groups. In some preferred embodiments, the polyurethane copolymer chain is produced from diisocyanates, including HMDI, TDI, MDI, H... 12 Aliphatic compounds and their combinations.

[0191] Examples of suitable chain-extended polyols for producing polyurethane copolymer chains include ethylene glycol, lower oligomers of ethylene glycol (e.g., diethylene glycol, triethylene glycol, and tetraethylene glycol), 1,2-propanediol, 1,3-propanediol, lower oligomers of propylene glycol (e.g., dipropylene glycol, tripropylene glycol, and tetrapropylene glycol), 1,4-butanediol, 2,3-butanediol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 1,4-cyclohexanediol, 2-ethyl-1,6-hexanediol, 1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol, dihydroxyalkylated aromatic compounds (e.g., bis(2-hydroxyethyl) ethers of hydroquinone and resorcinol, xylene-α,α,diol, xylene-alcohol, bis(2-hydroxyethyl) ethers of α-alcohol diol), and combinations thereof.

[0192] Examples of suitable soft-segment polyols include polyethers, polyesters, polycarbonates, and combinations thereof. Examples of suitable polyethers include, but are not limited to, polyethylene oxide (PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF), polytetramethylene oxide (PTMO), and combinations thereof. Examples of suitable polyesters include those described above. Examples of suitable polycarbonates may be derived from the reaction of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol-1,5-diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanediol, and combinations thereof) with ethylene carbonate. Based on the total weight of the reactant monomers, the soft-segment polyol may be present in amounts of 5% to 85% by weight, 5% to 70% by weight, or 10% to 50% by weight.

[0193] On the other hand, the fiber / pad composition includes one or more polyolefins, which can be formed by free radical, cationic, and / or anionic polymerization. Examples of suitable polyolefins include polyethylene, polypropylene, polybutene, copolymers thereof, and mixtures thereof. The processes and articles described herein are particularly suitable for use with polymers that have limited chemical or modified bonding capabilities, such as polyolefins, which have traditionally been difficult to bond well with other polymers such as polyurethanes and polyamides.

[0194] As used herein, the term "polymer" refers to a molecule having polymeric units of one or more monomeric species. The term "polymer" is understood to include homopolymers and copolymers. The term "copolymer" refers to a polymer having polymeric units of two or more monomeric species and is understood to include terpolymers. The reference to "a (a)" polymer or other compound as used herein refers to molecules of one or more polymers or compounds, and is not limited to a single molecule of a polymer or compound. Furthermore, one or more molecules may be the same or different, provided they belong to the class of compounds. Thus, for example, "polylaurolamide" is interpreted to include one or more polymer molecules of polylaurolamide, wherein the polymer molecules may be the same or different (e.g., different molecular weights and / or isomers).

[0195] A brief list of non-limiting materials envisioned for forming at least a portion of fibers, fiber layers, bedding, bedding elements, and other elements provided herein includes the following: vegetation-derived (cellulose- or lignin-based) materials (e.g., plant-based, algae-based, or microbial-based materials), such as cotton, hemp, jute, flax, ramie, sisal, bagasse, or banana; wood-derived materials, such as groundwood pulp, sage bark, thermomechanical pulp, bleached or unbleached sulfate pulp or sulfite pulp; animal-derived materials, such as silk, spider silk, tendon, catgut, wool, sea silk, hair (cashmere, mohair, Angora goat hair), and fur; and mineral-derived materials, such as asbestos. Materials may also be biologically derived fibrous proteins or protein filaments.

[0196] Another short list of non-limiting materials envisioned to form at least a portion of fibers, fiber layers, padding, padding elements, and other elements provided herein includes the following: recycled natural materials, such as regenerated cellulose (Tencel, rayon, modal, bamboo fiber, sponge fiber, cellulose diacetate, and cellulose triacetate); collagen- or peptide-based materials; fibers derived from processed animal products such as processed animal hides (e.g., leather); metallic materials; carbon fibers; silicon carbide fibers; glass fibers; and mineral fibers.

[0197] Another short list of non-limiting materials envisioned for forming at least a portion of fibers, fiber layers, padding, padding elements, and other elements provided herein includes the following: synthetic polymers, polyesters (e.g., PET, PBT, and PTT), polyamides (nylon), polyolefins (e.g., polyethylene, polypropylene, polybutene, and UHMPE), polyurethanes, thermoplastic polyurethanes, polycarbonates, aromatic polyamides (APAs), phenolic resins (PF), polyvinyl chloride (PVC) fibers, acrylic polyesters, liquid crystal polymers, copolymers of two or more of the above polymers, mixtures of two or more of the above polymers, and fiber-reinforced polymers (e.g., glass fibers).

[0198] Individual components may be made of polymeric materials comprising one or more of the polymers mentioned above, or substantially composed of one or more of the polymers mentioned above.

[0199] Individual elements can be made of two or more different polymeric materials (i.e., not only as a mixture, but also as separate components of multicomponent fibers, such as in the form of segmented discs, islands, sheath / core formats, etc.).

[0200] carrier network As previously described, fiber bonding is a process in which fibers from one or more fiber layers are entangled to form a complex composite material designed for an article. One or more fiber layers act as a platform and binder, to which additional material is anchored to construct a unique hybrid composite material that is consolidated into a single material through entanglement. Entanglement causes the fibers of one or more fiber layers to physically interact with and lock into the additional material, resulting in a cohesive and complete material that can be formed into an article. The materials added to the fiber layers and the materials forming the fiber layers can be intentionally and / or strategically positioned to achieve desired functional properties at intended relative locations, allowing highly engineered materials to be formed as complex composite materials that are consolidated into a single material through entanglement.

[0201] The formation of fiber-bonded engineered materials can be performed in automated and / or manual environments. In some aspects, the formation of fiber-bonded engineered materials can be performed using a carrier net. The carrier net has a mesh structure comprising multiple pores. In some examples, the pores are formed between the intersections of multiple linear elements such as filaments, yarns, ropes, or wires. The linear elements can take the form of vertical elements and multiple horizontal elements. In other examples, the pores are formed in a film or sheet. Thus, the carrier net provides a permeable platform on which one or more fiber layers and / or paddings can be placed during the formation of the fiber-bonded engineered material. The carrier net can also provide a mechanism for holding the fibers forming one or more fiber layers and / or paddings in place during processing. As an example, in the manufacture of conveyors for fiber-bonded engineered materials, the carrier net can be placed on a first surface of the input material (fiber layers and / or paddings) to act as a conveyor belt on which such material can be placed. Optionally, a second carrier net can be placed on an opposite surface of the input material to hold the material in the desired position for processing. In other words, the input material can be positioned on a carrier web, or sandwiched between two or more carrier webs, so that the material is held in place before and during entanglement. In this way, the carrier web provides a permeable platform and can also provide a permeable material holding mechanism, allowing fluids (e.g., water) to pass through the carrier web and entangle the fiber layers and / or padding with each other to form a fiber-bonded engineered material.

[0202] Utilizing carrier meshes to form fiber-bonded engineered materials can be advantageous in a variety of manufacturing scenarios. For example, carrier meshes facilitate the alignment and registration of fiber layers and / or padding, including material inputs and masks that are difficult to feed into the entanglement apparatus otherwise without losing proper alignment and registration, or the required shape and size. Furthermore, carrier meshes are advantageous for holding shaped fiber sheets in place for processing, post-entanglement, which forms stable boundary portions adjacent to exposed padding portions (i.e., portions of padding exposed without additional fiber bonding, creating areas of, for example, enhanced breathability, elasticity, and / or drape in clothing or footwear). Additionally, carrier meshes are advantageous for holding small material inputs, such as loose fibers or masks, in place and protecting them during processing. The use of carrier meshes in the formation of fiber-bonded engineered materials can also impart surface texture to the output fiber-bonded material. For example, multiple different textures can be applied to the output fiber-bonded material if the net includes a first portion with a first texture and a second portion with a second texture on the same side, if the net includes different net textures on opposite sides, or if the net includes any combination of various textures on one or both sides. Similarly, if two carrier nets are used on opposite surfaces of the material input, output fiber-bonded engineered materials with different textures on each surface can be produced. Furthermore, carrier net-mediated entanglement allows the fiber-bonded components to be manufactured into near-net-shapes, which allows for a significant reduction in waste caused by post-processing finishing operations. For example, in netless entanglement, where the continuous fiber and padding rolls themselves are used to advance the material input through the entangler, the resulting fiber-bonded components typically need to be cut across the entire roll width, with unwanted portions discarded, resulting in additional waste and costs.

[0203] Suitable carrier webs can be made of any material strong enough to withstand the pressure exerted by a hydroentangled fluid flow. (It should be noted that although the term "hydroentangling" is used throughout this specification, fluid entanglement using any suitable fluid is contemplated. The use of these terms is not intended to limit the scope of this application to fluid entanglement utilizing water.) As an example, mesh textiles, such as those formed from synthetic polymer fibers, including yarns comprising monofilament yarns or coated glass fiber filaments, such as those used for window screens, can be used as carrier webs and can be polymer extrusions, films, or cut meshes. Carrier webs can also consist of woven metal linear element meshes, such as aluminum wire mesh, bronze wire mesh, or multimaterial composite meshes (e.g., copper / zinc composite mesh), such as those commonly used for window screens. Perforated films or sheets, such as perforated extruded polymer films and expanded perforated metal sheets, can also be used as carrier webs. A suitable carrier web can be dimensionally stable during use, while being flexible enough to move through the geometry required by the fiber bonding process. Furthermore, a suitable carrier web can be sufficiently consistent to match the surface profile of the material being entangled before and after entanglement. A suitable carrier web can be easily separated from and removed from the entangled material being transported and / or supported. That is, a suitable carrier web may not be permanently entangled with the material being carried and / or supported, or may only be permanently entangled with a portion or area of ​​the material being carried and / or supported. In some examples, a suitable carrier web may have little or no elongation in the length or width direction, and / or may not undergo permanent deformation due to passing through the station of the hydraulic entangler. Therefore, aspects of this application are contemplated for the weaving, knitting, braiding, or punching perforation construction of the carrier web. A suitable carrier web can be reusable (as is useful for reducing waste) or disposable.

[0204] As previously described, the carrier mesh described herein has a mesh structure comprising multiple apertures formed between the intersections of multiple vertical linear elements and multiple horizontal linear elements, forming a mesh structure. The size of the apertures in the carrier mesh is typically expressed as the number of apertures traversing a one-square-inch portion of the carrier mesh (warp apertures) and the number of apertures traversing the same one-square-inch portion of the carrier mesh longitudinally (weft apertures). For example, by way of example only in various aspects of this document, suitable carrier meshes may include 15x10 (displaying 15 warp holes and 10 weft holes in a one-square-inch portion of the mesh), 18x16 (displaying 18 warp holes and 16 weft holes in a one-square-inch portion of the mesh), 20x20 (displaying 20 warp holes and 10 weft holes in a one-square-inch portion of the mesh), 17x20 (displaying 17 warp holes and 20 weft holes in a one-square-inch portion of the mesh); 18x14 (displaying 18 warp holes and 14 weft holes); or 20x30 (displaying 20 warp holes and 30 weft holes in a one-square-inch portion of the mesh). More generally, in some aspects, suitable carrier meshes may include a number of warp holes between 14 and 20. In further aspects, suitable carrier meshes may include a number of warp holes between 16 and 20. In some aspects, suitable carrier meshes may include a number of weft holes between 14 and 30. In a further aspect, a suitable carrier mesh may include a number of latitudinal holes between 16 and 20. While exemplary scopes are provided herein, it should be understood that any suitable number of meridional and latitudinal holes may be used in various aspects of this application.

[0205] In addition to the number of holes per square inch, the size of the holes in the carrier web can be varied by the diameter of the linear elements used to form the carrier web. The larger the diameter of the linear element, the smaller the diameter of the holes in the resulting carrier web (assuming the number of warp and weft holes is the same). Exemplary linear element diameters, by way of example only, include 0.005 mm to 0.03 mm. Further exemplary linear element diameters, by way of example only, include 0.01 mm to 0.025 mm. Even further exemplary linear element diameters, by way of example only, include 0.01 mm to 0.02 mm. While exemplary diameter ranges are provided herein, it should be understood that any suitable linear element diameter can be used in all aspects of this application.

[0206] Because the carrier network described herein has a mesh structure comprising multiple pores penetrating its entire depth, it is envisioned that the carrier network can permeate to fluids including liquids. For use in hydraulic entanglement, a suitable carrier network includes pores that provide a generally straight path for the liquid from a first side of the carrier network to a second side, thereby allowing the liquid to move into, through, and out of the other side of the carrier network while maintaining sufficient pressure to entangle the fibers positioned on the network. In other words, a suitable carrier network includes a sufficient number and size of pores to allow the fluid to exert the forces required to entangle the input material and form fibers bonded to engineered materials. If it is also necessary to split the microfibers, a suitable carrier network has a sufficient number and size of pores to allow the pressure of the fluid jet to separate the fiber segments.

[0207] Various aspects of the invention envision that portions of the carrier mesh can be solid (i.e., without pores), for example, in a predetermined pattern or design, such that the solid portions provide a masking effect relative to the material being treated. Using a carrier mesh with strategically positioned portions having variable solidity and permeability can create portions of entangled and non-entangled material in the resulting fiber-bonded engineered material. Additionally or alternatively, the first portion of the carrier mesh may include pores of a different size or number compared to the second portion of the carrier mesh. These first and second portions can exist in a predetermined pattern or design. Using a carrier mesh with strategically positioned first and second portions can create portions of first and second entangled material in the resulting fiber-bonded engineered material, wherein the first and second portions have different levels of entanglement or density. In some aspects herein, the first and second portions can have different levels of entanglement or density, differing by at least 10%, and each of the first and second portions has a diameter of at least 0.25 cm. 2 Surface area.

[0208] refer to Figure 32The illustration depicts an exemplary conveyor configuration 3200 for forming fiber-bonded engineered materials using a carrier web. Configuration 3200 includes a fluid-permeable first carrier web 3210. The illustrated first carrier web 3210 acts as a carrier for input materials before and during processing. Configuration 3200 includes a first fiber layer 3212 comprising a first plurality of fibers. The first plurality of fibers can be homogeneous or heterogeneous and can be formed as a nonwoven material, sometimes referred to as flocculents. Flocculents can be formed from a single fiber layer or multiple fiber layers. Each layer can have a different or similar fiber composition. Flocculents can be formed as continuous materials (e.g., rolled goods) or they can be formed as discrete elements (e.g., batched goods). As illustrated, the first fiber layer 3212 consists of a plurality of pre-sized cut fiber flocculent sheets that can be placed manually or automatically onto the first carrier web 3210. Once the first fiber layer 3212 is in place, padding and other desired elements (e.g., textiles, cables, elements formed of thermoplastic materials, foams, molded polymeric or metal parts, etc.) 3214 are placed (automatically or manually) on the first fiber layer 3212 (or adjacent to and overlapping the first fiber layer 3212 when laid in the Z direction). In the illustrated configuration 3200, padding and other desired elements 3214 are illustrated on a roll (which may include a removable backing 3216, which is dissolved or otherwise removed during processing). For example, the removable backing 3216 may be formed of a water-soluble polymeric material, such as a polymeric material containing water-soluble polyvinyl alcohol. Although in Figure 32 Although not illustrated, this article also envisions separately placed padding and / or other desired elements.

[0209] An optional second fiber layer may be placed on top of the padding material and other desired elements 3214 (or adjacent to and overlapping the padding material and other desired elements 3214 when laid in the Z direction). The illustrated configuration 3200 does not include the second fiber layer, but such a configuration will be described in the following reference. Figure 33 A more comprehensive description follows. When present, the second fiber layer can be placed manually or automatically onto the padding material and other desired elements 3214. In some respects, a fluid-permeable second carrier net 3218 can then be placed onto the padding material or other desired elements 3214 (or the second fiber layer, when present). The second carrier net 3218 cooperates with the first carrier net 3210 to hold the input materials (fiber layer, padding material, and other desired elements) in place and under tension. The material input / carrier net assembly can be conveyed to an entanglement machine, such as a hydraulic entanglement machine, which entangles the assembly into a fiber-bonded engineered material.

[0210] In some aspects, after entanglement, the first carrier net 3210 and the second carrier net 3218 can be removed, and the fiber-bonded engineered material can be output. In such aspects, the fiber-bonded engineered material can then be passed through one or more manufacturing stations where one or more post-processing operations (e.g., cutting, trimming, energy application, application of colorants, dyes and finishing agents, application of impregnating polymers, molding, or tumbling) can occur. Alternatively, the first carrier net 3210 and the second carrier net 3218 can remain in place after entanglement, and the fiber-bonded engineered material can be transferred through one or more post-processing stations (e.g., for the application of heat energy (e.g., for drying), the addition of colorants, dyes and / or finishing agents, or for the application of impregnating fibers). After such post-processing operations, the fiber-bonded engineered material can enter into an article-forming process, such as an automated shoe manufacturing process, to form sized articles (e.g., shoes) from the fiber-bonded engineered material.

[0211] Now go to Figure 33 The illustration depicts a second exemplary conveyor configuration 3300 for forming fiber-bonded engineered materials using a carrier web. Configuration 3300 includes a fluid-permeable first carrier web 3310. The illustrated first carrier web 3310 acts as a carrier for input materials before and during processing. Configuration 3300 includes a first fiber layer 3312 composed of a plurality of pre-sized cut fiber flocs attached to a minimal or removable roll that dissolves or otherwise removes during processing. Once the first fiber layer 3312 is in place, padding and other desired elements (e.g., textiles, cables, elements formed of thermoplastic materials, foams, molded polymeric or metal parts, etc.) 3314 are placed (automatically or manually) on the first fiber layer 3312 (or placed adjacent to and overlapping the first fiber layer 3212 in the Z direction). In the illustrated configuration 3300, padding and other desired elements 3314 are illustrated on a roll (which may also include a removable backing 3316, which is dissolved or otherwise removed during processing). Although in Figure 33 Although not illustrated, this article also envisions separately placed padding and / or other desired elements.

[0212] An optional second fiber layer may be placed on top of the padding material and other desired elements 3314 (or positioned adjacent to and overlapping the padding material and other desired elements 3214 in the Z direction). The illustrated configuration 3300 includes a second fiber layer 3318 composed of a plurality of pre-sized fiber sheets attached to small or removable rolls that dissolve or otherwise remove during processing. The second fiber layer 3318 may be placed manually or automatically onto the padding material and other desired elements 3314. In some aspects, a fluid-permeable second carrier net 3320 may then be placed on the second fiber layer 3318. The second carrier net 3320 cooperates with the first carrier net 3310 to hold the input material (fiber layer, padding material, and other desired elements) in place and under tension. The material input / carrier net assembly may be conveyed to an entanglement machine, such as a hydraulic entanglement machine, which entangles the assembly into a fiber-bonded engineered material.

[0213] After entanglement, the first carrier net 3310 and the second carrier net 3320 can be removed, and the fiber-bonded engineered material can be output. The fiber-bonded engineered material can then be passed through one or more manufacturing stations where one or more post-processing operations (e.g., cutting, trimming, energy application, application of colorants, dyes and finishing agents, application of impregnating polymers, molding, or tumbling) can occur. Alternatively, the first carrier net 3310 and the second carrier net 3320 can remain in place after entanglement, and the fiber-bonded engineered material can be transferred through one or more post-processing stations (e.g., for the application of heat energy (e.g., for drying), the addition of colorants, dyes and / or finishing agents, or for the application of impregnating fibers). The fiber-bonded engineered material can then be incorporated into an article-forming process, such as an automated shoe manufacturing process, to form sized articles (e.g., shoes) from the fiber-bonded engineered material.

[0214] Now for reference Figure 34The illustration depicts a third exemplary conveyor configuration 3400 for forming fiber-bonded engineered materials using a carrier web. Configuration 3400 includes a fluid-permeable first carrier web 3410. The illustrated first carrier web 3410 acts as a carrier for input materials before and during processing. Configuration 3400 includes a first fiber layer 3412, which consists of multiple loose fibers distributed on the first carrier web 3410. Once the first fiber layer 3412 is in place, padding and other desired elements (e.g., textiles, cables, elements formed of thermoplastic materials, foams, molded polymeric or metal parts, etc.) 3414 are placed (automatically or manually) on the first fiber layer 3412 (or placed adjacent to and overlapping the first fiber layer 3212 in the Z direction). In the illustrated configuration 3400, the padding and other desired elements 3414 are illustrated on a roll (which may include a removable backing 3416, which is dissolved or otherwise removed during processing). Figure 34 Although not illustrated, this article also envisions separately placed padding and / or other desired elements.

[0215] An optional second fiber layer may be placed on top of the padding material and other desired elements 3414 (or positioned adjacent to and overlapping the padding material and other desired elements 3214 in the Z direction). The illustrated configuration 3400 includes a second fiber layer 3418 composed of multiple loose fibers. The second fiber layer 3418 may be manually or automatically distributed onto the padding material and other desired elements 3414. A fluid-permeable second carrier net 3420 may then be placed on the second fiber layer 3418. The second carrier net 3420 cooperates with the first carrier net 3410 to hold the input material (fiber layer, padding material, and other desired elements) in place and under tension. The material input / carrier net assembly may be conveyed to an entanglement machine, such as a hydraulic entanglement machine, which entangles the assembly into a fiber-bonded engineered material.

[0216] After entanglement, the first carrier net 3410 and the second carrier net 3420 can be removed, and the fiber-bonded engineered material can be output. The fiber-bonded engineered material can then be passed through one or more manufacturing stations where one or more post-processing operations (e.g., cutting, trimming, energy application, application of colorants, dyes and finishing agents, application of impregnating polymers, molding, or tumbling) can occur. Alternatively, the first carrier net 3410 and the second carrier net 3420 can remain in place after entanglement, and the fiber-bonded engineered material can be transferred through one or more post-processing stations (e.g., for the application of heat energy (e.g., for drying), the addition of colorants, dyes and / or finishing agents, or for the application of impregnating fibers). The fiber-bonded engineered material can then be incorporated into an article-forming process, such as an automated shoe manufacturing process, to form sized articles (e.g., shoes) from the fiber-bonded engineered material.

[0217] Regional bedding As previously described, a padding material is an element held in relative position by one or more fiber layers as a fiber-bonded element. Padding materials can be described as continuous padding materials, localized padding materials, regional padding materials, engineered padding materials, base padding materials, or element padding materials. A particular padding material bonded to a fiber-bonded engineered material can be classified as one or more different types of padding materials. For example, a regional padding material can also be an engineered padding material.

[0218] Regional padding is a combination of padding materials, such as the overlap or stacking of multiple padding materials to form a padding assembly. For example, a padding material with specific properties in a single direction can be stacked on top of another padding material with properties in a single but different direction to achieve one or more multidirectional properties. As an example, and not a limitation, macro-mesh padding can be overlapped with fine-mesh padding, allowing the first side of the fiber-bonded engineered material to have a coarse texture and the opposite side associated with the fine mesh to have a more uniform texture. It is also envisioned that different padding materials of different materials can be stacked. For example, a high-toughness material for limiting tension can be stacked with a foam material for providing cushioning.

[0219] As used herein, stacked padding includes adjacent padding that allows one or more layers to be inserted, but which share a common X and Y location regardless of their Z-direction position. However, stacking does not require all X and Y locations to be shared between the stacked materials (e.g., they can be of different sizes and / or shapes). At least regarding Figure 11A and Figure 11B , Figure 12A and Figure 12B as well as Figure 13A and Figure 13B The bedding components described herein and their corresponding descriptions, as well as the regional bedding described above.

[0220] As explained above, Figure 11A and Figure 11B A first fiber layer 1100 and a padding assembly consisting of a first padding material 1104 and a second padding material 1106 are depicted, with a portion of the second padding material 1106 overlapping a portion of the first padding material 1104 to create a regional padding material. This provides an example illustrating how multiple padding materials (engineered or raw materials) can be combined and bonded in relative positions through fiber entanglement. Thus, if the first padding material has a first property and the second padding material has a second property, a combination of the first and second properties can be achieved through fiber bonding, resulting in the production of engineered textiles. Depending on the implemented entanglement technique, entanglement can occur only from a first side of the assembly or from both sides of the assembly. Figure 11A and Figure 11B In the examples depicted, since the fiber layer is only on a single side, an entanglement process capable of allowing the fibers to pass through the padding can be utilized. One example may include hook entanglement, in which one or more barbs of a needle effectively push and pull the fibers to facilitate entanglement. Another example may include structured needle entanglement, in which the contours of one or more sharp tips of one or more needles effectively entangle the fibers into a desired structural pattern. Furthermore, hydraulic entanglement from at least the rear side of the component is envisioned.

[0221] As described above, Figure 12A and Figure 12B A fiber layer 1200 and a mattress assembly consisting of a first mattress 1204 and a second mattress 1206 are depicted to produce regional mattresses. For example, along... Figure 12A The best view of the cutting line 12B is seen in the cross-sectional view and as in Figure 12B As indicated, the first padding material 1204 and the second padding material 1206 are encased within a fiber layer 1200. Encasing can be achieved by starting with at least a first fiber layer on a first side of the padding assembly and at least a second fiber layer on an opposing second side of the padding assembly, and then entangled the first and second fiber layers (e.g., via hook entanglement, structured needle entanglement, and / or hydraulic entanglement) to create the fiber layer 1200. Similarly, as... Figure 12B As depicted, one or more of the multiple fibers 1202 of the fiber layer 1200 also extend through and entangle with the first padding material 1204 and the second padding material 1206. The first padding material 1204 and the second padding material 1206 are bonded together by at least a portion of the multiple fibers 1202 to form a fiber-bonded engineered material, wherein the padding materials 1204, 1206 are enclosed within fibers.

[0222] As described above, Figure 13AA fiber layer 1300 and a mattress assembly consisting of a first mattress 1304 and a second mattress 1306 are depicted to produce regional mattresses. The first mattress 1304 and the second mattress 1306 are arranged in a similar manner to... Figure 12A and Figure 12B The material is encased within the fiber layer 1300. However, the first padding material 1304 and the second padding material 1306 are formed of unaffected materials. Figure 13B The description in Figure 13B It is along Figure 13A A cross-sectional view of the cut line 13B shows that the multiple fibers 1302 of the fiber layer 1300 do not extend through the first padding 1304 or the second padding 1306. In this example, the padding is held in place by perimeter entanglement between the multiple fibers 1302, rather than by entanglement between the multiple fibers 1302 and the padding 1304, 1306 themselves. Therefore, if the fiber layer 1300 is manipulated (e.g., torn) near one of the paddings, the padding can be removed or dissolved, and the volume previously filled with padding will remain as a pocket within the fiber layer 1300. Thus, in an exemplary aspect, the use of an unaffected material allows for the creation of voids or other cavities within the fiber layer. As previously described, with respect to truncated padding or components, an unaffected material can allow for bonding while still allowing movement within the formed fiber wrapping.

[0223] In an exemplary aspect of this document, a component for a footwear article is provided. The component includes a first fiber layer and a padding assembly. The first fiber layer includes a first plurality of fibers, and the padding assembly is positioned adjacent to the first fiber layer. At least a first portion of the first plurality of fibers extends into and entangles with at least a first portion of the padding assembly. The padding assembly includes a first padding and a second padding. Each of the first and second paddings has a first surface and an opposite second surface. A portion of the first surface of the first padding is positioned adjacent to the first fiber layer, and a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding, thus forming a regional padding.

[0224] In another exemplary aspect of this document, a component for a footwear article is provided. The component includes a first fiber layer comprising a first plurality of fibers, a second fiber layer comprising a second plurality of fibers, and a padding assembly positioned between the first and second fiber layers. At least a first portion of the first plurality of fibers extends into and entangles with at least a first portion of the second plurality of fibers. The padding assembly includes a first padding and a second padding. Each of the first and second paddings has a first surface and an opposite second surface. A portion of the first surface of the first padding is positioned adjacent to a portion of the first fiber layer, and a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding, thus forming a regional padding.

[0225] An exemplary aspect of this document also provides a method of forming a component of a footwear article. The method includes placing a padding assembly on (or adjacent to and overlapping with) a first fiber layer, the first fiber layer comprising a first plurality of fibers. The padding assembly includes a first padding material and a second padding material. Each of the first and second padding materials has a first surface and an opposite second surface. At least a portion of the first surface of the first padding material is positioned adjacent to at least a portion of the first fiber layer, and at least a portion of the second surface of the first padding material is positioned adjacent to at least a portion of the first surface of the second padding material. The method further includes placing a second fiber layer comprising a second plurality of fibers on (or adjacent to and overlapping with) the padding assembly, comprising a second plurality of fibers, and presenting a Z-direction offset. Furthermore, the method includes entanglement of at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers (e.g., using a crochet hook, structured needle, or fluid flow). In an exemplary aspect, the method may optionally further include entanglement of at least a portion of a second plurality of fibers of the second fiber layer with one or more fibers of the padding assembly (e.g., using one or more barbs of a hook, a structured needle, or a fluid flow), wherein the second fiber layer is adjacent to the first padding on a second side opposite to the first fiber layer.

[0226] As will be seen from the foregoing, aspects of the present invention are well suited to achieving all the objectives and purposes set forth above, as well as other advantages that are obvious and inherent in the structure.

[0227] It should be understood that certain features and sub-combinations are practical and can be adopted without reference to other features and sub-combinations. This is covered by and within the scope of the claims.

[0228] While specific elements and steps are described in conjunction with each other, it should be understood that any element and / or step provided herein is contemplated to be combined with any other element and / or step, whether expressly specified or not, and remains within the scope provided herein. Because many possible implementations can be derived from this disclosure without departing from its scope, it should be understood that everything set forth herein or shown in the accompanying drawings is to be interpreted illustratively and not limitingly.

[0229] The claims are provided below. Although the fiber-bonded engineered materials formed from regional padding and methods of manufacturing such materials have been described above with reference to specific aspects, it should be understood that modifications and variations may be made without departing from the intended scope of protection provided by the following claims. It is contemplated that any of the dependent claims may be multiple dependents of other claims in the same independent group of claims. Thus, although not specifically listed as "[t] the component of claim XY, wherein..." or "[t] the component of claim XY, further comprising...", the applicant contemplates that each dependent claim may be multiple dependents in some respects.

[0230] As used herein and in conjunction with the features listed below, the term "any one of the features" or similar variations thereof are intended to be interpreted as allowing the features to be combined in any combination. For example, exemplary feature 4 may indicate a method / apparatus for any one of features 1 through 3, which is intended to be interpreted as allowing elements of features 1 and 4 to be combined, elements of features 2 and 4 to be combined, elements of features 3 and 4 to be combined, elements of features 1, 2, and 4 to be combined, elements of features 2, 3, and 4 to be combined, elements of features 1, 2, 3, and 4 to be combined, and / or other variations thereof. Furthermore, the term "any one of the features" or similar variations thereof are intended to include "any one of the features" or other variations of the term, as indicated by some examples provided above.

[0231] Exemplary features with multiple subordinations: Feature 1. A component comprising: a first fiber layer including a first plurality of fibers; a second fiber layer including a second plurality of fibers; and a padding assembly positioned between the first fiber layer and the second fiber layer, wherein at least a first portion of the first plurality of fibers extends into and is entangled with at least a first portion of the second plurality of fibers, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first fiber layer to exhibit a first Z-direction offset, and wherein a portion of the second surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first surface of the second padding to exhibit a second Z-direction offset.

[0232] Feature 2. The component according to Feature 1, wherein the component is one of a component of footwear, a component of clothing, or a component of sports equipment.

[0233] Feature 3. A component based on either Feature 1 or 2, wherein the component is a component of a footwear article.

[0234] Feature 4. A component according to any one of features 1 to 3, wherein the component is the upper of a footwear article.

[0235] Feature 5. The component according to Feature 1, wherein the upper of the footwear article includes the inner side, outer side and forefoot portion of the footwear article.

[0236] Feature 6. A component according to any one of features 1 to 5, wherein at least one of the first plurality of fibers and the second plurality of fibers comprises a polymeric composition consisting of at least one polymer.

[0237] Feature 7. The component according to any one of features 1 to 6, wherein at least one of the first plurality of fibers and the second plurality of fibers is composed of at least one selected from polyurethane, thermoplastic polyurethane, polyester, polyether, polyamide, polyolefin, polycarbonate, polyacrylate, aromatic polyamide, cellulose material, glass, carbon, metal, mineral, copolymer thereof, and any combination thereof.

[0238] Feature 8. A component according to any one of features 1 to 7, wherein at least one of the first plurality of fibers and the second plurality of fibers is composed of short fibers or continuous filament fibers.

[0239] Feature 9. A component according to any one of features 1 to 8, wherein at least one of the first plurality of fibers and the second plurality of fibers consists of fibers having a linear mass density measurement of 1 denier per filament (dpf) to 9 dpf.

[0240] Feature 10. A component according to any one of features 1 to 8, wherein at least one of the first plurality of fibers and the second plurality of fibers consists of fibers having a linear mass density measurement of 1 denier per filament (dpf) to 4 dpf.

[0241] Feature 11. A component according to any one of features 1 to 8, wherein at least one of the first plurality of fibers and the second plurality of fibers consists of fibers having a linear mass density measurement of 0.001 denier per filament (dpf) to 0.999 dpf.

[0242] Feature 12. A component according to any one of features 1 to 11, wherein at least one of the first plurality of fibers and the second plurality of fibers is composed of fibers having a width measurement of 200 micrometers to 100 nanometers.

[0243] Feature 13. A component according to any one of features 1 to 11, wherein at least one of the first plurality of fibers and the second plurality of fibers is composed of fibers having a width measurement of 100 micrometers to 100 nanometers.

[0244] Feature 14. A component according to any one of features 1 to 11, wherein at least one of the first plurality of fibers and the second plurality of fibers is composed of fibers having a width measurement of 25 micrometers to 0.01 micrometers.

[0245] Feature 15. A component according to any one of features 1 to 11, wherein at least one of the first plurality of fibers and the second plurality of fibers is composed of fibers having a width measurement of 10 micrometers to 0.01 micrometers.

[0246] Feature 16. A component according to any one of features 1 to 15, wherein at least one of the first fiber layer and the second fiber layer is a nonwoven textile.

[0247] Feature 17. A component according to any one of features 1 to 16, wherein at least one of the first plurality of fibers and the second plurality of fibers comprises a thermoplastic polymer.

[0248] Feature 18. A component according to any one of features 1 to 17, wherein at least one of the first plurality of fibers and the second plurality of fibers comprises at least one selected from thermosetting polymers, aromatic polyamides, glass, cellulose-based materials or protein-based materials.

[0249] Feature 19. A component according to any one of features 1 to 19, wherein the padding assembly is formed as a knitted, woven, braided, nonwoven, direct fiber lay-up, molded, cast, extruded, deposited, expanded, reduced-shape, 3D printed, sheet, film or embroidered element.

[0250] Feature 21. A component according to any one of features 1 to 19, wherein at least one of the first padding material and the second padding material has a first functional area and a second functional area, and wherein the first functional area and the second functional area include functional characteristics that differ by at least 10% between the first functional area and the second functional area.

[0251] Feature 22. A component according to any one of features 1 to 19, wherein at least one of the first padding material and the second padding material has a first functional area and a second functional area, and wherein the first functional area and the second functional area include functional characteristics that differ by 15% to 20% between the first functional area and the second functional area.

[0252] Feature 23. A component according to any one of features 21 and 22, wherein the functional characteristic is at least one of air permeability, moisture permeability, modulus of elasticity, abrasion resistance, elasticity, durability, strength, tensile strength, hardness, elongation at flexural angle, tear strength, or thermal insulation.

[0253] Feature 24. A component according to any one of features 21 and 22, wherein the functional characteristics include at least one of the following: breathability, porosity, moisture absorption, water resistance, water resistance, impermeability, hydrophobicity, fineness, burst strength, toughness, shear strength, post-elongation recovery, flexural modulus, cold flexibility, crack propagation resistance, thermal degradation resistance, thermal glass transition temperature, melting point, heat set capability, Z-direction thickness, gauge, specific gravity, density per unit area, weight per unit area, surface area, surface continuity, dimensional stability, resistance to compression deformation, deformability, creep resistance, bonding ability, adhesive compatibility, electrical conductivity, light transmittance, fluid transport capability, washability, shrinkage resistance, solvent resistance, colorfastness, UV photodegradation resistance, antimicrobial properties, moisture permeability, modulus of elasticity, abrasion resistance, elasticity, durability, strength, tensile strength, hardness, elongation at flexural angle, tear strength, and thermal insulation.

[0254] Feature 25. A component according to any one of features 1 to 24, wherein the component has a first functional area and a second functional area, the first functional area having a functional characteristic that differs from the second functional area by 15% to 20% in the same functional characteristic.

[0255] Feature 26. A component according to any one of features 1 to 24, wherein the component has a first functional area and a second functional area, the first functional area having a functional characteristic that differs from the second functional area by at least 10% in the same functional characteristic.

[0256] Feature 27. A component according to any one of features 25 and 26, wherein the functional characteristic of the component is at least one of air permeability, moisture permeability, elastic modulus, abrasion resistance, elasticity, durability, strength, tensile strength, hardness, flexural elongation, tear strength, or thermal insulation.

[0257] Feature 28. A component according to any one of features 25 and 26, wherein the functional characteristics include at least one of the following: breathability, porosity, moisture absorption, water resistance, water resistance, impermeability, hydrophobicity, fineness, burst strength, toughness, shear strength, post-elongation recovery, flexural modulus, cold flexibility, crack propagation resistance, thermal degradation resistance, thermal glass transition temperature, melting point, heat set capability, Z-direction thickness, standard dimensions, specific gravity, density per unit area, weight per unit area, surface area, surface continuity, dimensional stability, resistance to compression deformation, deformability, creep resistance, bonding ability, adhesive compatibility, electrical conductivity, light transmittance, fluid transport capability, washability, shrinkage resistance, solvent resistance, colorfastness, UV photodegradation resistance, antimicrobial properties, moisture permeability, modulus of elasticity, abrasion resistance, elasticity, durability, strength, tensile strength, hardness, elongation at flexural angle, tear strength, and thermal insulation.

[0258] Feature 29. A component according to any one of features 1 to 28, wherein the first pad is formed of a first material and the second pad is formed of a second material, wherein the first material is different from the second material.

[0259] Feature 30. The component according to feature 29, wherein the first material is composed of a foamy or foamable material, and the second material is composed of textiles.

[0260] Feature 31. A component according to any one of features 1 to 30, wherein a first pad has a first elastic modulus along a first axis of the first pad and a second pad has a second elastic modulus along a second axis of the second pad, wherein the first axis and the second axis are parallel and the first elastic modulus is different from the second elastic modulus.

[0261] Feature 32. The component according to feature 31, wherein the first elastic modulus differs from the second elastic modulus by at least 10%.

[0262] Feature 33. A component according to any one of features 31 and 32, wherein the first elastic modulus differs from the second elastic modulus by 15% to 20%.

[0263] Feature 34. A component according to any one of features 31 to 33, wherein the first elastic modulus is less than the second elastic modulus.

[0264] Feature 35. A component according to any one of features 31 to 32, wherein the second elastic modulus is less than the first elastic modulus.

[0265] Feature 36. A component according to any one of features 31 to 35, wherein the second pad has a third elastic modulus along a third axis substantially perpendicular to the second axis line, and wherein the third elastic modulus is different from the second elastic modulus.

[0266] Feature 37. The component according to feature 36, wherein the second elastic modulus is greater than the first elastic modulus and greater than the third elastic modulus.

[0267] Feature 38. A component according to any one of features 1 to 37, wherein a first portion of the first plurality of fibers extends through the first padding material and is entangled with a first portion of the second plurality of fibers.

[0268] Feature 39. A component according to any one of features 1 to 38, wherein a first portion of the first plurality of fibers extends through the second padding material and is entangled with a first portion of the second plurality of fibers.

[0269] Feature 40. A component according to any one of features 1 to 39, wherein a first portion of the second plurality of fibers extends through the first padding material and the second padding material and is entangled with the first portion of the first plurality of fibers.

[0270] Feature 41. A component according to any one of features 1 to 40, wherein a first portion of the first plurality of fibers is entangled with one or more fibers of the first padding material.

[0271] Feature 42. The component according to any one of features 1 to 41 further includes a polymer encapsulation portion of at least a portion of the first fiber layer, the second fiber layer, and the padding assembly.

[0272] Feature 43. The component according to feature 42, wherein the polymer encapsulation portion is formed of a composition comprising one or more polymeric materials.

[0273] Feature 44. According to the component of feature 43, one or more polymeric materials include thermoplastic or thermosetting materials.

[0274] Feature 45. The component according to any one of features 42 to 44, wherein the polymer encapsulation portion is formed of a composition consisting of at least one selected from polyurethane, polyester, polyether, polyamide, polyolefin, polycarbonate, polyacrylate vinyl polymer, aromatic polyamide, any copolymer thereof, and any combination thereof.

[0275] Feature 46. A component according to any one of features 42 to 45, wherein at least a portion of the polymer-encapsulated portion is impregnated with the component.

[0276] Feature 47. The component according to feature 46, wherein the polymer encapsulation portion is composed of a porous structure.

[0277] Feature 48. The component according to feature 46, wherein the polymer wrapping is synthetic leather.

[0278] Feature 49. A method of forming a component of a footwear article, the method comprising: placing a first fiber layer comprising a first plurality of fibers on a surface; placing a second fiber layer comprising a second plurality of fibers on the first fiber layer, wherein at least a first portion of the first plurality of fibers extends into the second plurality of fibers; placing a padding assembly between the first and second fiber layers, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first fiber layer to exhibit a first Z-direction offset, and wherein a portion of the second surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first surface of the second padding to exhibit a second Z-direction offset; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers.

[0279] Feature 50. A method of forming a component of a footwear article, the method comprising: placing a first fiber layer comprising a first plurality of fibers on a surface; placing a padding assembly on the first fiber layer, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to the first fiber layer, and wherein a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding; placing the second fiber layer comprising a second plurality of fibers on the padding assembly; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers.

[0280] Feature 51. A method of forming a component of a footwear article, the method comprising: placing a first fiber layer comprising a first plurality of fibers on a surface; placing a padding assembly adjacent to and overlapping the first fiber layer with a first Z-direction offset, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to the first fiber layer, and wherein a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding; placing the second fiber layer comprising a second plurality of fibers on the padding assembly; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers.

[0281] Feature 52. The method according to any one of features 49 to 51 further includes entanglement of a second plurality of fibers of the second fiber layer with one or more fibers of the first padding material, wherein the second fiber layer is adjacent to the first padding material on a second side opposite to the first fiber layer.

[0282] Feature 53. The method according to any one of features 49 to 53, wherein the entanglement is performed at least in part with one or more barbs of a crochet hook and a structured needle.

[0283] Feature 54. The method according to any one of features 49 to 53, wherein the entanglement is performed at least in part by a fluid flow.

[0284] Feature 55. The method according to any one of features 49 to 54, wherein at least one of the first plurality of fibers or the second plurality of fibers comprises at least partially a material selected from polyurethane, thermoplastic polyurethane, polyester, polyether, polyamide, polyolefin, polycarbonate, polyacrylate, aromatic polyamide, cellulose material, glass, carbon, metal, mineral, copolymers thereof, and any combination thereof.

[0285] Feature 56. The method according to any one of features 49 to 55 further includes applying energy to the component after tangling.

[0286] Feature 57. The method according to any one of features 49 to 56 further includes impregnating the part with a polymer and forming the part into synthetic leather.

[0287] Feature 58. The method according to any one of features 49 to 57, wherein at least one of the first plurality of fibers and the second plurality of fibers comprises at least one of a cellulose-based material and a protein-based material.

[0288] Feature 59. The method according to any one of features 49 to 57, wherein at least one of the first plurality of fibers and the second plurality of fibers comprises an animal-derived material and a polymeric material.

[0289] Feature 60. The method according to any one of features 49 to 59, wherein the first padding material is formed by knitting, weaving, braiding, non-woven, direct fiber placement, molding, extrusion, deposition, expansion, shrink forming, casting, 3D printing, sheet, film or embroidered element.

[0290] Feature 61. A component formed by means of any one of features 49 to 60.

[0291] Feature 62. A component comprising: a first fiber layer including a first plurality of fibers; and a padding assembly positioned adjacent to the first fiber layer, wherein at least a first portion of the first plurality of fibers extends into and entangles with at least a first portion of the padding assembly, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to a portion of the first fiber layer and a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding.

[0292] Feature 63. A component of a footwear article, the component comprising: a first fiber layer including a first plurality of fibers; and a padding assembly positioned adjacent to and overlapping the first fiber layer with a first Z-direction offset, wherein at least a first portion of the first plurality of fibers extends into and entangles with at least a first portion of the padding assembly, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to a portion of the first fiber layer and a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding.

[0293] Feature 64. A component according to any one of features 62 and 63, wherein the component is one of a component of footwear, a component of clothing, or a component of sports equipment.

[0294] Feature 65. A component according to any one of features 62 to 64, wherein the component is a component of a footwear article.

[0295] Feature 66. A component according to any one of features 62 to 65, wherein the component is the upper of a footwear article.

[0296] Feature 67. The component according to feature 66, wherein the upper of the footwear article includes an inner side, an outer side, and a forefoot portion of the footwear article.

[0297] Feature 68. A component according to any one of features 68 to 67, wherein the first fiber layer is a nonwoven textile.

[0298] Feature 69. A component according to any one of features 62 to 68, wherein at least one of the first padding material and the second padding material is formed as a knitted, woven, braided, nonwoven, direct fiber lay-up, molded, cast, extruded, deposited, expanded, reduced-shape, 3D printed, sheet, film or embroidered element.

[0299] Feature 70. A component according to any one of features 62 to 69, wherein at least one of the first padding material and the second padding material has a first functional area and a second functional area, the first functional area having a functional characteristic that differs from the second functional area by at least 10%.

[0300] Feature 71. A component according to any one of features 62 to 69, wherein at least one of the first padding material and the second padding material has a first functional area and a different second functional area, the first functional area having a functional characteristic that differs from the second functional area by 15% to 20% in the same functional characteristic.

[0301] Feature 72. A component according to any one of features 62 to 71, wherein the component has a first functional area and a second functional area, the first functional area having a functional feature that differs from the second functional area by at least 10% in the same functional feature.

[0302] Feature 73. The component according to any one of features 62 to 72, wherein the component has a first functional area and a second functional area, the first functional area having a functional characteristic that differs from the second functional area by 15% to 20% in the same functional characteristic.

[0303] Feature 74. A component according to any one of features 62 to 73, wherein the first padding material is formed of a first material and the second padding material is formed of a second material, wherein the first material is different from the second material.

[0304] Feature 75. The component according to feature 74, wherein the first material is composed of a foam-like or foamable material, and the second material is composed of textiles.

[0305] Feature 76. A component according to any one of features 62 to 73, wherein a first padding material has a first elastic modulus along a first axis of the first padding material, and a second padding material has a second elastic modulus along a second axis of the second padding material, wherein the first axis and the second axis are parallel and the first elastic modulus is different from the second elastic modulus.

[0306] Feature 77. The component according to feature 76, wherein the first elastic modulus differs from the second elastic modulus by at least 10%.

[0307] Feature 78. The component according to feature 76, wherein the first elastic modulus differs from the second elastic modulus by 15% to 20%.

[0308] Feature 79. A component according to any one of features 76 to 78, wherein the first elastic modulus is less than the second elastic modulus.

[0309] Feature 80. A component according to any one of features 76 to 78, wherein the second elastic modulus is less than the first elastic modulus.

[0310] Feature 81. A component according to any one of features 76 and 80, wherein the second pad has a third elastic modulus along a third axis substantially perpendicular to the second axis line, and wherein the third elastic modulus is different from the second elastic modulus.

[0311] Feature 82. The component according to feature 81, wherein the second elastic modulus is greater than the first elastic modulus and greater than the third elastic modulus.

[0312] Feature 83. The component according to any one of features 61 to 82 further includes a second fiber layer composed of a second plurality of fibers, wherein at least a portion of the second fiber layer is positioned adjacent to at least a portion of the second surface of the second padding material.

[0313] Feature 84. The component according to feature 83, wherein at least a first portion of the second plurality of fibers extends into and entangles with at least a second portion of the padding assembly.

[0314] Feature 85. A component according to any one of features 83 and 84, wherein at least a second portion of the first plurality of fibers extends through the padding assembly and is entangled with at least a second portion of the second plurality of fibers.

[0315] Feature 86. A method of forming a component of a footwear article, the method comprising: placing a first fiber layer comprising a first plurality of fibers on a surface; placing a padding assembly adjacent to and overlapping the first fiber layer with a first Z-direction offset, wherein at least a first portion of the first plurality of fibers extends into at least a first portion of the padding assembly, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to a portion of the first fiber layer and a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the padding assembly.

[0316] Feature 87. The method according to feature 86 further includes placing a second fiber layer comprising a second plurality of fibers as part of a second surface adjacent to the second padding material; and entanglement of at least a portion of the second plurality of fibers with one or more fibers of the second padding material.

[0317] Feature 88. A component of a footwear article, the component comprising: a first fiber layer including a first plurality of fibers; a second fiber layer including a second plurality of fibers; and a padding assembly positioned between the first fiber layer and the second fiber layer, wherein at least a first portion of the first plurality of fibers extends into and entangles with at least a first portion of the second plurality of fibers, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to the first fiber layer and a portion of the second surface of the first padding is positioned adjacent to a portion of the first surface of the second padding.

[0318] Feature 89. A method of forming a component of a footwear article, the method comprising: placing a padding assembly on a first fiber layer, the first fiber layer comprising a first plurality of fibers, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and (2) a second padding having a first surface and an opposite second surface, wherein at least a portion of the first surface of the first padding is positioned adjacent to at least a portion of the first fiber layer and at least a portion of the second surface of the first padding is positioned adjacent to at least a portion of the first surface of the second padding; placing the second fiber layer comprising a second plurality of fibers on the padding assembly; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers.

[0319] Feature 90. The method according to feature 89 further includes entanglement of at least a portion of the second plurality of fibers of the second fiber layer with one or more fibers of the padding assembly, wherein the second fiber layer is adjacent to the first padding on a second side opposite to the first fiber layer.

[0320] Feature 91. The method according to any one of Features 89 and 90, wherein the entanglement is performed at least in part with one or more barbs of a crochet hook and a structured needle.

[0321] Feature 92. The method according to any one of features 89 and 90, wherein the entanglement is performed at least in part by a fluid flow.

[0322] Feature 93. The method according to any one of features 89 to 92, wherein at least one of the first padding material and the second padding material is formed as a knitted, woven, braided, nonwoven, direct fiber lay-up, molded, cast, extruded, deposited, expanded, reduced-shape, 3D printed, sheet, film or embroidered element.

[0323] Feature 94. A method of forming a component of a footwear article, the method comprising: placing a padding assembly adjacent to and overlapping a first fiber layer with a Z-direction offset, the first fiber layer comprising a first plurality of fibers, the padding assembly comprising: a first padding having a first surface and an opposite second surface, and (2) a second padding having a first surface and an opposite second surface, wherein at least a portion of the first surface of the first padding is positioned adjacent to at least a portion of the first fiber layer and at least a portion of the second surface of the first padding is positioned adjacent to at least a portion of the first surface of the second padding; placing the second fiber layer comprising a second plurality of fibers adjacent to and overlapping the padding assembly with a Z-direction offset; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers.

[0324] Feature 95. The method according to feature 94 further includes entanglement of at least a portion of the second plurality of fibers of the second fiber layer with one or more fibers of the padding assembly, wherein the second fiber layer is adjacent to the first padding on a second side opposite to the first fiber layer.

[0325] Feature 96. The method according to any one of features 94 and 95, wherein the entanglement is performed at least in part with one or more barbs of a crochet hook and a structured needle.

[0326] Feature 97. The method according to any one of features 94 and 95, wherein the entanglement is performed at least in part by a fluid flow.

[0327] Feature 98. The method according to any one of features 94 to 97, wherein at least one of the first padding material and the second padding material is formed as a knitted, woven, braided, nonwoven, direct fiber lay-up, molded, cast, extruded, deposited, expanded, reduced-shape, 3D printed, sheet, film or embroidered element.

[0328] This application also relates to the following aspects.

[0329] 1) A component of a footwear article, the component comprising: a first fiber layer including a first plurality of fibers; and a padding assembly positioned adjacent to the first fiber layer, wherein at least a first portion of the first plurality of fibers extends into and entangles with at least a first portion of the padding assembly, the padding assembly comprising: (1) a first padding having a first surface and an opposite second surface, and (2) a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first fiber layer to present a first Z-direction offset, and wherein a portion of the second surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first surface of the second padding to present a second Z-direction offset.

[0330] 2) The component as described in 1), wherein the component is the upper of the footwear article.

[0331] 3) The component as described in 1), wherein the first fiber layer is a nonwoven textile.

[0332] 4) The component as described in 1), wherein at least one of the first padding material and the second padding material is formed as a knitted element, a braided element, a knitted element, a nonwoven element, a direct fiber placement element, a molded element, a cast element, an extruded element, a deposited element, an expanded element, a shrink-forming element, a sheet element, a film element, or an embroidered element.

[0333] 5) The component as described in 1), wherein at least one of the first padding material and the second padding material has a first functional area and a different second functional area, wherein the first functional area has functional characteristics different from those of the second functional area.

[0334] 6) The component as described in 1), wherein the first pad is formed of a first material and the second pad is formed of a second material, and wherein the first material is different from the second material.

[0335] 7) The component as described in 6), wherein the first material is composed of a foam or foamable material, and the second material is composed of textiles.

[0336] 8) The component as described in 1), wherein the first pad has a first elastic modulus along a first axis of the first pad and the second pad has a second elastic modulus along a second axis of the second pad, wherein the first axis and the second axis are parallel to each other, and wherein the first elastic modulus is different from the second elastic modulus.

[0337] 9) The component as described in 8), wherein the first elastic modulus is at least 10% of the second elastic modulus.

[0338] 10) The component as described in 8), wherein the second pad has a third elastic modulus along a third axis substantially perpendicular to the second axis, and wherein the third elastic modulus is different from the second elastic modulus.

[0339] 11) The component as described in 10), wherein the second elastic modulus is greater than the first elastic modulus and greater than the third elastic modulus.

[0340] 12). The component as described in 1) further includes a second fiber layer composed of a second plurality of fibers, wherein at least a portion of the second fiber layer is positioned adjacent to at least a portion of the second surface of the second padding material and overlaps with at least a portion of the second surface of the second padding material to present a third Z-direction offset.

[0341] 13) The component as described in 12), wherein at least a first portion of the second plurality of fibers extends into and entangles with at least a second portion of the padding assembly.

[0342] 14). The component as described in 12), wherein at least a second portion of the first plurality of fibers extends through the padding assembly and is entangled with at least a second portion of the second plurality of fibers.

[0343] 15) A component of a footwear article, the component comprising: a first fiber layer including a first plurality of fibers; a second fiber layer including a second plurality of fibers; and a padding assembly positioned between the first fiber layer and the second fiber layer, wherein at least a first portion of the first plurality of fibers extends into and is entangled with at least a first portion of the second plurality of fibers, the padding assembly comprising: (1) a first padding having a first surface and an opposite second surface, and (2) a second padding having a first surface and an opposite second surface, wherein a portion of the first surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first fiber layer to present a first Z-direction offset, and wherein a portion of the second surface of the first padding is positioned adjacent to and overlaps with at least a portion of the first surface of the second padding to present a second Z-direction offset.

[0344] 16) A method of forming a component of a footwear article, the method comprising: placing a padding assembly adjacent to and overlapping the first fiber layer with a first Z-direction offset, the first fiber layer comprising a first plurality of fibers, the padding assembly comprising: (1) a first padding having a first surface and an opposite second surface, and (2) a second padding having a first surface and an opposite second surface, wherein at least a portion of the first surface of the first padding is positioned adjacent to at least a portion of the first fiber layer, and wherein at least a portion of the second surface of the first padding is positioned adjacent to at least a portion of the first surface of the second padding; placing a second fiber layer comprising a second plurality of fibers adjacent to and overlapping the padding assembly with a second Z-direction offset; and entangled at least a first portion of the first plurality of fibers with at least a first portion of the second plurality of fibers.

[0345] 17) The method of 16) further includes entanglement of at least a portion of a second plurality of fibers of the second fiber layer with one or more fibers of the padding assembly, wherein the second fiber layer is positioned on the second surface of the second padding adjacent to and overlapping the second padding to present a third Z-direction offset.

[0346] 18). The method as described in 16), wherein the tangling is performed at least in part with one or more barbs of a crochet hook or a structured needle.

[0347] 19) The method as described in 16), wherein the entanglement is performed at least in part by a fluid flow.

[0348] 20) The method as described in 16), wherein at least one of the first padding material and the second padding material is formed as a knitted element, a woven element, a braided element, a nonwoven element, a direct fiber placement element, a molded element, a cast element, an extruded element, a deposited element, an expanded element, a shrink-forming element, a sheet element, a film element, or an embroidered element.

Claims

1. A type of footwear, comprising: The shoe upper, comprising a composite textile, wherein the composite textile comprises: The first layer includes a nonwoven fiber web, and the nonwoven fiber web includes a first fiber; The second layer comprises a padding material having a mesh structure having a positive structure surrounding a negative opening, wherein the padding material is entangled with the first fiber based on a portion of any fiber extending through the positive structure in the first fiber, and wherein said portion of any fiber and the positive structure include an embossed relief protruding relative to the negative opening; and The third layer comprises a polymer film at least connected to the portion of any fiber extending through the positive structure, wherein the second layer is positioned between the third layer and the first layer, and wherein the embossing is perceptible, at least visually and tactilely, through the polymer film.

2. The footwear article according to claim 1, wherein, The padding material includes knitted textiles.

3. The footwear article according to claim 1, wherein, At least a portion of the positive structure of the padding material includes a first color, wherein the polymer film is transparent, and the at least portion of the padding material including the first color is visually perceptible through the polymer film.

4. The footwear article according to claim 3, wherein, The first fiber includes a second color, which is different from the first color.

5. The footwear article according to claim 1, wherein, At least some of the first fibers include fibers that are at least partially split.

6. The footwear article according to claim 5, wherein, The fibers that are at least partially split include first split fibers split to a first degree and second split fibers split to a second degree, which is different from the first degree.

7. A type of footwear, comprising: The shoe upper, comprising a composite textile, wherein the composite textile comprises: The first layer includes a nonwoven fiber web, and the nonwoven fiber web includes a first fiber; The second layer comprises a padding material having a mesh structure having a positive structure surrounding a negative opening, wherein at least a first portion of the padding material is entangled with the first fiber based on a portion of any fiber extending through the positive structure in the first fiber, and wherein at least the first portion of the padding material comprises a first color; and The third layer includes a transparent film that covers at least the first portion of the padding material having the first color.

8. The footwear article according to claim 7, wherein, At least the first portion of the padding material, including the first color, can be visually perceived through the transparent film.

9. The footwear article according to claim 7, wherein: The nonwoven fiber web also includes a second fiber; At least a second portion of the padding material is entangled with the second fiber based on at least a partial extension of the second fiber through any portion of the positive structure; and The second portion of the padding material includes a second color that is different from the first color.

10. The footwear article according to claim 7, wherein, The padding material includes knitted textiles.

Images