Method for producing an abrasion-resistant material

Abstract

Method for producing an abrasion-resistant material (100, 200, 300, 400, 500), comprising: Providing a first layer (110, 111, 211, 311, 411, 511) comprising a first textile material; Providing a second layer (120, 121, 221, 321, 421, 521) comprising a second textile material, wherein at least part of the first and / or second layer is knitted, crocheted, woven or a combination thereof; Arranging the second layer (120, 121, 221, 321, 421, 521) on the first layer (110, 111, 211, 311, 411, 511); and at least partial heat bonding of both layers, whereby the heat bonding causes shrinkage of the first layer (110, 111, 211, 311, 411, 511) and the second layer (120, 121, 221, 321, 421, 521); wherein the first textile material has a first shrinkage and the second textile material has a second shrinkage, wherein the first shrinkage is greater than the second shrinkage when the first layer (110, 111, 211, 311, 411, 511) and the second layer (120, 121, 221, 321, 421, 521) are at least partially heat-bonded together.

Description

1. Technical field

[0001] The present invention relates to an abrasion-resistant material and a method for producing such an abrasion-resistant material, which is particularly suitable for sports accessories, clothing and footwear. 2. Technical Background

[0002] Textile fabrics used in sportswear and footwear offer a wide variety of applications and designs. For example, a shoe upper or part of a garment can be made from different textile fabrics, providing a rich diversity of appearance and feel while remaining lightweight, which is particularly important for competitive athletes. A large proportion of the materials used for textile fabrics are made from synthetic fibers with thermoplastic properties. In recent years, methods for joining such thermoplastic textiles without the need for sewing or gluing have been developed using heat treatment.

[0003] For example, the state-of-the-art document KR 2016 0019 725 A describes an adhesive woven fabric with a circular knit, produced by weaving yarn and TPU fibers with a hot-melt resin coated with a circular knit. US 9,682,512 B2 relates to methods for joining textiles and other elements containing a thermoplastic polymer material. In these elements, various fused areas can be formed by heat bonding processes to modify various properties, including permeability, durability, and elongation resistance. Furthermore, EP 0 747 518 B1 relates to a woven fabric used to manufacture various textile products, such as bags, where strong bond strength can be achieved by heat bonding without the need to sew at least two pieces of woven fabric.

[0004] Furthermore, document WO 2018 / 163 090 A1 relates to a shoe upper for a footwear article, wherein the upper comprises a base layer defining at least part of the upper and polymer threads sewn to the base layer. US 2017 / 0 203 539 A1 relates to a method for producing a laminate with at least two superimposed nonwoven layers made of continuous filaments. At least two of the superimposed nonwoven layers are partially bonded together, with shrinkage of the first nonwoven layer being activated in the unbonded areas following the bonding. Document WO 2017 / 142 857 A1 relates to a knitted shoe upper having two sides, wherein yarns of the shoe upper are first set or shrunk using steam, and then a portion of the yarns are partially melted in a heated mold.Document DE 10 2017 223 743 A1 relates to a process for manufacturing a sports article component, wherein two textiles with different shrinkage ratios are selected under a predetermined shrinkage condition and formed into a first and second part of the sports article component.

[0005] However, conventional textile materials, which include synthetic fibers with thermoplastic properties, and state-of-the-art textile materials have several disadvantages for use in applications such as sportswear. For example, high durability and low wear in sportswear or shoes, which result in a longer lifespan and thus in resource conservation and reduced pollution, are often considered less important. This applies particularly to lightweight sports equipment and footwear, where surfaces are often subjected to high stress and abrasion during athletic activities, such as when part of a shoe slides across the ground.

[0006] Therefore, one of the problems underlying the present application is to at least partially improve the disadvantages of the prior art and to provide an improved material and a method for producing such an improved material which has high abrasion resistance but is also flexible and lightweight. 3. Summary of the invention

[0007] The problem mentioned above is at least partially solved by the subject matter of the independent claim. Exemplary embodiments of the invention are defined in the dependent claims.

[0008] The claimed manufacturing process of the present invention provides an abrasion-resistant material comprising a first layer, which includes a first textile material, and a second layer, which includes a second textile material. The second layer is arranged on top of the first layer, wherein the first layer and the second layer are at least partially heat-bonded to each other. The first textile material exhibits a first shrinkage property, and the second textile material exhibits a second shrinkage property, wherein the first shrinkage property is greater than the second shrinkage property when the first layer and the second layer are at least partially heat-bonded.

[0009] The claimed invention provides an abrasion-resistant material that can be used for or applied to sports components, in particular, but not limited to, footwear, clothing, sports equipment, and the like. The claimed abrasion-resistant material also provides a material with high wear resistance without being stiff, which can facilitate processing and expand the potential field of application. In particular, the different shrinkage rates of the first and second textile layers result in the formation of a three-dimensionally shaped abrasion-resistant material that exhibits the aforementioned improved properties. This three-dimensional shape is obtained when the first and second layers are heat-bonded due to the different shrinkage rates of the first and second textile materials.

[0010] At least part of the first and / or second layer is knitted, crocheted, woven, or a combination thereof. By using different textile manufacturing techniques, the abrasion-resistant material can be specifically adapted to its intended use. For example, woven textiles are generally stiffer than knitted or crocheted textiles, whereas knitted or crocheted textiles generally exhibit higher elasticity. By varying the different textile manufacturing techniques for the first and second layers, or by using the same technique and combining them according to the required properties, the present invention provides a versatile abrasion-resistant material.

[0011] Furthermore, the first textile material can comprise a first yarn and the second textile material a second yarn. One aspect of the present invention is the different shrinkage rates of the first and second textile materials. The degree of shrinkage occurring in both materials can be controlled by selecting the appropriate first and second yarns. For example, the first yarn can exhibit a higher shrinkage rate than the second yarn during heat treatment, such as during a heat joining process.

[0012] In some embodiments, the first yarn comprises a first thermoplastic material, the term thermoplastic material describing a polymeric material made of plastic that becomes pliable or malleable at a certain temperature and hardens upon cooling. This process can lead to a change in the material properties, which, if carried out as claimed in the present invention, results in a material with high abrasion resistance. The first yarn can comprise only the first thermoplastic material, thus providing a high-quality yarn at a reasonable price because there is no need to accurately combine different materials during the yarn's manufacture. The first yarn can also be a monofilament yarn, preferably a 100% TPU monofilament yarn.

[0013] In some embodiments of the present invention, the second yarn comprises a second thermoplastic material and a polyester. The polyester may also be a thermoplastic material or, in some embodiments, a thermoset. By selecting these two materials for the production of the second yarn, their different melting temperatures and other properties can provide a variety of high-performance material characteristics for the production of the second textile material of the present invention.

[0014] In some embodiments, the second yarn comprises a polyester core and a second thermoplastic material coating. This core-sheath structure can combine the individual advantages of each of the materials bonded in a yarn. For example, polyester is known to have high tensile strength and a high modulus of elasticity compared to other industrial yarns, which is combined in the second yarn of the present invention with the flexible and malleable properties of the second thermoplastic material.

[0015] In some embodiments, the second textile material melts at least partially during heat bonding. This partial melting can lead to softening of the sheath layer of the second yarn, which can result in bonding of adjacent parts of the second yarn within the second layer, as well as bonding of parts of the second layer with parts of the first layer. The polyester core can remain solid during the partial melting of the second textile material.

[0016] The diameter of the second yarn can be the same as or larger than the diameter of the first yarn. Using a fine yarn with a low denier value for the first layer allows for small stitch sizes, resulting in a homogeneous appearance. Conversely, having the second yarn at least the same diameter as, or larger than, the first provides a yarn that enables the creation of various patterns and creative designs. For example, the second layer can incorporate numerous openings larger than the average stitch size of the second layer. Alternatively, the average opening size of the second layer can be larger than the stitch size of the first layer. In addition to the properties mentioned above, this can create a design for an abrasion-resistant material where the first layer is visible through the numerous openings of the second layer.By using different colors for the first and second layers, the present invention allows for the provision of a high-performance, abrasion-resistant material with the possibility of creating various interesting patterns and designs. Additionally, the openings in the second layer can contribute to the air permeability of the abrasion-resistant material. This results in a lightweight and breathable, yet abrasion-resistant material.

[0017] In some embodiments of the present invention, the first textile material has a first elasticity and the second textile material has a second elasticity, wherein the first elasticity is greater than the second elasticity. By combining materials with different elasticities before heat bonding, the present invention, as claimed, provides a versatile abrasion-resistant material that is flexible and easy to shape, but also exhibits high tensile strength when, for example, it is attached to a stretch part of a garment or part of a shoe.

[0018] The present invention provides a method for producing an abrasion-resistant material. The method comprises providing a first layer comprising a first textile material, providing a second layer comprising a second textile material, and arranging the second layer on top of the first layer. The method further comprises the step of heat-bonding both layers at least partially, wherein the first textile material exhibits a first shrinkage capacity and the second textile material exhibits a second shrinkage capacity, the first shrinkage capacity being greater than the second shrinkage capacity when the first layer and the second layer are at least partially heat-bonded.

[0019] The present invention thus provides a method for producing a material with high abrasion resistance. The different shrinkage rates of the first and second textile materials, in combination with an application-dependent heat treatment during heat bonding, can be adapted to provide a material with an increasing or decreasing gradient in abrasion resistance and / or a variable degree of abrasion resistance. The heat bonding can include applying a pressure of up to 1 bar at a temperature between 100 and 200°C for a duration of at least 10 seconds. In some embodiments, the heat bonding can preferably include applying a pressure of 0.5 to 0.7 bar at a temperature between 150 and 180°C for a duration of 20 to 40 seconds.By varying the various parameters of heat bonding, such as time, temperature and / or pressure, the present invention provides a method for producing a material that can achieve a wide range of abrasion resistance and durability, depending on how it is heat-treated, without being stiff.

[0020] In some embodiments, the present invention provides a method for inserting a non-stick protective film between the first layer and the heat press and / or between the second layer and the heat press. Preferably, the protective film is inserted before heat bonding, i.e., before a heat pressing process is carried out. The use of a protective film, such as a Teflon®-coated film or the like, between the heat press and the first and / or second layer enables a method for producing an abrasion-resistant material, preventing the respective layer from adhering to the surface of the heat press after the heat pressing process is complete, thereby ensuring high product quality. It should be noted that the term "and / or," used in combination with, for example,two features of the present invention, relating to a combination of “only the first feature” or “only the second feature” or “the first and the second feature”.

[0021] The process may further include removing the abrasion-resistant material from the heat press within a period of less than 10% of the heat bonding time after the heat bonding time has elapsed. For example, heat bonding the first and second layers for a duration of 30 seconds would require the abrasion-resistant material to be removed within 3 seconds after this time has expired. This can prevent the first or second layer from adhering to the film after heat bonding and during subsequent cooling to room temperature.

[0022] The present invention further provides a method in which heat bonding causes shrinkage of the first and second layers. The term shrinkage defines a process of reducing a surface area of ​​the first and second layers comprising the first and second textile materials. The reduction of a surface area can be used to characterize the degree of shrinkage of a layer comprising a textile material. Additionally or alternatively, the present invention can provide a method in which heat bonding causes a first change in the surface area of ​​the first layer and a second change in the surface area of ​​the second layer. In some embodiments, the absolute value of the first change in the surface area is greater than the absolute value of the second change in the surface area.It should be noted that the extent of shrinkage and / or the extent of change in the surface area of ​​the second layer, encompassing the second textile material, may also be zero.

[0023] The above-claimed method for producing an abrasion-resistant material can also include a method wherein the first textile material has a first elasticity and the second textile material has a second elasticity, wherein the first elasticity is greater than the second elasticity.

[0024] In a further embodiment, the present invention provides an abrasion-resistant material which is produced by one of the methods described above. 4. Brief description of the illustrations

[0025] Aspects of the present invention are described in further detail below with reference to the figures. These figures show: Fig. an illustration of a second layer placed on top of a first layer before heat bonding; Fig. two embodiments illustrating the heat-bonded first and second layers; Fig. another embodiment illustrating a different first and second layer that are heat-bonded to each other; Fig. another embodiment illustrating an abrasion-resistant material in direct comparison to a standard material known in the prior art; Fig. an illustration of a shoe upper comprising a further embodiment of the present invention attached to a shoe upper; and Fig. an illustration of a shoe comprising an abrasion-resistant material according to the present invention. 5. Detailed description of some exemplary embodiments

[0026] Exemplary embodiments of the present invention are described in further detail below with reference to an abrasion-resistant material. While specific combinations of features are described below with reference to the exemplary embodiments of the present invention, it should be understood that the disclosure is not limited to such embodiments. In particular, not all features need to be present to realize the invention, and the embodiments can be modified by combining certain features of one embodiment with one or more features of another embodiment.

[0027] Fig. Figure 1 shows two layers 110, 120 of the textile material, loosely arranged on top of each other before heat bonding. The lower first layer 110 comprises a first textile material and can include a uniform network of meshes 113, which is also shown in an enlarged illustration on the right. Fig. The textile material of the first layer 110 can be a thermoplastic material, in particular a thermoplastic polyurethane (TPU). The upper, second layer 120 comprises a second textile material and can include openings 123 that are larger than an average mesh size (not shown) of this layer or the mesh size 113 of the first layer 110. The textile material of the second layer 120 can be a polyester core with a thermoplastic sheath. In some embodiments, the thermoplastic sheath can comprise a thermoplastic material that is different from the thermoplastic material of the first layer 110. In another embodiment, the thermoplastic sheath can be TPU.

[0028] The first textile material may exhibit greater extensibility than the second textile material. One way to characterize the extensibility of a textile material according to the present invention is to stretch a strip of predefined dimensions at both ends using a force less than the force required to tear the material. By characterizing two different textile materials with identical predefined dimensions and using the same force, a comparison of the resulting lengths of the textile materials allows the determination of which one stretches more and is thus defined as having greater extensibility.

[0029] The first textile material may exhibit greater shrinkage than the second textile material if the two layers 110, 120 are at least partially heat-bonded. One way to characterize the shrinkage of a textile material is to determine the change in the surface area of ​​the textile material during the application of heat.

[0030] By starting with two different textile materials with the same surface area and applying the same temperature and pressure to both textile materials for the same duration, the one with a smaller resulting surface area can be defined as the one with greater shrinkage.

[0031] In some embodiments of the present invention, the greater shrinkage of the first textile material compared to the second textile material can lead to a strong bond between the two layers 110, 120 when they are at least partially heat-bonded. It should be noted that the shrinkage of the second layer 120 can also be zero. Provided the processes are carried out in accordance with the present invention, the resulting material can be a versatile, abrasion-resistant material that is flexible and easily shaped.

[0032] Fig. shows an illustration of the first 111 and second 121 positions, which are in Fig. shown are after heat bonding. The heat bonding in accordance with the present invention can comprise the application of a pressure of up to 1 bar at a temperature of 100°C to 200°C for a period of at least 10 seconds. During the heat bonding of the two layers 111, 121, the second textile material can at least partially melt, which can lead to a puffed or swollen appearance of the second textile material, as shown in Fig. shown. Additionally or alternatively, the first textile material can shrink during heat bonding. These two aspects, partial melting of the second textile material and shrinkage of the first textile material, can bring about a strong bond between the two layers 111, 121 and can form the abrasion-resistant material 100 of the present invention.

[0033] By varying the parameters of the heat bonding process, specifically temperature, pressure, and time, different effects and appearances can be achieved. For example, increasing the temperature can lead to a greater degree of melting of the second textile material, resulting in a more puffed or swollen look and a higher degree of abrasion resistance. Similar effects can be achieved by increasing the duration. In some embodiments, the heat bonding can be applied to an entire arrangement of the two layers 111, 121, as shown in Fig. As shown, the effects mentioned above can be achieved homogeneously over the entire arrangement. In some embodiments, the openings 122 of the second layer 121 can still be larger than the average mesh size of the second layer 121 after heat bonding.

[0034] In another embodiment, heat bonding can be applied to different regions of the arrangement of the two layers 211, 221 using different parameters, whereby the effects mentioned above may appear differently in the different regions. For example, shows Fig. An embodiment of the present invention comprising two regions 230, 240. A first region 240 is located in a central part of the arrangement, and a second region 230 surrounds the central part. Using a higher temperature and / or a longer duration of heat bonding applied to the first region 240, compared to the second region 230, can result in higher abrasion resistance and a more puffed / swollen appearance of the second textile material. Different embodiments may include a different number of regions, arranged differently from those shown. Fig. The openings 224 of the first region 240 of the second layer 221 can have a different size and shape compared to the openings 222 of the second region 230 of the second layer 221. In some embodiments, the transition between the different regions 230, 240 can be abrupt, while in other embodiments the transition is gradual or smooth. This not only allows the intended degree of abrasion resistance to be varied for different parts of, for example, a shoe or sportswear, but also provides a method for creating different looks and appearances of, for example, a shoe or sportswear comprising the abrasion-resistant material 200.

[0035] Fig. Figure 3 shows a further embodiment of the present invention comprising a third region 301 and a fourth region 350, wherein the transition between the two regions is abrupt. The third region 301 comprises the abrasion-resistant material 300 of the present invention with a puffed or swollen appearance and openings 322 in the second layer 321. The openings 322 can allow a translucent effect in which parts of the first layer 311 are visible, thereby providing a method for creating different designs and looks using different colors to produce the abrasion-resistant material 300. The fourth region 350 comprises a second layer 352, which is identical to the second layer 321 of the third region 301.However, the first layer 351 of the fourth region 350 is made of a standard material known in the prior art, which does not exhibit the first shrinkage property claimed in the present invention. Therefore, the heat bonding of such a first layer 351, known in the prior art, and the second layer 352 of the present invention does not provide a material with high abrasion resistance, as claimed in the fourth region 350. Fig. presented with a non-puffy or non-swollen appearance.

[0036] Fig. Figure 450 shows an embodiment of the present invention attached to a medial or lateral side of a shoe upper 450. This makes it possible to provide a shoe, in particular a sports shoe, which, by using the abrasion-resistant material 400 of the present invention in areas of the shoe that are more prone to wear, has a long service life and thus lasts longer. In some embodiments, the outer layer of, for example, sports equipment, clothing, or shoes can also comprise a fusible layer known in the prior art, such as the first 451 and second layer 452 of the upper 450, so that the abrasion-resistant material 400 can be applied directly to the outer layer by heat bonding. This allows for application without the need for sewing or gluing. Similar to Fig. The abrasion-resistant material can include 400 openings 422 in the second layer 421, so that the first layer 411 is visible.

[0037] Fig.Figure 570 shows a front part of a shoe comprising a sole 560 and the abrasion-resistant material 500, which is attached to an upper 550 of the shoe 570. This allows for the protection of areas of the shoe 570, such as the medial or lateral forefoot region, which are subject to rough use during athletic activities. It is known, for example, that tennis players frequently drag their shoes by sliding across the rough surface of a tennis court to reach a ball. This can expose the upper 550 of the tennis shoe 570 to a high degree of abrasion, especially when playing on a clay court. By providing an upper 550 of a tennis shoe 570 with an abrasion-resistant material 500, particularly in high-wear areas, the overall lifespan of the shoe 570 can be increased.This can reduce the amount of waste and therefore provide a more environmentally friendly version of the 570 shoe by incorporating the abrasion-resistant material 500. In some embodiments, the materials used to produce the first yarn for the first layer 511 and the second yarn for the second layer 521 can be recycled material. The second layer 521 can include openings 522 that provide improved breathability and ventilation through the mesh of the first layer 511 for the foot of an athlete wearing the 570 shoe incorporating the abrasion-resistant material 500.

[0038] In addition to the high performance of the abrasion-resistant material 100, 200, 300, 400, 500 of the present invention, the present invention can also provide a visually appealing appearance and the possibility of creating interesting patterns and designs on, for example, sports equipment, clothing, or shoes 570 by using textile materials of different colors. Furthermore, by varying the parameters of the heat bonding, different looks and structures can be easily achieved, for example, openings 122, 222, 224, 322, 422, 522 of different sizes and shapes, or similar features. Moreover, the methods of the present invention, as described above, can provide an abrasion-resistant material 100, 200, 300, 400, 500 which, in contrast to the use of a conventional TPU film, offers a high degree of flexibility for, for example,Sports equipment, clothing or shoes, when covered with the abrasion-resistant material 100, 200, 300, 400, 500.

Claims

[1] Method for producing an abrasion-resistant material (100, 200, 300, 400, 500), comprising: Providing a first layer (110, 111, 211, 311, 411, 511) comprising a first textile material; Providing a second layer (120, 121, 221, 321, 421, 521) comprising a second textile material, wherein at least part of the first and / or second layer is knitted, crocheted, woven or a combination thereof; Arranging the second layer (120, 121, 221, 321, 421, 521) on the first layer (110, 111, 211, 311, 411, 511); and at least partial heat bonding of both layers, whereby the heat bonding causes shrinkage of the first layer (110, 111, 211, 311, 411, 511) and the second layer (120, 121, 221, 321, 421, 521); wherein the first textile material has a first shrinkage and the second textile material has a second shrinkage, wherein the first shrinkage is greater than the second shrinkage when the first layer (110, 111, 211, 311, 411, 511) and the second layer (120, 121, 221, 321, 421, 521) are at least partially heat-bonded together. [2] Method according to claim 1, wherein the heat joining comprises: Applying a pressure of up to 1 bar at a temperature between 100 and 200°C for a period of at least 10 seconds. [3] Method according to claim 1 or 2, wherein the heat joining comprises: Apply a pressure of 0.5 to 0.7 bar at a temperature between 150 and 180°C for a period of 20 to 40 seconds. [4] Method according to any one of claims 1 to 3 further comprising: Inserting a non-stick protective film between the first layer (110, 111, 211, 311, 411, 511) and the heating press and / or between the second layer (120, 121, 221, 321, 421, 521) and the heating press. [5] Method according to any one of claims 1 to 4 further comprising: removing the abrasion-resistant material (100, 200, 300, 400, 500) from the heating press within a period of less than 10% of the heat bonding time after the heat bonding time has elapsed. [6] Method according to any one of claims 1 to 5, wherein the heat bonding causes a first change in the surface area of ​​the first layer (110, 111, 211, 311, 411, 511) and a second change in the surface area of ​​the second layer (120, 121, 221, 321, 421, 521). [7] Method according to claim 6, wherein the absolute value of the first change of the surface area is greater than the absolute value of the second change of the surface area. [8] Method according to any one of claims 1 to 7, wherein the first textile material has a first extensibility and the second textile material has a second extensibility, wherein the first extensibility is greater than the second extensibility. [9] Method according to any one of claims 1 to 8, wherein the first textile material comprises a first yarn and the second textile material comprises a second yarn. [10] Method according to claim 9, wherein the first yarn comprises a first thermoplastic material. [11] Method according to one of claims 9 or 10, wherein the first yarn comprises only the first thermoplastic material. [12] Method according to any one of claims 9 to 11, wherein the first yarn is a monofilament yarn. [13] Method according to any one of claims 9 to 12, wherein the second yarn comprises a second thermoplastic material and a polyester. [14] Method according to any one of claims 9 to 13, wherein the second yarn comprises a polyester core and a second thermoplastic material coating. [15] Method according to any one of claims 1 to 14, wherein the second textile material melts at least partially during heat bonding. [16] Method according to any one of claims 9 to 15, wherein the diameter of the second yarn is identical to or greater than the diameter of the first yarn. [17] Method according to any one of claims 1 to 16, wherein the second layer (120, 121, 221, 321, 421, 521) comprises a plurality of openings (122, 123, 222, 322, 422, 522) larger than an average mesh size of the second layer (120, 121, 221, 321, 421, 521). [18] Method according to claim 17, wherein the plurality of openings (122, 123, 222, 322, 422, 522) of the second layer (120, 121, 221, 321, 421, 521) is on average larger than the mesh size (113) of the first layer (110, 111, 211, 311, 411, 511).

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