Method for manufacturing textile components

Abstract

The present disclosure relates to a method for manufacturing a textile material (1), particularly a shoe upper, comprising the steps of: providing a molding carrier (2), particularly a shoe last; providing a plasticizing unit (3) for melting a polymer composition at a first temperature to provide a molten polymer composition; providing a deposition unit (4) equipped with a quantitative feeding head (5) having at least one nozzle (6); and coating the molten polymer composition onto the molding carrier (2) via at least one nozzle (6) in the form of filaments (7) forming a plurality of loops (8) on the molding carrier (2). During step d, the deposition unit (4) and / or the molding carrier (2) are moved relative to each other in a first movement such that at least one nozzle (6) moves along a drive path extending over the molding carrier (2). While each loop (8) is being formed, the quantitative supply head (5) and / or at least one nozzle (6) are further moved in a second movement different from the first movement along a loop deposition path having a path length, such that the length of each loop (8) formed on the carrier is greater than the path length of the deposition path.

Description

Technical Field

[0001] The present disclosure relates to the field of manufacturing textile materials, specifically shoe uppers, and relates to a method for manufacturing such a textile material, and the textile material manufactured by this method. Background Art

[0002] Many methods for manufacturing textile materials are known in the prior art. Specifically, shoe uppers are typically made from traditionally manufactured textile materials. Traditionally, textile shoe uppers are, for example, knitted and then joined to a sole. In known processes, the properties of the knitted textile material can be influenced by the choices made with respect to the selected knitting technique or wrapping. In addition, solid shoe uppers used for hard shell shoes such as ski boots, ice skate boots and the like are typically made in a casting process, for example by injection molding, or by additive manufacturing, correspondingly also by 3D printing. The advantage of 3D printed shoe uppers lies in the fact that the shoe upper can be individually adapted to the characteristics of the wearer's foot, specifically the contour of the foot. Summary of Invention

[0003] Textiles are often associated with woven fabrics, but weaving is not the only method of production. Knitted fabrics and non-woven fabrics are other common types of fabric manufacturing. In the modern world, textiles meet material needs for diverse applications ranging from simple everyday clothing to bulletproof jackets, spacesuits and the like.

[0004] Compared to traditional textile engineering manufacturing methods, additive manufacturing of textile materials has the advantage of allowing different sections of a textile to be constructed with significantly less effort. For example, fibers produced by 3D printing may have a larger diameter in some areas than in others, for instance, to selectively reinforce a particular area. In contrast, in traditional manufacturing, it is not easily possible to use yarn with a larger diameter in a desired area of ​​a textile than in other areas. Furthermore, additive manufacturing makes it possible to reproduce different wrapping patterns and mesh widths. Thus, for example, one sub-area of ​​a textile may be constructed as knitted fabric and another sub-area as woven fabric. This is virtually impossible with traditional textile manufacturing methods. In addition, traditional textile manufacturing methods are usually associated with a considerable amount of scraps, which negatively impacts the sustainability of such methods.

[0005] Specifically, in the case of shoes with flexible textile uppers made from fibrous materials, these are typically used for sports shoes, running shoes, and everyday shoes, but additive manufacturing still presents several problems. This is mainly because, with additive manufacturing of knitted or woven fabrics, the printed fibers often stick together, making it impossible to obtain the same properties as traditional textile engineering manufacturing methods such as knitting or weaving, especially in terms of flexibility. Because the fibers stick together, they cannot move relative to each other, which affects the adaptability / flexibility caused by the shear of the textile. Therefore, 3D printing is not preferable for producing flexible and lightweight textile materials. In addition, 3D printing is a rather slow process and is therefore not cost-effective for mass production.

[0006] As an alternative to 3D printing, particularly FDM, the meltblown process is known and used to manufacture textile materials. However, the meltblown process can only produce nonwoven fabrics, and it is not possible to manufacture regularly formed textile materials, especially mesh-like or loop-like ones.

[0007] Therefore, one objective of this disclosure can be seen as proposing a method that enables the creation of mesh-like textile materials having various mesh geometric shapes.

[0008] This disclosure relates to a method for manufacturing textile materials, specifically shoe uppers. Textile materials include various fiber-based materials, including fibers, yarns, filaments, and twisted yarns, or different fabric types. A molding carrier is provided for manufacturing textile materials in the sense of this disclosure. Since the textile materials according to this disclosure are not limited to any geometric constraints, the molding carrier can be any physical object. In the context of manufacturing shoe uppers, the molding carrier is typically a shoe last. The last can be a conventional last made of a polymer composition, metal, wood, etc., as will be described in more detail below. The textile materials proposed by this disclosure are made from polymer materials, typically polymer compositions. Therefore, it may be preferable if the temperature of the molding carrier can be controlled. In some embodiments, the molding carrier includes a heating element or a cooling element and is correspondingly heatable or coolable. Alternatively, the applied material can be melted by an external heat source. One of the advantages of this is that the manufactured textile material can be directly material-bonded, specifically welded, to another element. In addition, other advantages include the ability to modify the plasticization of the polymer, which can affect the manufacturing cycle time and / or the bonding of the polymer layers. For example, in some embodiments, at least a sub-region of the carrier may be heated after the molten polymer composition has been applied to a heatable molding carrier, and optionally after the applied polymer composition has cooled and cured, so that additional components can be welded to the textile material. In the context of shoemaking, an insole or midsole may be directly welded to the upper of a shoe made of the textile material.

[0009] Textile components are typically made from polymer compositions, usually thermoplastic polymers, specifically polyamides, polyether block amides, polyurethanes and / or polyesters, or combinations thereof. Alternatively, or in addition, at least partially biodegradable polymers or polymer compositions are also possible. Conventional 3D printing techniques typically use filaments with diameters ranging from 1.75 mm to 2.85 mm. The filaments are typically supplied in the form of thin plastic threads wound on reels. Since the objective of the presented method is to manufacture textile materials, these conventional methods are unsuitable because the resulting molten filaments are too thick and therefore not sufficiently flexible. In this method, filaments typically with thicknesses ranging from 0.01 mm to 0.3 mm, specifically 0.05 mm to 0.2 mm, are desired and used. A standard configuration may include a nozzle with an exit diameter of 0.35 mm to 0.4 mm, typically resulting in a filament diameter of 0.4 mm to 0.5 mm.

[0010] Accordingly, a plasticizing unit is provided for melting a polymer composition at a first temperature, thereby providing a molten polymer composition. The polymer composition may be provided, for example, in the form of granules or semi-finished products to be melted by the plasticizing unit. The plasticizing unit typically comprises an extruder and a metering feed head interconnected to the extruder. In some embodiments, the plasticizing unit may include an extruder having a drum and a screw located within the drum. The plasticizing unit may further have a heating element for setting the first temperature. When an extruder is used, the extruder can increase the pressure at which the polymer composition exits at least one nozzle. Alternatively, a pump or cylinder can be used to increase the pressure at which the polymer composition exits at least one nozzle. A pump, specifically a gear pump, allows for significantly more precise adjustment and control of the pressure. The pressure applied by the pump may be particularly 10 to 80 bar, preferably 20 to 70 bar, more preferably 30 to 60 bar, and most preferably 40 to 60 bar.

[0011] Those skilled in the art will also understand that the selection of the first temperature depends on the melting point or melt range of the polymer composition, and is typically selected such that the polymer composition is melted and sufficiently viscous to be applied to a molding carrier by at least one nozzle. The first temperature may also include a temperature range, such that a typical temperature range is 100°C to 300°C, preferably 160°C to 260°C. For example, when a thermoplastic polyurethane, such as Desmopan 2790a® or Desmopan 9392A® (Covestro), is used as the polymer composition, the first temperature may have a value of, for example, 210 to 240°C, specifically 210 to 220°C.

[0012] The plasticizing unit may include a plurality of, specifically three, consecutively arranged temperature zones. Each temperature zone may have a separately controllable heating element. Specifically, the polymer composition may pass, for example, through a first temperature zone, then a second temperature zone having a higher temperature than the first temperature zone, and then optionally a third temperature zone having a higher temperature than the first and second temperature zones, before exiting at least one nozzle. For example, the first temperature of the first temperature zone may be in the range of 180°C to 185°C, the second temperature of the second temperature zone may be in the range of 230°C to 235°C, and optionally the third temperature of the third temperature zone may be in the range of over 235°C to 240°C.

[0013] A deposition unit is provided that includes a quantitative dispensing head with at least one nozzle, enabling the application of a molten polymer composition in a controlled manner. The nozzle may have an outlet, such as a nozzle exit. The polymer composition, molten within the plasticizing unit, is typically applied onto the molding carrier via the outlet of at least one nozzle in the form of filaments that form multiple loops on the molding carrier. The outlet may be an opening of a nozzle having a diameter that changes over the course of the outlet. A loop is typically defined as a shape produced by a curve that bends in a circular fashion and intersects itself, or as a closed curve whose initial and final points coincide at a fixed point known as the base point. The term "loop" in the sense of this disclosure should be understood in a broader sense. In addition to substantially circular loops, oval, snake-line, or zigzag patterns are also possible. Loops with contours following periodic functions, expressed as a superposition of sine wave functions (multimodal decomposition), are also possible. Thus, loops in the sense of this disclosure may also have a sinusoidal or sine wave shape. The polymer composition may also be applied directly and / or indirectly to the molding carrier. When multiple layers of filament are applied, the application can be considered indirect. In this case, only the first layer of filament can come into direct contact with the molding carrier.

[0014] Typically, only a single filament exits the nozzle at least once, but not multiple filaments simultaneously. During dispensing, the distance between at least one nozzle and the molding carrier is typically 20mm to 110mm, specifically 40mm to 60mm.

[0015] When a molten polymer composition is applied to a molding carrier to create a textile material, the deposition unit and / or molding carrier may be moved in a first motion relative to each other such that at least one nozzle moves along a drive path extending over the molding carrier. The drive path defines the pattern and structure of the textile material. Typically, the textile is created by laying a web of filaments that form loops. Depending on the required design or mechanical properties, the webs may be laid adjacent to each other substantially parallel to each other, overlapping or intersecting, and / or forming several overlapping layers.

[0016] While each loop is being formed, the quantitative feed head and / or at least one nozzle may be further moved in a second movement different from the first movement along a loop deposition path having a path length, such that the length of each loop formed on the carrier is greater than the path length of the deposition path. The textile pattern is typically formed by superimposing a primary movement on a secondary movement. The loops are typically round, preferably circular or oval, or have a regular waveform such as a sinusoidal wave. The length of each loop formed on the carrier should be understood as the length of one loop, for example, a round loop, starting from an intersection along the loop and ending at this intersection, or, for example, the length of one turn in a circular loop, or the length of one period in a sinusoidal loop. Alternatively, while each loop is being formed, the forming carrier may, alternatively or additionally, be moved relative to the quantitative feed head and / or at least one nozzle along a loop deposition path having a path length, such that the length of each loop formed on the carrier is greater than the path length of the deposition path.

[0017] The filament is accelerated along its flight path between the outlet and the forming carrier due to the movement of the nozzle relative to the quantitative feed head or the quantitative feed head relative to the quantitative feed head holder. Due to the acceleration of the filament along its flight path between at least one nozzle and the forming carrier, the filament is deflected radially, thereby increasing the length of each loop formed on the carrier relative to the path length of the loop deposition path. The deposition path is typically different from the drive path, specifically, the path length of the drive path along which at least one nozzle moves during the formation of each loop is shorter than the path length of the deposition path during the formation of each loop.

[0018] In some embodiments, the method involves at least the following method steps: The steps include providing a molding carrier, specifically a shoe last, The steps include: providing a plasticizing unit for melting a polymer composition at a first temperature to provide a molten polymer composition; The step of providing a deposition unit equipped with a quantitative feeding head having at least one nozzle, The steps include: applying a molten polymer composition onto a molding carrier via at least one nozzle in the form of a filament that forms multiple loops on the molding carrier; Includes, During the application of the molten polymer composition, the deposition unit and / or molding carrier can be moved relative to each other in a first movement such that at least one nozzle moves along a drive path extending over the molding carrier. While each loop is being formed, at least one nozzle may be further moved relative to the quantitative feeding head in a second movement different from the first movement, along a loop deposition path having a path length, such that the length of each loop formed on the carrier is greater than the path length of the deposition path. This is a method for manufacturing textile materials.

[0019] Typically, the first and second movements overlap. The second movement may involve moving at least one nozzle relative to the metering head. The molten polymer composition exits the at least one nozzle, typically through an exit in the form of an opening, forming a filament. During dispensing, the at least one nozzle may be moved relative to the distribution axis, preferably rotated around the distribution axis, so that the filament forms a loop. The nozzle is mounted and moved within the nozzle housing so as to be axially rotatable, and rotated by the plasticizing polymer composition flowing through the nozzle housing. The nozzle may extend along an exit axis aligned at an angle of inclination with respect to the distribution axis.

[0020] During coating, the forming carrier may be spaced a certain distance from at least one nozzle, and the shape of the formed loop corresponds to the movement pattern of at least one nozzle defined by a first and second movement on an enlarged scale. Those skilled in the art will understand that the enlarged shape of such a loop may be described, for example, by a conical surface, and thus the filament path from the exit to the forming carrier may be substantially conical. Specifically, the shape of the loop may be described by a conical surface having an opening angle greater than 5°, more specifically greater than 10°, and more specifically greater than 15°. The opening angle of the cone may preferably be 5° to 25°, particularly 10° to 20°.

[0021] The molten polymer composition typically exits at least one nozzle through an exit in the form of a filament along a distribution axis. During dispensing, at least one nozzle may be moved relative to the distribution axis so that the filament forms a loop. "Along the distribution axis" is not limited to being on or along the axis, but also includes rotating or orbiting about the distribution axis. In the case of rotation around the axis or orbiting relative to the axis, the molten polymer along its flight path moves relative to the axis. The distribution axis typically intersects the molding carrier and the metering feed head. The distribution axis may be substantially perpendicular to the molding carrier, typically to utilize the effect of gravity.

[0022] In alternative modifications, the nozzle can be positioned to be swivelable and rotatable, for example, by a ball joint. Eccentric motion can be achieved by a disc or cantilever arm attached to the nozzle and projecting radially from the nozzle. The disc or cantilever arm may be moved by at least two actuating elements. Each of the at least two actuating elements is configured to engage with one of the cantilever arm or disc at a different actuating point. If the metering head has only two actuating elements, only swirling motion of the nozzle, and therefore the material being dispensed (e.g., a molten polymer composition), is possible. Therefore, it is preferable that the metering head has at least three actuating elements, ideally more, to allow the most precise possible movement of the nozzle outlet approximating a circular path. It is preferable that both the actuating elements and the points of application are positioned at a constant angular distance from each other with respect to the longitudinal axis of the nozzle, resulting in a high degree of symmetry.

[0023] Due to the filaments exiting the nozzle that form loops, the textile material typically contains regular filament segments that intersect with each other at points of intersection, forming a circular coil. Due to the circular motion of the nozzle and / or the metering head, the resulting loop is also substantially circular. This deformation has the advantage that the eccentricity of the nozzle exit can be continuously and rapidly changed by the proper design and control of the metering head, resulting in loops of various diameters. In addition, the dispensing is not necessarily circular and can take other shapes with the proper control of the metering head. The metering head can be kept stationary with respect to its longitudinal axis so that the material can be dispensed in a relatively narrow, linear manner.

[0024] Typically, the filament is continuous and moves freely between the outlet and the forming carrier on the flight path. During application of the polymer composition, at least one nozzle is typically moved relative to the dispensing axis and / or the forming carrier is moved relative to the at least one nozzle such that the filament forms loops on the forming carrier. The movement of the metering head with the forming carrier and / or the at least one nozzle can be controlled by a control unit. As a result, a loop-shaped textile material comprising the polymer composition is formed on the forming carrier. In this context, the loop-shaped textile material may comprise a plurality of coils or loops that intersect but preferably do not become entangled.

[0025] In some embodiments, the method comprises at least the following method steps, - providing a forming carrier, specifically a last; - providing a plasticizing unit for melting the polymer composition at a first temperature to provide a molten polymer composition; - providing a deposition unit comprising a metering head with at least one nozzle; - applying the molten polymer composition onto the forming carrier via the at least one nozzle in the form of a filament forming a plurality of loops on the forming carrier; comprising, During application of the molten polymer composition, the deposition unit and / or the forming carrier can be moved in a first movement relative to one another such that the at least one nozzle moves along a drive path extending over the forming carrier, During formation of each loop, the metering head and the at least one nozzle can be further moved in a second movement different from the first movement along a loop deposition path having a path length, such that the length of each loop formed on the carrier is greater than the path length of the deposition path, A method for producing a textile material.

[0026] In the second movement, at least one nozzle, and / or the metering feed head and at least one nozzle, can be moved in a round, preferably circular or oval, and / or eccentric and / or pendulum motion. This allows for the creation of irregular and non-circular patterns. The metering feed head can be interconnected to an eccentric rod interconnected to an eccentric body to generate a lateral reciprocating motion along its longitudinal axis. The eccentric body can convert rotational motion into translational motion, and vice versa. The eccentric body allows at least one nozzle and / or the molding carrier to be moved in a reciprocating motion.

[0027] In some embodiments, the method involves at least the following method steps: The steps include providing a molding carrier, specifically a shoe last, The steps include: providing a plasticizing unit for melting a polymer composition at a first temperature to provide a molten polymer composition; The step of providing a deposition unit equipped with a quantitative feeding head having at least one nozzle, The steps include: applying a molten polymer composition onto a molding carrier via at least one nozzle in the form of a filament that forms multiple loops on the molding carrier; Includes, During the application of the molten polymer composition, the deposition unit and / or molding carrier can be moved relative to each other in a first movement such that at least one nozzle moves along a drive path extending over the molding carrier. While each loop is being formed, the quantitative feeding head and at least one nozzle can be moved together with respect to the quantitative feeding head holder in a second movement different from the first movement, along a loop deposition path having a path length, such that the length of each loop formed on the carrier is greater than the path length of the deposition path. This is a method for manufacturing textile materials.

[0028] Therefore, compared to nonwoven fabrics, the shoe upper has one or more regularly arranged filaments. When at least one nozzle moves relative to the distribution axis, the filaments exit the at least one nozzle and are accelerated along the flight path between the at least one nozzle and the molding carrier, caused by the relative movement of the at least one nozzle. When at least one nozzle rotates on a circular path around the distribution axis, the resulting centrifugal force accelerates the filaments radially away from the circular path of the at least one nozzle. The deposition unit may include a metering head holder to which a metering head is connected, and a second movement includes moving the metering head and at least one nozzle together relative to the metering head holder.

[0029] The molten polymer composition can exit through an outlet that forms a filament and at least one nozzle, and during dispensing, the metering head and at least one nozzle are moved together with respect to the metering head holder around the distribution axis so that the filament forms a loop. At least one nozzle may be inclined with respect to the metering head at a certain angle. In some embodiments, the angle between the distribution axis and the outlet and dispensing direction may be 40° to 60°, preferably 50° to 60°, specifically 55°. At least one nozzle may be dynamically rotated around the axis with respect to the distribution axis. In addition, the molding carrier can move along at least one degree of freedom around the axis. This movement allows for the creation of loops with more complex geometric shapes. For example, loops with a shape substantially like an infinity symbol can be made possible by a tumbling nozzle.

[0030] By pre-selecting the motion pattern of at least one nozzle with respect to the distribution axis, the properties of the manufactured textile material can then be selectively modified and adjusted at any predetermined time. For example, a very small radius creates areas in the textile material with very dense loops or coils, resulting in lower elasticity and higher stability, for example, as required in areas exposed to high mechanical loads. Selecting a larger radius for the helical filament creates areas in the textile material with larger loops or coils, which results in higher elasticity in these areas. Specifically, the radius of the filament may preferably increase constant from the exit toward the molding carrier.

[0031] The advantage of this method is that it is possible to manufacture textile materials, particularly shoe uppers, in a much shorter process time. The molding carrier can move toward the quantitative feed head and at least one nozzle at a speed of 1 m / min to 20 m / min, particularly 5 m / min to 15 m / min. For example, in this way, it is possible to manufacture an entire shoe upper in just 1 to 5 minutes, typically about 3 minutes. In particular, due to this very short process time, it is possible to significantly reduce the energy consumption per unit of textile material manufactured, particularly per shoe upper. In particular, only 0.035 to 0.06 kWh is required to manufacture a shoe upper. For the purposes of this disclosure, a shoe upper refers to a shoe upper that is constructed as a textile and is therefore softer and more flexible in structure compared to a shoe upper made of a hard shell. Such types of shoe uppers made of textiles are known from sports shoes such as tennis or running shoes.

[0032] Filaments are typically applied as continuous filaments, at least intermittently, or entirely. Polymer compositions are typically applied to a molding carrier as continuous filaments to form textile segments. Depending on the product to be manufactured, polymer compositions may, alternatively or in addition, be applied as discontinuous filaments to form nonwoven textile segments. The resulting textile material then contains multiple continuous loops or coils consisting of single continuous filaments. Thus, such a textile material is not nonwoven. After a predetermined number of coils or loops have been applied, the application and the associated filaments may be interrupted and resumed at different locations on the molding carrier. In addition, the area to be covered or the length of the material layer may be predetermined. In some embodiments, the molding carrier, in particular a shoe mold, may include one or more depressions, in particular grooves or ridges. To produce discontinuous filaments, air outlet openings may be positioned around the outlet of at least one nozzle. By air blasting of pressurized air, the filaments can be divided into discontinuous segments along their flight path. In addition, discontinuous fibers can be generated by stopping the polymer extrusion or by abrupt movement of the nozzle.

[0033] For the manufacture of shoe uppers or even entire shoes, the molding carrier may be a shoe last, as described above. The shoe last may be manufactured in the first step based on a 3D model of the wearer's foot. For this purpose, the wearer's foot may be measured and a 3D model of the foot may be created based on that measurement. This allows for the manufacture of individual shoe uppers that fit the wearer's foot. In an alternative embodiment, the molding carrier may be a model of a textile product such as a bag or backpack. The molding carrier may also be a plate for manufacturing substantially two-dimensional textile products. The molding carrier may be heatable so that the manufactured textile material can be directly material-bonded, in particular welded, to another element.

[0034] Alternatively, welding may be performed by an external heat source, such as hot air or radiation. The molding carrier may be coolable to shorten cycle time by accelerating the demolding process. In some embodiments, at least a sub-region of the carrier may be heated after the molten polymer composition has been applied to the heatable molding carrier, and optionally after the applied polymer composition has cooled and cured, so that the insole or midsole can be directly welded to the upper of the shoe. The fabricated textile material is the upper of the shoe, which is bonded to the sole, or the upper of the shoe is directly bonded to the sole during application.

[0035] In some embodiments, the molding carrier, particularly the shoe last, may include one or more depressions, especially grooves or ridges. Thus, it may be possible to insert additional elements, such as textile material, foam material, cushioning material, metal, or plastic material, into the depressions before the molten polymer composition is applied to the molding carrier. Once the molten polymer composition is applied, a material bond is created between the polymer composition and the additional elements. For example, the molding carrier may be a shoe last with one or more depressions in the heel region. Shock-absorbing material may be distributed into these depressions, configuring the heel region of the shoe upper to absorb shock, or to form a heel cushion (also called "heel padding"). Alternatively, the additional elements may not be inserted into the depressions, but instead be completely filled with the polymer composition when the molten polymer composition is applied. This has the effect of reinforcing the textile material in a predetermined area of ​​the textile material.

[0036] In some embodiments, the polymer composition may have a second temperature that can be adjusted during coating, particularly in contact with the molding carrier. The second temperature is typically influenced, for example, by defining the length of the flight path between the outlet and the molding carrier after the filament has exited the nozzle, and / or by actively influencing the temperature, for example, by heating or cooling with hot or cold air or radiation. The second temperature may be selected so that the filament coated on the molding carrier does not bond at the intersections of the filament segments, or so that the filament coated on the molding carrier bonds at the intersections of the filament segments, particularly by fusion.

[0037] Unbonded filament segments are typically able to move relatively freely and independently relative to one another. In this way, desirable flexibility is achieved in the manufacture of textile materials. The bonding of loops of the polymer composition applied to the molding carrier can be created at any predetermined time and in predetermined areas. The greater the proportion of bonded intersections, the lower the flexibility or elasticity of the manufactured textile material, particularly in certain areas of a shoe upper, and therefore the greater the stability and strength of those areas. This may be particularly suitable in areas of textile material subjected to strong mechanical stress, such as the upper surface of the forefoot area of ​​a shoe upper, which is folded, compressed, and stretched during the rollover process.

[0038] In response to this, a lower proportion of intersecting material locations increases the flexibility and elasticity of the corresponding areas of the shoe upper, which is preferable, for example, in areas of the shoe that are strongly stretched during running for anatomical movement. In this regard, the second temperature may be selected to be a predetermined value lower than the melting temperature or melting temperature range so that material bonding of the filament segments does not occur. If material bonding is intended to occur, the second temperature is selected to be at least substantially equal to the melting temperature or melting temperature range of the polymer composition, or to be appropriately lower than the melting temperature. In some embodiments, the second temperature may be set by an airflow having a predetermined temperature that strikes the polymer composition. The airflow may be supplied from an air discharge device located in the region between the outlet of at least one nozzle and the molding carrier. Thus, for example, an air discharge device having an air nozzle from which an airflow is discharged in the direction of the filament at a predetermined temperature may be located along the filament, after the filament exits the outlet.

[0039] Further aspects of the present invention relate to textile materials, garments, and especially shoes, including shoe uppers, manufactured by methods according to any of the embodiments disclosed herein. Such garments, and especially shoe uppers, include a looped textile material, which may have a plurality of substantially regularly arranged coils. The plurality of coils, correspondingly loops, are preferably made from a single filament. The filament segments may intersect each other at intersecting locations. The filament segments may be material-bonded to each other at intersecting locations and / or not material-bonded to each other. The looped textile material preferably includes at least one intersecting location where filament segments, particularly filament segments of the same filament, are material-bonded. The coils, correspondingly loops, are preferably substantially circular or elliptical in shape. Shoe uppers manufactured according to one of the embodiments disclosed herein typically do not form a continuous surface, but instead are mesh-like, i.e., have a certain degree of porosity and permeability.

[0040] A further embodiment is an extrusion apparatus for carrying out a method according to one of the embodiments disclosed herein. The extrusion apparatus comprises a plasticizing unit and a metering head in fluid communication with a separate metering pump. The plasticizing unit typically comprises an extruder having a drum and a screw located within the drum. The extrusion apparatus further includes a separate metering pump in fluid communication with the metering head. The metering head has at least one nozzle having an outlet in fluid communication with the metering head. The extrusion apparatus may further comprise a molding carrier, preferably in the form of a shoe last for shoes, as described in more detail above. The extruder has the advantage that the polymer composition is directly and freshly melted in the amount required in each case and is not kept in a molten state indefinitely in a plasticizing unit such as a heatable tank. If the polymer composition is kept in a molten state for a long period of time, the polymer composition partially degrades, and the quality of the polymer is considerably reduced. Quality, in particular the stability of the filament, is very important in the manufacture of textile materials. The combination of the metering head and the extruder allows for the melting of only the amount of polymer composition required at that time, thereby avoiding degradation of the polymer composition and the associated loss of stability.

[0041] In this regard, the plasticizing unit may include a plurality, in particular three, consecutively arranged temperature zones. Each temperature zone may include a separately controllable heating element. In particular, for example, a polymer composition may pass through a first temperature zone, then a second temperature zone having a higher temperature than the first temperature zone, and then optionally a third temperature zone having a higher temperature than the first and second temperature zones, before exiting at least one nozzle. For example, the first temperature of the first temperature zone may be in the range of 180°C to 185°C, the second temperature of the second temperature zone may be in the range of 230°C to 235°C, and optionally the third temperature of the third temperature zone may be in the range of over 235°C to 240°C.

[0042] The metering pump is a separate pump from the extruder. While polymer compositions can be extruded from the outlet onto a molding carrier using only the extruder, precisely controlling the extrusion pressure is crucial for the production of textile materials having a mesh structure and containing a single filament across multiple mesh structures and coils, which is not possible to a sufficient degree with the extruder alone. Therefore, a separate pump helps to fine-tune the pressure at which the molten polymer composition is extruded. The metering pump is preferably a gear pump. The dispensing device may further include a motor for driving the metering pump. In a further embodiment, the dispensing device further includes an air dispensing device configured to impound an airflow at a predetermined temperature onto a helical filament after it has left the outlet of at least one nozzle to set a second temperature for the extruded polymer composition.

[0043] It should be understood that both the general description above and the detailed description below are intended to present embodiments and provide an overview or framework for understanding the nature and features of this disclosure. The accompanying drawings are included to provide further understanding and are incorporated herein and constitute part of this specification. The drawings illustrate various embodiments and, together with the description, illustrate the principles and operation of the disclosed concepts.

[0044] The disclosures described herein should not be considered to limit the disclosures described in the appended claims, which will be more fully understood from the detailed description and accompanying drawings provided herein below. The drawings are shown below. [Brief explanation of the drawing]

[0045] [Figure 1] This is a schematic front-up perspective view showing a first modified example of the discharge device. [Figure 2] Figure 1 is a schematic diagram of the textile material produced by the dispensing device shown. [Figure 3] This is a schematic front-up perspective view showing a first modified example of the quantitative dispensing head. [Figure 4] Figure 3 is a top view of the quantitative dispensing head. [Figure 5] This is a schematic front-up perspective view showing a second modified example of the quantitative dispensing head. [Figure 6] Figure 5 is a top view of the quantitative dispensing head. [Figure 7] This is a schematic front-up perspective view showing a third modified example of the quantitative dispensing head. [Figure 8] Figure 7 is a cross-sectional view of the quantitative dispensing head. [Figure 9] This is a schematic diagram of textile material produced by a quantitative feeding head, as shown in one of Figures 3 to 8. [Figure 10] This is a schematic front-up perspective view showing a second modification of a dispensing device having a rotating quantitative dispensing head. [Figure 11] Figure 10 is a rear perspective view schematically showing the discharge device at three different positions. [Figure 12] This is a schematic front-up perspective view showing a fourth modified example of a quantitative dispensing head having an eccentric drive device. [Figure 13] Figure 12 is a top view of the quantitative dispensing head. [Figure 14] These are schematic diagrams of textile materials produced by the quantitative feeding heads shown in Figures 10 and 11, or Figures 12 and 13. [Figure 15] This is a first side view schematically showing a fifth modified example of a quantitative feeding head having a swirling nozzle. [Figure 16] This is a second side view schematically showing a fifth modified example of a quantitative feeding head having a swirling nozzle. [Figure 17] Figures 15 and 16 show schematic diagrams of textile materials produced by the quantitative feeding head. [Modes for carrying out the invention]

[0046] Herein, certain embodiments are referred to in detail, examples of which are shown in the accompanying drawings, which illustrate some, though not all, of their features. In fact, the embodiments disclosed herein may be embodied in many different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided to satisfy the legal requirements to which this disclosure is applicable. Wherever possible, similar reference numbers are used to refer to similar components or parts.

[0047] Figure 1 shows a schematic front-up perspective view illustrating a first modification of the discharge device 13. The illustrated discharge device 13 comprises a plasticizing unit 3 and a metering head 5 in fluid communication with a separate metering pump 14. The plasticizing unit 3 typically comprises an extruder 15 having a drum 16 and a screw (not shown) located within the drum. The metering pump 14 is in fluid communication with the metering head 5. The metering head 5 has at least one nozzle 6 having an outlet 9 in fluid communication with the metering head 5. The illustrated metering head 5 is interconnected to a deposition unit by a metering head holder 17. The metering head holder 17 movably connects the metering head 5 to the deposition unit 4. The illustrated plasticizing unit 3 includes a plurality, in particular three, consecutively arranged temperature zones. Each temperature zone includes a separately controllable heating element.

[0048] The polymer composition passes through a first temperature zone, then a second temperature zone having a higher temperature than the first temperature zone, and then optionally a third temperature zone having a higher temperature than the first and second temperature zones. For example, the first temperature of the first temperature zone may be in the range of 180°C to 185°C, the second temperature of the second temperature zone may be in the range of 230°C to 235°C, and optionally the third temperature of the third temperature zone may be in the range of greater than 235°C to 240°C.

[0049] The metering pump 14 is a separate pump from the extruder 15. While the polymer composition can be extruded from the outlet 9 onto the molding carrier 2 using only the extruder 15, precisely controlling the extrusion pressure is important for the production of the textile material 1, which has a mesh structure and contains a single filament 7 across multiple mesh structures and loops 8, and this is not possible to a sufficient extent with the extruder 15 alone. Therefore, a separate pump helps to fine-tune the pressure at which the molten polymer composition is extruded. The metering pump 14 is preferably a gear pump. The dispensing device 13 may further include a motor for driving the metering pump 14.

[0050] Figure 2 shows a schematic diagram of the textile material 1 produced by the extrusion device 13 shown in Figure 1. Due to the filaments 7 exiting the outlet 9 which form a loop 8, the textile material 1 includes regular filament segments 7 that intersect with each other at the intersection 12 and form a circular coil. Depending on the second temperature setting, the filament segments 7 may or may not be material-bonded at the intersection 12.

[0051] Figure 3 shows a schematic front-up perspective view illustrating a first modification of the metering head 5. Figure 4 shows a top view of the metering head 5 according to Figure 3. The illustrated nozzle 6 is interconnected with the metering head 5, which is rotatably mounted about the distribution axis D. In the illustrated modification, the nozzle 6 is tiltable with respect to the distribution axis D by an angle α. This allows for an influence on the loop size. A larger angle results in a larger loop on the molding carrier 2, and a smaller angle results in a smaller loop. In some embodiments, the angle α between the distribution axis D and the outlet 9 and the discharge direction is 40° to 60°, preferably 50° to 60°, and particularly 55°.

[0052] As the nozzle 6 moves relative to the distribution axis D, the filament 7 exits the nozzle 6 and is accelerated along the flight path between the nozzle 6 and the forming carrier, caused by the relative movement of the nozzle 6. As the nozzle 6 rotates on a circular path around the distribution axis D, the resulting centrifugal force accelerates the filament 7 radially away from the circular path of the nozzle 6 and therefore away from the distribution axis D. At least one nozzle 6 may be dynamically rotated about an axis relative to the distribution axis D. In addition, the forming carrier can move along at least one degree of freedom about an axis. This movement allows for the creation of loops with more complex geometric shapes.

[0053] Figure 5 shows a schematic perspective view from the front and above illustrating a second modified version of the quantitative feeding head. Figure 6 shows a top view of the quantitative feeding head according to Figure 5. The illustrated nozzle 6 is interconnected with the quantitative feeding head 5 and is mounted on the quantitative feeding head so as to be rotatable about the distribution axis D. In the modified version shown in Figure 4, the quantitative feeding head itself rotates, but here only the nozzle 6 rotates around the distribution axis D. Due to the rotation, the filament 7 exits the outlet 9 and is accelerated radially.

[0054] Figure 7 shows a schematic front-up perspective view illustrating a third modification of the metering head 5, with the flow of molten material indicated by a dotted line. Figure 8 shows a cross-sectional view (AA) of the metering head according to Figure 7. In the illustrated modification, the second movement involves moving at least one nozzle 6 relative to the metering head 5. In the illustrated modification, the molten polymer composition exits at least one nozzle 6 through an outlet 9 in the form of a through-hole opening extending through the nozzle 6, thereby forming a filament 7. During dispensing, at least one nozzle 6 is moved relative to the distribution axis D by rotating around the distribution axis D. This rotation causes the filament 7 to form a loop. In the illustrated modification, the nozzle 6 is moved within a nozzle housing 18. The nozzle 6 is rotatably mounted within the nozzle housing 18, and the plasticized and pressurized polymer composition pushed into the nozzle housing 18 rotates the nozzle 6. The nozzle 6 extends along an outlet axis O aligned at an inclination angle α with respect to the distribution axis D.

[0055] Figure 9 shows a schematic diagram of textile material 1 produced by a quantitative feed head as shown in any of Figures 3 to 8. Due to the filaments 7 exiting the outlet that form loop 8, the textile material 1 contains regular filament segments 7 that intersect with each other at intersection 12 to form a circular coil. A second temperature setting may affect whether or not the filament segments 7 bond at intersection 12. Due to the circular motion of the nozzle and / or quantitative feed head, the resulting loop 8 is also substantially circular.

[0056] Figure 10 shows a schematic front-up perspective view illustrating a second modification of an extrusion device 13 having a swirling metering head 5 for dispensing a filament 7. The illustrated extrusion device 13 comprises a plasticizing unit 3 and a metering head 5 in fluid communication with a separate metering pump 14. The plasticizing unit 3 typically comprises an extruder 15 having a drum 16 and a screw (not shown) located within the drum. The metering pump 14 is in fluid communication with the metering head 5. The metering head 5 has at least one nozzle 6 having an outlet 9 in fluid communication with the metering head 5. The illustrated plasticizing unit 3 includes a plurality, in particular three, consecutively arranged temperature zones. Each temperature zone includes a separately controllable heating element. The illustrated deposition unit 4 comprises a metering head holder 17 to which the metering head 5 is connected, and the second movement includes moving the metering head 5 and at least one nozzle 6 together relative to the metering head holder 17. The quantitative feeding head 5 shown in the figure is rotatably mounted to allow the nozzle 6 to pivot relative to the distribution axis D and the molding carrier 2.

[0057] Figure 11 shows a schematic rear perspective view of the extrusion device 13 according to Figure 10, with the swirling nozzle 6 in three positions. Figure 9b shows the extrusion device 13 in a neutral position aligned with the distribution axis D. In Figures 9a and 9c, the nozzle is displaced to its limit point. During operation, the metering head 5 swirls between the two limit points. Due to the distance D between the outlet and the forming carrier 2 and the dynamic motion of the metering head 5, the filament is accelerated laterally. In addition, if the forming carrier 2 is moved perpendicular to the movement of the metering head 5, a winding loop is formed on the forming carrier.

[0058] Figure 12 shows a schematic front-up perspective view of a fourth modification of the quantitative dispensing head 5 having an eccentric drive device. Figure 13 shows a top view of the quantitative dispensing head 5 according to Figure 12. The illustrated dispensing device 13 comprises a quantitative dispensing head 5 that is in fluid communication with a plasticizing unit not shown in this modification. The quantitative dispensing head 5 has at least one nozzle 6 having an outlet 9 that is in fluid communication with the quantitative dispensing head 5. The illustrated quantitative dispensing head 5 is interconnected to a deposition unit by a quantitative dispensing head holder 17. The quantitative dispensing head holder 17 movably connects the quantitative dispensing head 5 to the deposition unit 4. The illustrated quantitative dispensing head 5 is connected to an eccentric body via an eccentric rod, which moves the quantitative dispensing head 5 laterally along the longitudinal axis L. The eccentric body converts the rotational motion of the motor into translational motion of the quantitative dispensing head 5. The eccentric body moves at least one nozzle in a reciprocating motion, thereby applying the filament 7 to the molding carrier 2.

[0059] Figure 14 shows a schematic diagram of the textile material 1 produced by the quantitative feed head 5 shown in Figures 10 and 11 or Figures 12 and 13. The illustrated textile material 1 includes regular filament segments 7 that intersect with each other at intersection positions 12, forming a regular pattern. Due to reciprocating motion and correspondingly revolving motion, the filaments form a snake pattern having a sinusoidal shape on the molding carrier 2.

[0060] Figures 15 and 16 show a first side view (Figure 15) and a second side view (Figure 16) schematicly illustrating a fifth modification of a quantitative feed head 5 having a swivel nozzle 6. The nozzle 6 is swivelable and rotatable via a ball joint 19. The swivel motion is achieved by an illustrated disc 20 attached to the nozzle 6 and projecting radially from the nozzle 6. The disc 20 is moved by illustrated actuating elements 21, 21', 21''. Each of the actuating elements 21, 21', 21'' is configured to engage with the disc 20 at different actuating points AP, AP', AP''. The actuating elements 21, 21', 21'' allow the movement of the nozzle 6, thereby approximating a circular path of the outlet 9. The actuating elements 21, 21', 21'', 21'''' and actuating points AP, AP', AP'' are positioned at a constant angular distance from each other with respect to the longitudinal axis L, resulting in a high degree of symmetry.

[0061] Figure 17 shows a schematic diagram of the textile material produced by the quantitative feed head 5 shown in Figures 15 and 16. Due to the filaments 7 exiting the outlet that form a loop 8, the textile material 1 contains regular filament segments 7 that intersect with each other at the intersection 12, forming a circular coil. Due to the circular motion of the nozzle and / or quantitative feed head, the resulting loop 8 is also substantially circular. This deformation has the advantage that the eccentricity of the outlet can be continuously and rapidly changed by the proper design and control of the quantitative feed head, resulting in loops 8 of various diameters. In addition, the dispensing is not necessarily circular and can take other shapes by the proper control of the quantitative feed head. The quantitative feed head can be kept stationary with respect to its longitudinal axis so that the material can be dispensed in a thin, linear fashion.

[0062] Rather, the words used herein are descriptive, not restrictive, and it should be understood that they can be modified in various ways without departing from the intent and scope of this disclosure. [Explanation of Symbols]

[0063] 1. Textile materials 2. Molding Carrier 3 Plasticizing Unit 4. Sedimentary Units 5. Quantitative dispensing head 6 nozzles 7 Filaments 8 loops 9. Outlet (Nozzle) 10 Eccentric Rod 11 Eccentric body 12 Intersection Position 13 Discharge device 14 Metering supply pump 15 Extruder 16 drums 17. Quantitative dispensing head holder 18 Nozzle Housing 19 Ball joint 20 discs 21 Operating elements AP operating point D distribution axis O Outlet axis L Longitudinal axis D Distance α nozzle angle

Claims

1. Textile material (1), in particular a method for manufacturing shoe uppers, a. A step of providing a molding carrier (2), particularly a shoe mold, b. A step of providing a plasticizing unit (3) for melting a polymer composition at a first temperature to provide a molten polymer composition, c. Providing a deposition unit (4) equipped with a quantitative supply head (5) having at least one nozzle (6), d. A step of applying the molten polymer composition onto the molding carrier (2) via the at least one nozzle (6) in the form of a filament (7) that forms a plurality of loops (8) on the molding carrier (2), Includes, During step d, the deposition unit (4) and / or the molding carrier (2) are moved relative to each other in a first movement such that the at least one nozzle (6) moves along a drive path extending onto the molding carrier (2). A method wherein, while forming each loop (8), the quantitative feeding head (5) and / or the at least one nozzle (6) and / or the forming carrier (2) are further moved in a second movement different from the first movement along a loop deposition path having a path length such that the length of each loop (8) formed on the carrier is greater than the path length of the deposition path.

2. The method according to claim 1, wherein the deposition path differs from the drive path, and in particular, the path length of the drive path along which the at least one nozzle (6) travels during the formation of each loop is shorter than the path length of the deposition path during the formation of each loop.

3. The method according to claim 1 or 2, wherein in the second movement, the at least one nozzle (6), and / or the quantitative dispensing head (5) and the at least one nozzle (6) are moved in a round, preferably circular or oval, and / or eccentric and / or pendulum motion.

4. The method according to any one of claims 1 to 3, wherein the second movement includes moving the at least one nozzle (6) relative to the quantitative supply head (5).

5. The method according to claim 4, wherein the molten polymer composition exits the at least one nozzle (6) through an exit (9) that forms the filament (7), and during the coating, the at least one nozzle (6) is moved with respect to a distribution axis (D), and in particular rotated around the distribution axis (D), such that the filament forms a loop (8).

6. The method according to claim 4 or 5, wherein the nozzle (6) is mounted and moved within the nozzle housing (18) so as to be rotatable in the axial direction, and is rotated by the plasticizing polymer composition flowing through the nozzle housing (18).

7. The method according to claim 6, wherein the nozzle (6) extends along an outlet axis (O) aligned at an angle (α) with respect to the distribution axis (D).

8. The method according to any one of claims 1 to 7, wherein the deposition unit (4) comprises a quantitative supply head holder (17) to which the quantitative supply head (5) is connected, and the second movement includes moving the quantitative supply head (5) and the at least one nozzle (6) together with respect to the quantitative supply head holder (17).

9. The method according to claim 8, wherein the molten polymer composition exits the at least one nozzle (6) through the outlet (9) that forms the filament (7), and the quantitative dispensing head (5) and the at least one nozzle (6) are moved together with respect to the quantitative dispensing head holder (17) about the distribution axis (D) so that the filament forms a loop (8) during dispensing.

10. The method according to claim 8 or 9, wherein at least one nozzle (6) is inclined by an angle (α) with respect to the quantitative supply head (5).

11. The method according to claim 8, wherein the quantitative supply head (5) is interconnected with an eccentric rod (10) interconnected with an eccentric body (11) to generate a lateral reciprocating motion along the longitudinal axis (L).

12. The method according to any one of claims 1 to 11, wherein during the coating, the molding carrier (2) is separated from the at least one nozzle (6) by a distance (D), and the shape of the formed loop (8) corresponds to the movement pattern of the at least one nozzle defined by the first movement and the second movement on an enlarged scale.

13. The method according to any one of claims 1 to 12, wherein the distance (D) between the at least one nozzle (6) and the molding carrier (2) is 20 mm to 110 mm, particularly 40 mm to 60 mm.

14. The method according to any one of claims 1 to 13, wherein the filament (7) has a filament thickness in the range of 0.01 mm to 0.3 mm, particularly 0.05 mm to 0.2 mm.

15. The method according to any one of claims 1 to 14, wherein the molding carrier (2) is moved relative to the quantitative supply head (5) and the at least one nozzle (6) at a speed of 1 m / min to 20 m / min, particularly 5 m / min to 15 m / min, or vice versa.

16. The method according to any one of claims 1 to 15, wherein the polymer composition is applied to the molding carrier (2) as continuous filaments (7) to form textile segments, and / or the polymer composition is applied as discontinuous filaments (7) to form nonwoven textile segments.

17. The method according to any one of claims 1 to 16, wherein the polymer composition has a second temperature that can be adjusted during coating, the second temperature being selected so that the filaments coated on the molding carrier (2) do not bond at the intersections (12) of the filament (7) segments, or the second temperature being selected so that the filaments coated on the molding carrier (2) bond particularly by fusion at the intersections (12) of the filament segments (7).

18. The method according to any one of claims 1 to 17, wherein the polymer composition comprises a thermoplastic polymer, particularly a polyamide, a polyether block amide, a polyurethane and / or a polyester or a combination thereof.

19. The method according to any one of claims 1 to 18, wherein the fabricated textile material is the upper of a shoe and is bonded to the sole, or the upper of the shoe is directly bonded to the sole during application.

20. The method according to any one of claims 1 to 19, wherein the movement of the metering supply head (5) having the molding carrier (2) and / or the at least one nozzle (6) is controlled by a control unit.

21. Textile material manufactured by the process described in any one of claims 1 to 20, clothing including shoe uppers, and especially shoes.

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