Textile component and method for its production

Abstract

Disclosed herein is a method for foaming a textile component (1), the method comprising: Providing a coated textile component (2), which comprises the textile component (1) comprising a textile material, wherein the textile component (1) is coated with a coating material (3) having a lower gas permeability than the textile material to provide a coated textile component (4); Infusing the coated textile component (4) with a physical blowing agent to provide an infused coated textile component (5); Foaming the infused coated textile component (5) and removing the coating material. Furthermore, products and intermediate products of the method are disclosed.

Description

[0001] P28940PC00

[0002] 1 / 20

[0003] Textile Component and Method for its Production

[0004] Field of disclosure

[0005] The present invention lies in the field of textile technology, in particular textiles for shoes, and relates to a method for foaming a textile component, an infused coated textile component and a foamed textile component.

[0006] Background, prior art

[0007] Textile components which are being used in the apparel industry are often exposed to different conditions and different body areas of the wearer. For this reason, there may be textiles with different properties or with additional support materials in different areas. For example, body areas known to cause a lot of friction (e.g. at the elbows, the medial part of the hallux, the heel, or the knees) may be reinforced either by choosing different textile materials (softer materials or materials with a higher abrasion resistance) or by providing support materials, such as foam paddings. Foam paddings are for example commonly used in shoe uppers to enhance wearing comfort. Typically, such paddings may be provided in the heel area of a shoe upper and / or the collar and / or the tongue of the upper. Additionally, insulation materials are commonly added in the same manner to textile components, e.g. insulation materials against low outside temperatures. Foam materials cannot only be used for cushioning, but also as insulation material.

[0008] An issue with additional support materials, such as paddings, is that manufacturing of the article becomes more laborious and cumbersome. For example, paddings are usually foamed materials which are inserted into pockets formed in the upper. The pockets can be formed by sewing, then the padding is inserted and optionally adhered to the textile component of the upper, before the pocket is completely closed (e.g. by gluing or sewing). Also, in cases in which different materials are employed, additional manufacturing steps are necessary. For example, reinforced patches may be mounted to specific areas of a textile component to alter its properties in these areas. It would be desirable to be able to changeP28940PC00

[0009] 2 / 20

[0010] textile properties in a less laborious manner. Furthermore, it would be desirable to provide cushioning textile components without having to rely on separate paddings and / or it would be desirable to decrease the weight of the textile component. In further advantageous embodiments, a textile component having a padding and / or insulation can be produced without relying on additional stitching or adhesives. A further disadvantage known in the field of shoe technology is the dissatisfying cushioning functionality of textile components.

[0011] Summary of disclosure

[0012] It is the general object of the present disclosure to advance the state of the art in the field of textile technology and particularly to overcome the disadvantages of the prior art fully or at least partially. In advantageous embodiments, a foamed textile component is provided, which is easier to produce, respectively a method for its production is provided. In other advantageous embodiments, a textile component and a method for its production are provided, which allows accessing textile components with different cushioning areas, in particular in a straightforward manner. In other embodiments, a foamed textile component and a method for its production are disclosed, which has an improved cushioning effect and wearing comfort.

[0013] The general object is achieved by the subject-matter of the independent claims. Further advantageous embodiments follow from the dependent claims and the overall disclosure.

[0014] A first aspect of the present disclosure relates to a method for foaming a textile component. A second aspect of the disclosure relates to an infused coated textile component, a third aspect to a foamed coated textile component and a fourth aspect of the disclosure relates to a foamed textile component.

[0015] The method for foaming a textile component may in some embodiments comprise the step of providing a coated textile component which comprises the textile component. The textile component may comprise, or be made from, a textile material. In some embodiments, the textile component may be coated with a coating material. The coating material may in someP28940PC00

[0016] 3 / 20

[0017] embodiments have a lower gas permeability than the textile material of the coated textile component. For example, the gas permeability refers to the property of the material of the coating material and / or the textile material. In some embodiments, the gas permeability of the coating material and the textile material is compared when the two materials appear in the same physical form and shape. For example, solid blocks of equal size, dimension and shape may be used to compare the gas permeability of the materials to which it is referred herein. Therefore, the difference in gas permeability refers typically to an inherent material property and may be independent of the shape, dimension or size in which the coating material and the textile material appear. Using a lower gas permeability has the advantage that the blowing agent is retained at least to a certain extent from rapidly leaving the textile component. Thereby, an improved foam can be achieved and even small diameter fibers and filaments may be sufficiently foamed. Furthermore, the coating material may avoid generating a skin on the surface of the foamed textile component. As the skilled person understands the term “skin” typically refers to an outer layer with a decreased, e.g. significantly decreased, porosity as compared to the inner core of the material.

[0018] In some embodiments, the coated textile component may by infused, e.g. impregnated, with a physical blowing agent. Thereby, an infused, e.g. impregnated, coated textile component may be provided. An infused coated textile component may contain the blowing agent. Infusing the coated textile component may for example comprise the impregnation of the coated textile component by the physical blowing agent. Typically, the physical blowing agent enters the coated textile component. Thus, the physical blowing agent may typically not only be present on the textile component’s surface, but also inside the textile component, in particular inside the textile material.

[0019] In some embodiments, the method may comprise the step of foaming the infused coated textile component. In some embodiments, the coating material may be removed from the textile component, in particular after foaming. In the latter case, the coating material may be removed to form the foamed textile component. Typically, after removal of the coating material, the foamed textile component is devoid of, respectively free of, coating material. Using a coating material as described has the advantages that individual fibers or filamentsP28940PC00

[0020] 4 / 20

[0021] of the textile do not melt together during foaming. Furthermore, the extent of foaming is controlled by the coating material and micropores or even nanopores may be formed.

[0022] As the skilled person understands, there are two types of blowing agents. Physical blowing agents are blowing agents, which can expand, respectively form a gas upon changing the physical conditions, such as pressure and / or temperature. While it may be possible that the physical blowing agent undergoes a change of aggregation state (e.g. supercritical to gaseous or liquid to gaseous), to effect foaming, there is typically no chemical transformation involved. Examples of physical blowing agents which may be used herein are CO2, N2, hydrocarbons, such as ethane, propane, butane, pentane, and halogenated hydrocarbons, preferably CO2 and N2, more preferably CO2. In contrast, chemical blowing agents are blowing agents, which release a gaseous component upon undergoing a chemical transformation. Examples include metal hydrides or azo compounds. The chemical transformation may for example be effected by the addition of reagents, heating or irradiation.

[0023] It is generally understood herein that the term “comprising” is interpreted as meaning that it includes those features following this term, but that it does not exclude the presence of other features, as long as they do not render the matter unworkable. On the other hand, if the wording "consist of" is used, then no further features are present apart from the ones following said wording.

[0024] Removing the coating material typically involves separating, e.g. physically separating, the coating material and the foamed textile component. In some embodiments, it may additionally or alternatively comprise isolating the foamed textile component.

[0025] In some embodiments, the coating material of the provided coated textile component at least partially or even fully encompasses the textile component. That is, in some embodiments, the coating layer may be considered a shell layer and the textile component may form a core. The core may in some embodiments be fully surrounded by the shell layer.P28940PC00

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[0027] In some embodiments, providing the coated textile component may comprise the steps of providing a textile component and coating the textile component with the coating material, e.g. to form a shell layer. In some embodiments, this may comprise forming the coating layer which at least partially or fully encompasses the textile component.

[0028] Coating the textile component with the coating material may comprise applying a solution of the coating material to the textile component. The solution may for example comprise the coating material being dissolved in a solvent. Furthermore, the step may comprise evaporating the solvent, e.g. by heating and / or reducing the pressure to form the coated textile component. In some embodiments, the textile component may be dipped and / or immersed into the solution of the coating material. It may also be possible that such a solution of the coating material is sprayed or splashed on the textile component. It may also be possible that a first layer of a solution of the coating material is provided on a surface and the textile component is arranged on top of this first layer. Thereafter, a second layer of the solution of the coating material is provided on top, i.e. on the other side, of the textile component.

[0029] In some embodiments, the coating material is selected such that it is soluble in a solvent. In particular embodiments, the coating material is selected such that it is soluble in a solvent at predefined conditions (such temperature and pressure), while the textile component is insoluble in this solvent at the same conditions. In some embodiments, the coating material and / or the solvent are selected such that the coating material is soluble in the solvent at 1 atm. and a temperature of 15 °C to 100 °C, in particular 15 °C to 80 °C, in particular 15 °C to 70 °C. In some embodiments, the coating material may be a dissolvable coating material.

[0030] In some embodiments, the coating material is water soluble and removing the coating material comprises to dissolve the coating material in water.

[0031] Removing the coating material may for example be performed after foaming the infused coated textile material. In some embodiments, removing the coating material may comprise dissolving the coating material in a solvent. For example, the foamed coated textileP28940PC00

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[0033] component (which may be formed by foaming the infused coated textile component) may be dipped and / or immersed in a solvent, such as a solvent being capable of dissolving the coating material. In particular, the solvent is further selected such that dissolving the coating material can be achieved, while the textile component and / or the textile material is not dissolved, in particular unaltered. In some embodiments, dissolving the coating material may be performed at 1 atm. and a temperature of 15 °C to 100 °C, in particular 15 °C to 80 °C, in particular 15 °C to 70 °C. In some embodiments, dissolving the coating material may be performed under ultrasonication and / or stirring.

[0034] The textile component may be any suitable textile component, such as a non-woven, a knit, a weave, or a single filament or a single yarn. In some embodiments, the textile component may comprise, or consist of, one or more of filaments or yarns. The textile material may typically be a thermoplastic material. In some embodiments, the textile material may be a polymer, such as a synthetic polymer. The textile material (and also the first and second textile material) may be selected from: polyester, for example polyethylene terephthalate (PET), polyurethane, polyamide, polyether block amide (PEBA), ethylene-vinyl acetate (EVA), polyolefin, such as polyethylene and polypropylene, and copolymers thereof.

[0035] In some embodiments, the physical blowing agent used for infusing the coated textile is in a supercritical state, or in a liquid state, or in a gaseous state.

[0036] In some embodiments, the provided textile component (i.e. non-coated) has an initial thickness. The foamed textile component may, after foaming and removing the coating material, have a thickness which is 105% to 250 %, in particular 120% to 250%, in particular 150% to 200%, of its initial thickness.

[0037] Infusing the coated textile component and / or its foaming may be performed in an autoclave. In some embodiments, infusing may be performed at a temperature being 15 °C below to 5 °C above the melting temperature, in particular 10 °C below to 5 °C above the melting temperature, in particular 5 °C below to 5 °C above the melting temperature, in particular 5 °C below to equal the melting temperature, of the textile material. In some embodiments,P28940PC00

[0038] 7 / 20

[0039] infusing may be performed at a temperature being 15 °C below to equal the melting temperature, in particular 10 °C below to equal the melting temperature, in particular 5 °C below to equal the melting temperature, of the textile material.

[0040] In some embodiments, infusion may be performed at a temperature below the melting temperature, such as up to 15 °C below the melting temperature, in particular up to 10 °C below the melting temperature, in particular up to 5 °C below the melting temperature, of the textile material. In some embodiments, infusion may be performed at a temperature below the melting temperature, such 2 °C to 15 °C below the melting temperature, in particular 2 °C to 10 °C below the melting temperature, in particular 2 °C to 5 °C below the melting temperature, of the textile material.

[0041] For example, infusing may be performed at a temperature of 130 °C to 170 °C, in particular 145 °C to 165 °C, in particular 145 °C to 160 °C, in particular 145 °C to 155°C, in particular 148 °C to 152 °C.

[0042] Typically, infusing may be performed for 20 to 180 min, in particular 20 to 120 min, in particular 25 min to 70 min, in particular 30 to 60 min. In some embodiments, the temperature at which infusing is performed and the duration of the infusion may be selected such that fusion and / or complete melting of the textile material is prevented.

[0043] In some embodiments, the coating material has a higher melting temperature than the textile material. In some embodiments, the infusing may be performed at a temperature below the melting temperature of the coating material.

[0044] In some embodiments, infusing may be performed at a pressure of 5 MPa to 50 MPa, in particular 10 MPa to 30 MPa. It may also be possible to perform infusing a pressure of 5 MPa to 15 MPa, in particular 8 to 12 MPa. For example, a non-woven PEBA sample with a melting temperature of 149 °C being infused at 150 °C at 10 MPa for 60 min, provided excellent results. In some embodiments, a lower pressure in the range of 5 MPa to 20 MP, in particular 8 MPa to 15 MPa, in particular 8 MPa to 12 MPa, may be used. Such a lowP28940PC00

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[0046] pressure helps to avoid the formation of a skin and may provide a foamed textile component which has pores, e.g. micropores and / or nanopores, on its surface. In other embodiments, a higher pressure may be used, such as more than 20 MPa or more than 25 MPa, e.g. 20 MPa to 50 MPa, in particular, 25 MP to 40 MPa, in particular 25 MPa to 35 MPa. Such a higher pressure may allow to form a skin, but optionally concomitantly allows to provide filaments which have pores, e.g. micropores being surrounded by the skin.

[0047] Foaming the infused coated textile component may be performed by pressure reduction. For example, the pressure may be continuously released or in a stepwise manner. In some embodiments, the pressure may be released at a rate of 20 to 100 MPa / s, in particular 20 to 50 MPa / s, in particular 20 to 40 MPa / s, to atmospheric pressure. In alternative embodiments, the pressure is instantaneously released to atmospheric pressure.

[0048] In some embodiments, the provided textile component and / or the provided coated textile component may comprise at least a first zone and a second zone. The first zone may, for example comprise, or consist of, a first textile material and the second zone may comprise, or consist of, a second textile material being different from the first textile material. For example, the second textile material may have different physical properties than the first textile material, such as one or more selected from: gas permeability, softening temperature, melting temperature and glass transition temperature. Using different textile materials allows to generate predefined zones with different properties after foaming. The different physical properties allow to perform the infusion and / or foaming step such that only one of the first and second textile material is infused with the physical blowing agent, respectively that one of the first and second textile material is infused to a greater degree with the physical blowing agent than the other. Thereby, foaming is more pronounced in the corresponding zone, because this zone is infused with more blowing agent than the other. In some embodiments, the first zone may be at a different location than the second zone. In particular, the first and second zone may or may not overlap.

[0049] For example, it may be possible that the first textile material has a lower softening temperature, lower glass transition temperature and / or lower melting temperature than theP28940PC00

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[0051] second textile material. Infusing may then be performed at a temperature which is equal or larger than the softening temperature and / or glass transition temperature of the first textile material, but lower than the softening temperature and / or glass transition temperature of the second textile material. Thereby, much more physical blowing agent enters the first textile material than the second textile material. In some embodiments infusing may be performed at a temperature which is higher or equal or lower than the melting temperature of the first textile material.

[0052] In some embodiments, infusing the coated textile component and / or foaming the infused coated textile component is performed such that the first textile material foams to a larger extent as the second textile material, in particular such that only the first textile material foams.

[0053] In some embodiments, the coating material is selected from a polyalkylene alcohol, such as polyvinyl alcohol or ethylene vinyl alcohol, and polylactic acid. Polyvinyl alcohol is particularly preferred as it is well water soluble and can therefore be removed rapidly and under smooth and sustainable conditions. In some embodiments, low molecular weight polyvinyl alcohol having a molecular weight of 13 to 23 kDa or medium molecular weight polyvinyl alcohol having a molecular weight of 31 to 51 kDa is used as coating material. Medium molecular weight polyvinyl alcohol is particularly preferred. Since it is less soluble (e.g. in water) than low molecular weight polyvinyl alcohol, the coating, respectively the coating layer, is more homogenous. High molecular weight polyvinyl alcohol with a molecular weight of 84 to 124 kDa can be used, but is less preferred, because the coated textile component has a higher tendency to break. Furthermore, using medium molecular weight polyvinyl alcohol helps to generate hollow fibers from filaments.

[0054] In some embodiments, the coated textile component and / or the provided textile component (i.e. before coating), may comprise a chemical blowing agent. This may in some embodiments be advantageous as the chemical blowing agent supports foaming by the physical blowing agent and improved foams may be achieved.P28940PC00

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[0056] In some embodiments, foaming the infused coated textile component may generate a foamed textile component. The foamed textile component may in particular comprise nanopores at its surface. As the skilled person understands, a nanopore is a pore which has a pore size of below 1000 nm, e.g. 1 nm to less than 1000 nm, in particular 100 nm to less than 1000 nm, more particular 500 nm to less than 1000 nm. The pore size is given by the largest distance of opposing walls of the corresponding pore. For example, if the pore is circular, it is equal to the diameter. Foams with such nanopores enable an increased surface area compared to materials without such nanopores. Thereby the material dries quicker when it gets wet, e.g. due to rain or sweat. In addition, a better thermal insulation is achieved and the haptic properties, in particular hand-feel are improved. The nanopores provide a softer feeling. An additional benefit is that nanopores show strong light-scattering in the nanopores and thus pigments for influencing the color of the foamed textile component may be avoided or at least their required amount be reduced. This is for example desirable for footwear applications such as in heel paddings of shoe uppers. In some embodiments, the foamed textile component may additionally or alternatively comprise micropores. As the skilled person understands, micropores have a pore size of 1000 nm to 1000 pm. For example, the micropores may have a pore size of 5 to 200 pm, in particular 5 to 100 pm, in particular 5 to 50 pm, in particular 10 to 40 pm, in particular 20 to 30 pm. Such micropores allow to generate a foamed textile with a very pronounced cushioning.

[0057] In some embodiments, the coated textile component comprises one or more filaments which consist of the textile material. In some embodiments, the textile component may consist of a single textile material.

[0058] The infused coated textile component may be coated with the coating material and it may be infused with the physical blowing agent. The coating material may be removable as disclosed herein above. This means that the coating material can be removed, in particular fully removed from the foamed textile component without destroying and / or altering the foamed textile component as such. For example, it may be soluble in a solvent at certain conditions, while the textile component is not soluble at these conditions. In some embodiments, the coating material may be water soluble. The infused coated textileP28940PC00

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[0060] component may be obtained by infusing the coated textile component with a physical blowing agent as described in some of the embodiments herein.

[0061] The foamed coated textile component may comprise a foamed textile component, such as a foamed textile component being produced and / or being obtainable after foaming and before removing the coating material in the method as described herein. The foamed coated textile component may be coated with a coating material, e.g. a removable coating material as described herein. While the foamed coated textile component may comprise the foamed textile component and the coating material, the foamed textile component is typically devoid of the coating material.

[0062] In some embodiments, the foamed textile component and / or the foamed coated textile component may form, respectively comprise, tubular foam structures. Such tubular foam structures may for example be formed by infusing and foaming filaments, such as filaments of a non-woven. Thus, in some embodiments, the textile component is a non-woven. It may also be possible that the tubular foam structures may be formed by infusing and foaming filaments and / or yarns of a woven or knitted textile component. The tubular foam structures may therefore form the filaments and / or yarns of the foamed textile component.

[0063] Tubular foam structures may have a foam wall which circumferentially encompasses, respectively delimits a void. The tubular foam structures may have one or two openings. In case of two openings, the openings may be arranged at opposite ends of the tubular foam structure. The foam wall may completely delimit and / or encompass the void (e.g. with the exception of the one or two openings). Such structures have the advantage that the density of the foamed textile component can be reduced, and superior cushioning functionality can be achieved. In some embodiments, the tubular foam structures have an outer thickness (including the foam wall) of 1 to 50 pm, in particular 5 to 30 pm, in particular 10 to 30 pm. In some embodiments, the tubular foam structure may have an inner opening of 5 to 20 pm, in particular 10 to 20 pm. The inner opening is the longest distance between opposing foam wall sections (and thus therefore not include the foam wall). If the inner opening is circular, it may refer to the diameter. It is understood that this also applies for step b. and / or c. of theP28940PC00

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[0065] claimed method. That is, foaming the infused coated textile component may be performed such that tubular foam structures form, respectively that a foamed textile component is formed which comprises tubular foam structures. The tubular foam structures may for example be tubular filaments of the foamed textile component, e.g. a foamed non-woven, or they may form tubular yarns, e.g. of a weave or knit.

[0066] In some embodiments, the foamed textile component comprises open pores at its surface, in particular at the surface of the individual filaments. These pores may for example be nanopores and / or micropores.

[0067] In some embodiments, the foamed textile component comprises filaments or yarns which each comprise a porous core being encompassed by a skin. The skin may for example have no pores or smaller pores than the porous core, such as at least 100x or at least 500x, or even at least 1000x, smaller pores.

[0068] Brief description of the figures

[0069] The herein described disclosure will be more fully understood from the detailed description given herein below and the accompanying figures which should not be considered limiting to the disclosure described in the appended claims. The figures are showing:

[0070] Fig. 1 a schematic representation of certain steps of the method according to an embodiment of the invention;

[0071] Fig. 2a microscopic images of a non-woven textile component being foamed without being coated with a coating material;

[0072] Fig. 2b microscopic images of a non-woven textile component being foamed when being coated with a coating material;P28940PC00

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[0074] Fig. 3 microscopic images of foamed textile components being made from a nonwoven textile component having been coated with a coating material, whereas foaming has been performed at different temperatures as indicated;

[0075] Fig. 4 microscopic images of foamed textile components being made from a woven textile component having been coated with a coating material, whereas foaming has been performed with (left) or without coating;

[0076] Fig. 5 microscopic images of foamed textile components being made from a woven textile component having been coated with a coating material, whereas foaming has been performed at different temperatures as indicated;

[0077] Fig. 6 microscopic images of foamed textile components being made from a woven textile component having been coated with a coating material, whereas foaming has been performed at different pressures;

[0078] Fig. 7 shows a comparison of a textile component which has not yet been foamed and a foamed textile component having been produced according to an embodiment of the disclosure.

[0079] Exemplary embodiments

[0080] Fig. 1 shows certain steps as they can be performed in some embodiments of the method according to the present disclosure, (a) A textile component 1 is dipped into a solution of coating material 3 in a suitable solvent, (b) Thereafter, the textile component can be dried to evaporate the solvent and to establish a solidified coating layer on the textile component which encompasses the textile component, (c) The thereby formed coated textile component 2 may then be transferred into autoclave 4 inside which it is infused with a physical blowing agent, such as CO2, to form an infused coated textile component 5. (d) Thereafter, the pressure is released inside autoclave 4 which triggers foaming, (e) To remove the coating material 3, the foamed coated textile component is immersed in aP28940PC00

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[0082] solvent in which the coating material is soluble. Thereby, the foamed textile component 6 is obtained.

[0083] Fig. 2a and b compare the influence of the coating material. In both cases a PEBA nonwoven textile component has been foamed under the same conditions (10 MPa pressure for infusing CO2 as physical blowing agent at a temperature of 150 °C). However, the textile component shown in Fig. 2a has been foamed as such, i.e. without having been coated with a coating material. In contrast, the textile component shown in Fig. 2b has first been coated with polyvinyl alcohol to form a coated textile component which has then been placed in an autoclave, infused and foamed, after which the polyvinyl alcohol has been removed. It can be seen that the coating material avoids fusion of the filaments. While Fig. 2a shows that the foamed product has a relatively continuous solid structure in which no filaments are visible anymore, Fig. 2b shows that the coating prevents fusion and results in individually foamed filaments 8. The filament structure remains intact and foamed textile component 6 can still be considered a non-woven. The enlarged view of Fig. 2b surprisingly shows that foamed tubular structures 10 form under these conditions. The highlighted tubular structure has an outer thickness T (in this case of 23 pm) and an inner opening O, the latter being delimited by the foamed wall of the tubular structure.

[0084] Fig. 3 shows microscopic images of a foamed textile component (PEBA, non-woven) having been obtained by infusing a medium molecular weight (MMw) polyvinyl alcohol coated textile component with CO2 at different temperatures and constant pressure of 10 MPa. It can be seen that the outer thickness (referred to as “diameter”) of tubular structures and the inner opening (referred to as “cavity”) slightly varies depending on the temperature employed.

[0085] Fig. 4 shows microscopic images of a foamed textile component (PEBA, monofilament forming a woven textile component) having been obtained by infusing a medium molecular weight (MMw) polyvinyl alcohol coated textile component with CO2 at a temperature of 161 °C and constant pressure of 10 MPa (left column 3 pictures and the enlarged view at the bottom). The 3 pictures in the right column show a similar sample, which has beenP28940PC00

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[0087] foamed without coating under such conditions. It can be seen that the coating material generates a porous foamed textile component which comprises micropores 11 both inside the filaments and on their surface. From the bottom enlarged view, it can further be seen that the surface of the foamed textile component, respectively the surface of its filaments contains nanopores 9.

[0088] Fig. 5 shows microscopic images of foamed woven textile components (PEBA, monofilament forming a woven textile component) which have been obtained by infusing a medium molecular weight (MMw) polyvinyl alcohol coated textile component with CO2 at 3 different temperatures and constant pressure of 10 MPa.

[0089] Fig. 6 shows microscopic images of foamed woven textile components (PEBA, monofilament forming a woven textile component) which have been obtained by infusing a medium molecular weight (MMw) polyvinyl alcohol coated textile component with CO2 at 161 °C and a pressure of 10 MPa (left) and 30 MPa (right). It can be seen that while lower pressure of about 10 MPa prevent the formation of a skin and thus leads to open pores on the filament and / or textile component surface, a higher pressure of about 30 MPa leads to a formation of a skin 12. Skin 12 is understood as a sudden and drastic increase of porosity. It can be seen from the enlarged section on the bottom right that pores are formed inside the filament to form a porous core, the porous core is encompassed by a skin which has no pores or at least pores with a smaller, e.g. at least 100x smaller pores. The presence or absence of a skin influences the cushioning properties and can, depending on the intended use, be desired or undesired. However, if one compares the 30 MPa with the non-coated textile component of Fig. 4 (right 3 columns), it becomes clear that even at this high pressure, micropores form inside the textile component, respectively its filaments. In contrast, the sample having been obtained without coating is devoid of such micropores.

[0090] Fig. 7 shows a comparison of a textile component which has not yet been foamed (left) and a foamed textile component (right) having been produced according to an embodiment of the disclosure.P28940PC00

[0091] 16 / 20 List of designations

[0092] 1 textile component

[0093] 2 coated textile component

[0094] 3 coating material

[0095] 4 autoclave

[0096] 5 infused coated textile component 6 foamed textile component

[0097] 7 solvent

[0098] 8 filament

[0099] 9 nanopore

[0100] 10 tubular foam structure

[0101] 11 micropore

[0102] 12 skin

[0103] O inner opening

[0104] T outer thickness

Claims

P28940PC0017 / 20Claims1. Method for foaming a textile component (1), the method comprising:a. Providing a coated textile component (2), which comprises the textile component (1) comprising a textile material, wherein the textile component (1) is coated with a coating material (3) having a lower gas permeability than the textile material to provide a coated textile component (4);b. Infusing the coated textile component (4) with a physical blowing agent to provide an infused coated textile component (5);c. Foaming the infused coated textile component (5) and removing the coating material.

2. The method according to claim 1, wherein the coating material (3) forms a coating layer which at least partially encompasses the textile component (1) of the coated textile component (2).

3. The method according to claims 1 or 2, wherein step a. comprises coating a provided textile component (1) with the coating material (3) having a lower gas permeability as the textile material to provide the coated textile component (2).

4. The method according to claim 3, wherein coating the textile component (2) with the coating material (3) comprises dipping the textile component (1) in a solution of the coating material (3).

5. The method according to any of the previous claims, wherein the coating material (3) is soluble in a solvent.P28940PC0018 / 206. The method according to claim 5, wherein removing the coating material (3) is achieved by dissolving the coating material (3) in a solvent (7).

7. The method according to any of the previous claims, wherein the physical blowing agent is during step c in a gaseous or supercritical state.

8. The method according to any of the previous claims, wherein the provided coated textile component (2) comprises at least a first zone comprising a first textile material and a second zone comprising a second textile material being different from the first textile material.

9. The method according to claim 8, wherein infusing the coated textile component (2) and / or foaming the infused coated textile component (5) is performed such that the first textile material foams to a larger extent than the second textile material, in particular such that only the first textile material foams.

10. The method according to any of the previous claims, wherein the coating material (3) is selected from: a polyalkylene alcohol, such as polyvinyl alcohol or ethylene vinyl alcohol and polylactic acid.

11. The method according to claim 10, wherein the coating material is polyvinyl alcohol having a molecular weight of 13 to 23 kDa or a molecular weight of 31 to 51 kDa.

12. The method according to any of the previous claims, wherein the provided coated textile component (4) comprises at least one chemical blowing agent.

13. The method according to any of the previous claims, wherein foaming the infused coated textile component (2) generates a foamed textile component (6) comprising nanopores at its surface.

14. The method according to any of the previous claims, wherein the coated textile component (4) comprises one or more filaments (8) consisting of the textile material.P28940PC0019 / 2015. An infused coated textile component (5) comprising a textile component (1) being coated with a removable coating material (3), wherein the textile component (1) is infused with a physical blowing agent.

16. The infused coated textile component (5) according to claim 15, wherein the removable coating material (3) at least partially encompasses the textile component (1).

17. A foamed coated textile component (6) comprising a foamed textile component being coated with a removable coating material (3).

18. A foamed textile component (6) being produced by the method according to any of claim 1 to 14.

19. The foamed textile component (6) according to claim 18, wherein the foamed textile component (6) comprises nanopores (9) at its surface.

20. The foamed textile component (6) according to claim 18 or 19, wherein the foamed textile component (6) comprises tubular foam structures (10), wherein optionally the tubular foam structures (10) form the tubular filaments or tubular yarns of the foamed textile component (6).

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