Articles comprising coated fibers and methods of making articles with coated fibers
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Solution Overview
Problem
Existing methods for manufacturing footwear components fail to provide a durable, elastomeric coating that effectively bonds to polymeric materials, particularly those used in flexible and cushioning elements like bladders, while also offering UV protection and water resistance.
Innovation Solution
A method involving a coating composition of uncrosslinked polymers that are crosslinked to form a matrix of crosslinked polymers, which is then bonded to polymeric materials, creating an elastomeric matrix that traps colorants and provides UV blocking and water-resistant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a coating is applied to polymeric materials in footwear components, then color and appearance are improved, but durability and bonding strength deteriorate
Solution Approach 1:
The patent uses a composite coating system consisting of multiple polymer layers with different functions: a first polymer layer for adhesion to the substrate, a second polymer layer for flexibility and elastomeric properties, and optionally a third polymer layer for additional functionality. This multi-layer composite structure resolves the contradiction by combining materials that individually provide color retention with materials that provide durable bonding and flexibility.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the coating polymers, including molecular weight, glass transition temperature, and crosslinking density, to optimize both color retention and bonding durability. By carefully controlling these parameters, the coating maintains aesthetic properties while achieving long-term durability on flexible footwear components.
2Strength
If a rigid coating is applied to flexible footwear components, then structural strength is improved, but flexibility and elastomeric properties deteriorate
Solution Approach 1:
The patent employs thin film coating structures that are inherently flexible and conform to the substrate's movement. The coating layers are designed with controlled thickness and elastomeric properties that allow the coating to flex with the footwear component without cracking or delaminating, thus maintaining both strength and flexibility.
Solution Approach 2:
The patent creates a dynamic coating system where the polymer chains can move and reconfigure in response to mechanical stress and environmental conditions. The elastomeric nature of the coating polymers allows them to dynamically adapt to the flexing and stretching of footwear components like bladders, maintaining structural integrity while preserving flexibility.
3Object-affected harmful factors
If a thick coating is applied to provide UV protection and water resistance, then protection functionality is improved, but coating complexity and processing difficulty deteriorate
Solution Approach 1:
The patent develops multi-functional polymer coatings that simultaneously provide UV protection, water resistance, adhesion, and flexibility within a single integrated system. The polymer molecules are designed with functional groups that confer multiple protective properties, eliminating the need for separate thick coating layers for each function and simplifying the overall coating process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a durable, aesthetically pleasing, and functional coating that maintains elastomeric properties over the life of the footwear, offering protection against UV degradation and water uptake, while adhering well to various polymeric materials including thermoset and thermoplastic polymers.
Implementation Method 1
a cured coating, where the cured coating has been crosslinked from a coating composition that comprises uncrosslinked polymers in a dispersion in a carrier
Implementation Method 2
The cured coating includes a colorant, and the matrix of crosslinked polymers has trapped the colorant
Implementation Method 3
bonding the crosslinked polymeric matrix to the polymeric material on the side of the article
Data Source
Figure 1~3
AI summary
The present disclosure is directed to a component of an upper of an article of footwear or a component of a sole structure of an article of footwear. The component comprises an article having a first side comprising a polymeric material, and a cured coating disposed on the polymeric material of the first side. The cured coating includes a plurality of pigment particles entrapped in a matrix of cross linked polymers. The polymeric material is elastomeric and the cured coating is elastomeric. The present disclosure is also directed to a method of making a coated article, wherein the article is a component of an upper of an article of footwear or a component of a sole structure of an article of footwear.