Textiles and articles and processes for making the same

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Solution Overview

Problem

Existing materials for articles such as apparel, footwear, and sporting equipment, like vulcanized rubber and crosslinked polyurethanes, require high temperatures and pressures for processing, making it difficult to integrate them seamlessly without damaging other components, and there is a need for materials that provide traction and abrasion resistance without these limitations.

Innovation Solution

Thermoplastic elastomers are incorporated into textiles as coated yarns, allowing for industrial-scale knitting or weaving and subsequent thermoforming to create abrasion-resistant or high-traction surfaces without damaging other components, and can bond securely with other materials without adhesives or stitching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vulcanized rubber is used to provide traction and abrasion resistance, then the article gains superior durability and grip, but the high temperatures and pressures required for vulcanization damage other components of the article

Engineering Contradiction:

Improvetraction and abrasion resistanceVSAvoiddamage to other components from high temperature and pressure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the processing parameters from high temperature/pressure vulcanization to low temperature thermoforming. The thermoplastic elastomer allows the textile to be formed at temperatures below 200°C, eliminating thermal damage to other article components while still achieving the desired shape and surface properties for traction and abrasion resistance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the chemical vulcanization process with a physical thermoforming process. Instead of using chemical crosslinking at high temperatures, the thermoplastic elastomer is heated to melt and form the textile structure, then cooled to set the shape, providing a mechanical/physical alternative that avoids harmful thermal effects on other components

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If crosslinked polyurethanes are used as durable covering layers, then the article gains protection and durability, but separate components must be affixed using adhesives or stitching, increasing manufacturing complexity

Engineering Contradiction:

Improvedurability and protectionVSAvoidmanufacturing complexity from separate components and adhesives

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the protective covering layer with the textile structure itself by incorporating thermoplastic elastomer-coated yarns directly into the knit or weave. This integration eliminates the need for separate affixing steps, adhesives, or stitching, reducing manufacturing complexity while maintaining durability and protection

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermoplastic elastomer-coated yarn serves multiple functions simultaneously: it provides structural integrity as a yarn component, delivers durability and protection as a covering layer, and enables thermoforming for shape definition. This multi-functionality eliminates the need for separate components and simplifies the overall construction

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 thermoplastic elastomer-coated yarns provide superior traction and abrasion resistance, reduce manufacturing steps, and improve recyclability, with the thermoformed networks exhibiting properties comparable to or exceeding those of traditional materials like kangaroo skin leather and synthetic leather.

Implementation Method 1

the first polymeric composition is a reflowed and re-solidified product of a coating on a yarn

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

thermoforming to create abrasion-resistant or high-traction surfaces

Methodology Applied

Scientific EffectThermal softening and re-solidification: Phase Change

Data Source

PatentUS11564443B2Textiles and articles and processes for making the same

Publication Date: 2023.01.31 NIKE INC

AI summary

Films, fibers, filaments, yarns and textiles including thermoplastic elastomeric compositions are described, as are methods of making the films, fibers, filaments, yarns and textiles. These films, fibers, filaments, yarns and textiles can be used to make articles of apparel, footwear, and sporting equipment. When thermoformed, the thermoplastic elastomeric compositions can impart abrasion resistance, traction, and other advantageous properties to the articles. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.