EMBROIDERED ARTICLE
20170327985 · 2017-11-16
Assignee
Inventors
Cpc classification
A43B23/0275
HUMAN NECESSITIES
D05C17/00
TEXTILES; PAPER
A43B23/0265
HUMAN NECESSITIES
International classification
D05C17/00
TEXTILES; PAPER
Abstract
In one aspect, an article may include a base layer and a first strand comprising a thermoplastic polymer material. The first strand may be embroidered with the base layer. The thermoplastic polymer material of the first strand may at least partially adhere to the base layer. In another aspect, the article may include a first embroidered area and a second embroidered area. The first embroidered area may have a first degree of a mechanical property, and the second embroidered area may have a second degree of the mechanical property. The first degree of the mechanical property may be different than the second degree of the mechanical property.
Claims
1. An article, the article comprising: a base layer; and a first strand comprising a thermoplastic polymer material, wherein the first strand is embroidered with the base layer, and wherein the thermoplastic polymer material of the first strand at least partially adheres to the base layer.
2. The article of claim 1, wherein the base layer includes a layer of knitted material.
3. The article of claim 1, wherein the first strand is embroidered with the base layer after forming the base layer.
4. The article of claim 1, wherein the base layer includes a textile layer and is at least partially formed of a yarn comprising a material other than the thermoplastic polymer material.
5. The article of claim 1, wherein the first strand comprises a core and a thermoplastic polymer sheath.
6. The article of claim 1, wherein the article comprises the first strand and a second strand embroidered with the base layer, and wherein the first strand comprises more of the thermoplastic polymer material per unit of length than the second strand.
7. The article of claim 1, wherein the article comprises the first strand and a second strand embroidered with the base layer, and wherein the first strand and the second strand overlap at least at one area of the base layer.
8. The article of claim 1, wherein at least two yarns of the base layer, and/or at least two portions of one yarn of the base layer, are adhered to one another by the thermoplastic polymer material.
9. The article of claim 7, wherein the base layer comprises a first yarn and a second yarn, and wherein the thermoplastic polymer material from the first strand adheres the first yarn to the second yarn.
10. The article of claim 1, wherein the article is an upper for an article of footwear.
11. The article of claim 1, wherein the article is an article of apparel.
12. The article of claim 1, wherein the first strand is embroidered with the base layer at a first embroidered area, wherein at least one of the first strand and a second strand are embroidered with the base layer at a second embroidered area, wherein the first embroidered area has a first degree of a mechanical property, and wherein the second embroidered area has a second degree of the mechanical property that is different than the first degree of the mechanical property.
13. The article of claim 11, wherein the first degree of the mechanical property is a first stretchability in a direction, and wherein the second degree of the mechanical property is a second stretchability being less than the first stretchability in the direction.
14. An article, the article comprising: a base layer; and a first strand embroidered with the base layer, wherein the first strand is embroidered with the base layer at a first embroidered area, wherein at least one of the first strand and a second strand are embroidered with the base layer at a second embroidered area, wherein the first embroidered area has a first degree of a mechanical property, and wherein the second embroidered area has a second degree of the mechanical property that is different than the first degree of the mechanical property.
15. The article of claim 13, wherein the first strand includes a thermoplastic polymer material.
16. The article of claim 14, wherein the first strand includes a core surrounded by a sheath having the thermoplastic polymer material.
17. The article of claim 14, wherein the first strand is substantially formed of the thermoplastic polymer material.
18. The article of claim 13, wherein the base layer includes at least one yarn, and wherein the at least one yarn includes a thermoplastic polymer material.
19. The article of claim 13, wherein a thermoplastic polymer material is applied to the base layer after the first strand is embroidered with the base layer.
20. A method comprising: forming a base layer with a knitting machine; embroidering a first strand with the base layer at a first area, wherein the first strand comprises a thermoplastic polymer material; and at least partially melting the thermoplastic polymer material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
DETAILED DESCRIPTION
[0028] Various aspects are described below with reference to the drawings in which like elements generally are identified by like numerals. The relationship and functioning of the various elements of the aspects may better be understood by reference to the following detailed description. However, aspects are not limited to those illustrated in the drawings or explicitly described below. It also should be understood that the drawings are not necessarily to scale, and in certain instances details may have been omitted that are not necessary for an understanding of aspects disclosed herein, such as conventional fabrication and assembly.
[0029] Certain aspects of the present disclosure relate to articles at least partially formed from textiles. One example of an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear, or the like). One example of an article is an upper configured for use in an article of footwear. An upper may be used in connection with any type of footwear. Illustrative, non-limiting examples of articles of footwear include a basketball shoe, a biking shoe, a cross-training shoe, a global football (soccer) shoe, an American football shoe, a bowling shoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennis shoe, a running shoe, and a walking shoe. The upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal.
[0030] Referring to
[0031] In some embodiments, the sole 110 includes a midsole (not shown) and an outsole. The article of footwear 100 may additionally comprise a throat 126 and an ankle opening 128, which may be surrounded by a collar 130 and may lead to a void 132. The void 132 of the article of footwear 100 may be configured to accommodate a foot of a person. The throat 126 is generally disposed in the mid-foot region 102 of the upper 120. The mid-foot region 102 is generally a section of the upper 120 located between the heel region 101 and a toe region 103.
[0032] In
[0033] As depicted in
[0034] The upper 120 or other article (e.g., an article of apparel) may have at least one embroidered area. For example, referring to
[0035] The embroidered strand may be embroidered with (e.g., into) the base layer 140 by an embroidery process. For example, in some embodiments, conventional embroidery machines (such as a single or multi-head embroidery machine as sold by Barudan America Inc. of Solon, Ohio) may form patterns or designs on the base layer 140 with the embroidered strand by stitching the embroidered element to and/or through the textile structure of the base layer 140 (e.g., through the use of satin-stitches, running-stitches, fill-stitches, or the like). Each stitch may utilize a lock-stitch or other structure to secure the embroidered strand to the base layer 140. In some embodiments, the embroidery process may take place substantially after the base layer 140 is formed (e.g., after the completion of a knitting process).
[0036]
[0037]
[0038] Accordingly, different embroidered areas may be configured with different properties (e.g., different mechanical properties, different degrees of a certain mechanical property, or different visual properties). To illustrate,
[0039] Embroidered areas may additionally or alternatively be configured to exhibit other selected properties, such as a desirable degree of stretchability, flexibility, durability, breathability, weight (as compared to a skin layer), permeability, water-resistance, water repellence, or any other property. Advantageously, the embroidered areas with certain properties may be selectively placed on an article (such as the article 220 of
[0040] The upper 120 may have any number of embroidered areas. Referring to
[0041] Additionally, the upper 120 may include the first embroidered area 142 which may be relatively durable, inelastic (i.e. having a low stretchability), and strong when compared to the second embroidered area 144, and may be located in locations that are prone to damage and/or wear, such as the area corresponding to the ends of the toes of a person wearing the article of footwear. For example, the depicted embodiment shows the first area 142 as including a hallux portion 160 which is configured to associate with the area of the upper 120 that covers the hallux (also known as the “big toe”) of a person, which is an area of an upper that may commonly wear out and/or become damaged. Other areas, such as the second embroidered area 144, may be embroidered to exhibit lesser degrees of the desirable properties of the first embroidered area 142 (and/or different properties) as needed or desired, which may be advantageous when optimizing the amount of certain materials in certain areas of an article (e.g., to control or prohibit excessive costs).
[0042] In some embodiments, at least one of the strands embroidered with the base layer 140 may be at least partially formed of at least one thermoplastic polymer (collectively “the thermoplastic polymer material”). Illustrative, non-limiting examples of thermoplastic polymers include polyurethanes, polyamides, polyolefins, and nylons. In contrast to thermoset polymeric materials (described below), thermoplastic polymers melt when heated and return to a solid state when cooled. More particularly, a thermoplastic polymer transitions from a solid state to a softened or liquid state when subjected to temperatures at or above its melting point, and then the thermoplastic polymer transitions from the softened or liquid state to a solid state when sufficiently cooled. The embroidered strands may have one or more thermoplastic polymers. To illustrate, substantially the entirety of the embroidered strands may be formed of the thermoplastic polymer material. In one non-limiting example, the embroidered strands may be a yarn with a core made of a polyester (and/or another thermoset material or thermoplastic polymer material with a relatively high melting point) a thermoplastic polymer sheath. The thermoplastic polymer material of the sheath may have a melting temperature less than the melting temperature or decomposition temperature of the polyester core. For example, the melting temperature of the thermoplastic polymer material may have a melting temperature of approximately 100° C. less than the melting temperature of the polyester core in some embodiments, though any other suitable difference in melting temperatures is contemplated. The melting temperature of the polyester core may be about 260° C., and the decomposition temperature may be about 350° C. or greater. The melting temperature of the thermoplastic polymer may be, for example, between about 80° C. and about 140° C., such as from about 100° C. to about 125° C. based on atmospheric pressure at sea level. The embroidered strands may specifically be a yarn marketed as a DREAM SIL thermoplastic polyurethane coated yarn manufactured by Sambu Fine Chemical Co., LTD.
[0043] In contrast, when the base layer is a textile layer, the yarns forming the base layer 140 may be substantially formed of a material that has a melting point (e.g., if it is a thermoplastic polymer material) and/or a decomposition point (e.g., if it is a thermoset material) that is higher than the melting point of the embroidered strands. Illustrative, non-limiting examples of materials that may form the yarns of the base layer 140 may include thermoset polymeric materials and natural fibers such as cotton, silk, and wool, or thermoplastic polymer materials with a relatively high melting point, such as a polyester. When subjected to moderate levels of heat (e.g., up to 200° C. or more), these materials tend to remain stable. Moreover, when subjected to elevated levels of heat, thermoset polymeric materials and natural fibers may burn or otherwise degrade or decompose, and thermoplastic polymer materials with a relatively high melting point (like polyester) may soften and/or melt. In some embodiments, the melting point or decomposition temperature of the yarns forming the base layer 140 is greater than about 140° C. based on one atmosphere pressure, such as more than 200° C. For example, if the yarns forming the base layer 140 include a polyester, they may have a melting point of about 250° C. and a boiling or decomposition point of about 350° C.
[0044] It is contemplated that the yarns forming the base layer 140 may include a thermoplastic polymer material along with strands embroidered therein and also when strands embroidered therein are not configured to at least partially melt during heat processing. It is also contemplated that neither the yarns forming the base layer 140 nor the strands embroidered therein include a thermoplastic polymer material for heat-processing, but rather the thermoplastic polymer material may be added (e.g., sprayed, printed, or the like). For simplicity, the embodiments described herein generally refer to the thermoplastic polymer material with a melting point for heat-processing with moderate levels of heat (e.g., below 200° C. in some embodiments) being included only with embroidered strands.
[0045] Incorporating a thermoplastic polymer material with an appropriate melting point into an embroidered strand is advantageous for achieving several properties that are desirable in certain environments. For example, the application of heat to melt at least a portion of an embroidered strand may cause the embroidered strand to adhere to the yarns forming the base layer 140 and/or to other embroidered strands. The thermoplastic polymer material may further permeate or otherwise move through the base layer 140 when melted to thereby adhered at least two yarns forming the base layer 140, and/or at least two portions of one yarn forming the base layer 140, to one another. Advantageously, this may create a structure that has desirable strength, rigidity, and stretchability. This may additionally or alternatively secure certain yarns of the base layer 140, certain embroidered strands, and/or certain other objects in a desired orientation. Further, the melted and hardened thermoplastic polymer material may be utilized to form waterproof or water-resistant areas within the article, or even airproof or air-resistant areas. The embroidered strands may additionally or alternatively be manipulated while melted to achieve various desirable aesthetic effects (e.g., to form visually-pleasing textures).
[0046]
[0047]
[0048] Advantageously, the first strand 352 may have desirable characteristics associated with the thermoplastic polymer material (e.g., the first strand 352 adheres to the yarns forming the textile layer 340) without sacrificing breathability, stretchability, and/or other mechanical property (which is construed to mean any functional property) or aesthetic properties associated with the textile layer 340. For example, specifically referring to breathability for purposes of illustration, the breathability of an area of an article having an embroidered area with an embroidered strand that has been at least partially softened with heat and then cooled into a hardened state may exhibit a greater breathability than an otherwise comparable area that instead uses a skin layer and/or a layer of printed film.
[0049] The second strand 354, on the other hand, is depicted as being fully formed of a thermoplastic polymer material. When heat is applied, the thermoplastic polymer material of the second strand 354 may fully melt and may permeate or otherwise move a relatively far distance from the original location of the second strand 354. In some embodiments, the thermoplastic polymer from the second strand 354 may be displaced after the application of heat by greater than 0.5 millimeters, by greater than 1 millimeter, by greater than 3 millimeters, or by 5 millimeters or more. This may be advantageous when it is desired to produce a relatively large area of fused material, for example in areas or environments where the yarns of the textile layer 340 are particularly prone to wear or damage (e.g., by snagging), where waterproof or water resistance is desired, etc.
[0050] Embroidered strands may be configured to have an optimal amount of thermoplastic polymer material to achieve particular characteristics by varying the size of the strands, by varying the size of a core and/or sheath (e.g., where the sheath has a lower melting point than a melting point or decomposition point of the core), of the strands and/or the thickness of the coating (i.e., the thermoplastic polymer sheath), by selecting the amount of heat applied during the heat-application step, by selecting the proximity of one embroidered strand to another, by selecting the type of thermoplastic polymer materials used, or the like (and a combination thereof).
[0051] All of the structures and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While this invention may be embodied in many different forms, several specific aspects of the invention are described in detail herein. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular aspects illustrated. In addition, unless expressly stated to the contrary, use of the term “a” is intended to include “at least one” or “one or more.” For example, “a yarn” is intended to include “at least one yarn” or “one or more yarns.”
[0052] Any ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.
[0053] Furthermore, the invention encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.