阅读说明：本技术 针织纺织品和其形成方法以及包含针织纺织品的服装物品如鞋类物品 (Knitted textile, method of forming the same, and articles of apparel, such as articles of footwear, incorporating the knitted textile ) 是由 约翰·S·麦吉尔伯特 威廉·C·麦克法兰德 于 2018-03-23 设计创作，主要内容包括：针织纺织品(2)具有与第二层(6)一体地形成的第一层(4),第一层(4)包括具有热塑性组合物的第一纱线(12),第二层(6)包括第二纱线(14),第一纱线(12)形成针织图案(16)的阵列,该针织图案(16)的阵列界定穿过第一层(4)到第二层(6)的空隙(8)。第一层(4)可以被热处理以形成膜(24)。第一层(4)的处理可以改变针织纺织品(2)的区域拉伸性质和方向拉伸性质。在处理之前和/或之后,针织纺织品(2)在第一轴线(32)和/或第二轴线(30)中的泊松比率可以大于或等于零。公开了并入针织纺织品(2)的服装物品,服装物品包括鞋类物品(26)和衣服；以及形成针织纺织品(2)和物品的方法。(A knitted textile (2) has a first layer (4) integrally formed with a second layer (6), the first layer (4) comprising first yarns (12) having a thermoplastic composition, the second layer (6) comprising second yarns (14), the first yarns (12) forming an array of knitting patterns (16), the array of knitting patterns (16) defining voids (8) through the first layer (4) to the second layer (6). The first layer (4) may be heat treated to form a film (24). Treatment of the first layer (4) can alter the regional and directional stretch properties of the knitted textile (2). The poisson's ratio of the knitted textile (2) in the first axis (32) and/or the second axis (30) may be greater than or equal to zero before and/or after treatment. An article of apparel incorporating a knitted textile (2) is disclosed, the article of apparel including an article of footwear (26) and a garment; and methods of forming knitted textiles (2) and articles.)

1. A knitted textile having a knitted structure, the knitted structure comprising:

a first layer of the knit structure, the first layer comprising first yarns comprising a first thermoplastic composition having a first melting temperature, the first yarns forming an array of knit patterns in the first layer, the array of knit patterns defining voids in the first layer;

a second layer of the knit structure on an opposite side of the knit textile from the first layer and integrally formed with the first layer, the second layer including a second yarn,

the first yarn and the second yarn form an interlocking knit stitch;

the void passing through the first layer and to the second layer, wherein a portion of the yarn of the second layer is exposed through the void in the first layer;

the second yarn is formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first melting temperature being lower than the lowest of the second melting temperature and the second decomposition temperature.

2. The knitted textile of claim 1, wherein the first melting temperature is at least 5 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

3. The knitted textile of claim 1 or 2, wherein at least 90% of the first yarns are formed from the thermoplastic composition.

4. The knitted textile of any of claims 1-3, wherein the thermoplastic composition is selected from the group consisting of: thermoplastic polyurethanes, polyamides, polyesters, polypropylenes, and polyolefins.

5. The knitted textile of any of claims 1-4, wherein heating the textile above the first melting temperature and below the second melting temperature causes at least partial melting of the first yarns.

6. The knitted textile of any of claims 1-5, wherein the knitted textile comprises a first axis and a second axis, the first axis being perpendicular to the second axis, wherein an area of the void increases to expose more of the second layer when tension in the first axis and/or the second axis is applied to the knitted structure.

7. The knitted textile of any of claims 1-6, wherein the array of knitting patterns is continuous and interconnected in the first layer.

8. The knitted textile of any of claims 1-7, wherein the knitted structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

9. The knitted textile of claim 8, wherein the poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis, the second axis, or both.

10. The knitted textile of claim 9, wherein the poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

11. A knitted textile having a knitted structure, the knitted structure comprising:

a first layer of the knit structure, the first layer including a first yarn comprising a first thermoplastic composition,

the first layer having a first surface comprising a film comprising the first yarns in remelted form, the film forming an array of fused patterns on the first surface, the array of fused patterns defining voids in the first surface,

a second layer of the knitted structure on an opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn formed from a second composition;

the first and second yarns form interlocking knit stitches in the second layer and/or in the first layer beneath the film;

the void passes through the first layer and to the second layer, wherein a portion of the yarn of the second layer is exposed through the void in the first layer.

12. The knitted textile of claim 10, wherein the first thermoplastic composition has a first melting temperature and the second composition has a second melting temperature or a second decomposition temperature or both, the first melting temperature being lower than the lowest of the second melting temperature and the second decomposition temperature.

13. The knitted textile of claim 12, wherein the first melting temperature is at least 5 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

14. The knitted textile of any of claims 11-13, wherein at least 90% of the first yarns are formed from the thermoplastic composition.

15. The knitted textile of any of claims 11-14, wherein when tension in the first or second axis is applied to the knitted structure, the area of the void increases to expose more of the second layer.

16. The knitted textile of any of claims 11-15, wherein the array of fused patterns is discontinuous in the first layer.

17. The knitted textile of any of claims 11-16, wherein the knitted structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

18. The knitted textile of claim 17, wherein the poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis, the second axis, or both.

19. The knitted textile of claim 18, wherein the poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

20. An article of apparel comprising the knitted textile of any of claims 1-19.

21. The article of apparel recited in claim 20, wherein the article of apparel is an article of clothing or footwear.

22. The article of apparel recited in claim 21, wherein the article of apparel is an article of footwear.

23. Sports equipment comprising the knitted textile of any one of claims 1-19.

24. An article of footwear including an upper and a sole structure, the upper including a knit textile having a knit structure, the knit structure comprising:

a first layer of the knit structure, the first layer including a first yarn, the first yarn including a first thermoplastic composition,

the first layer having a first surface comprising a film comprising the first yarns in remelted form, the film forming an array of fused patterns on the first surface, the array of fused patterns defining voids in the first surface,

a second layer of the knitted structure on an opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn formed from a second composition;

the first and second yarns form interlocking knit stitches in the second layer and/or in the first layer beneath the film;

the void passes through the first layer and to the second layer, wherein a portion of the yarn of the second layer is exposed through the void in the first layer.

25. The article of footwear recited in claim 24, wherein the knit structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

26. The article of footwear of claim 25, wherein the first axis is oriented on the article of footwear from a medial side to a lateral side, and the second axis is oriented on the article of footwear from a toe to a heel.

27. The article of footwear of claim 25, wherein a poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis, the second axis, or both.

28. The article of footwear of claim 27, wherein a poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

29. The article of footwear of any of claims 24-28, wherein the first layer is disposed on an exterior surface of the article of footwear.

30. A method of forming a knitted textile, the method comprising:

a knitted textile structure, the knitted textile structure comprising:

a first layer comprising first yarns comprising a first thermoplastic composition having a first melting temperature, and

a second layer on an opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn and the second yarn forming an interlocking knit stitch, and

forming an array of knitting patterns with the first yarn in the first layer, the array of knitting patterns defining voids in the first layer that pass through the first layer and to the second layer, wherein a portion of the yarn of the second layer is exposed through the voids in the first layer.

31. The method of claim 30, wherein the first melting temperature is lower than the lowest of the second melting temperature and the second decomposition temperature.

32. The method of claim 31, wherein the first melting temperature is at least 5 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

33. The method of any of claims 30-32, further comprising heating the first layer to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition.

34. The method of claim 33, wherein the melted first thermoplastic composition forms a film on the first layer.

35. The method of any of claims 30-34, wherein the knit structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

36. The method of claim 35, wherein the poisson's ratio of the knitted structure is greater than or equal to zero when measured in the first axis, the second axis, or both.

37. The method of claim 36, wherein the poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

38. A method of manufacturing a knitted textile, the method comprising:

providing a knit structure comprising:

a first layer comprising first yarns comprising a first thermoplastic composition having a first melting temperature, and

a second layer on an opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn and the second yarn forming interlocking knit stitches,

the first layer comprising an array of knitting patterns formed by the first yarns defining voids in the first layer that pass through the first layer and to the second layer, wherein a portion of the yarns of the second layer are exposed through the voids in the first layer,

the first melting temperature is lower than the lowest temperature of the second melting temperature and the second decomposition temperature; and

heating the first layer to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition.

39. The method of claim 38, wherein the melted first thermoplastic composition forms a film on the first layer.

40. The method of claim 38 or 39, wherein the first melting temperature is at least 5 degrees Celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

41. The method of claim 38 or 39, wherein the knit structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

42. The method of claim 41, wherein the poisson's ratio of the knitted structure is greater than or equal to zero when measured in the first axis, the second axis, or both.

43. The method of claim 42, wherein the poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

44. The method of claim 43, further comprising incorporating the knitted textile into an article of apparel.

45. The method of claim 38 or 39, further comprising incorporating the knit textile into an upper for an article of footwear.

46. The method of claim 38, further comprising attaching the upper to an outsole to form an article of footwear.

47. The method of claim 44, wherein the article of apparel is an article of footwear.

48. The method of claim 47, wherein the article of apparel is a garment.

49. A method of manufacturing an article of footwear, the method comprising:

providing a knit structure comprising:

a first layer comprising first yarns comprising a first thermoplastic composition having a first melting temperature, and

a second layer on an opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn and the second yarn forming interlocking knit stitches,

the first layer comprising an array of knitting patterns formed by the first yarns defining voids in the first layer that pass through the first layer and to the second layer, wherein a portion of the yarns of the second layer are exposed through the voids in the first layer,

the first melting temperature is lower than the lowest temperature of the second melting temperature and the second decomposition temperature;

forming the knit structure into an upper;

heating a portion of the first layer to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition and form a film on the first layer; and

attaching the upper to an outsole to form an article of footwear.

50. The method of claim 49, wherein the first melting temperature is at least 5 degrees Celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

51. The method according to claim 49 or 50, wherein the knitted structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

52. The article of footwear of claim 51, wherein the first axis is oriented on the article of footwear from a medial side to a lateral side, and the second axis is oriented on the article of footwear from a toe to a heel.

53. The article of footwear of claim 51, wherein a Poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis, the second axis, or both.

54. The article of footwear of claim 53, wherein a Poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

55. The article of footwear of any of claims 49, 50, 52, 53, and 54, wherein the first layer is disposed on an exterior surface of the article of footwear.

56. A method of forming an article of footwear, the method comprising:

providing a knit structure comprising:

a first layer comprising first yarns comprising a first thermoplastic composition, the first layer having a first surface comprising a film comprising the first yarns in remelted form, the film forming an array of fused patterns on the first surface, the array of fused patterns defining voids in the first surface,

a second layer on an opposite side of the knitted structure from the first layer and integrally formed with the first layer, the second layer including a second yarn formed from a second composition;

the first and second yarns form an interlocking knit stitch in the second layer and/or in the first layer beneath the film, the void passing through the first layer and to the second layer, wherein a portion of the yarns of the second layer are exposed through the void in the first layer;

forming the knit structure into an upper; and

attaching the upper to an outsole to form an article of footwear.

57. The method according to claim 56, wherein the knit structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

58. The article of footwear according to claim 57, wherein the first axis is oriented on the article of footwear from a medial side to a lateral side, and the second axis is oriented on the article of footwear from a toe to a heel.

59. The article of footwear of claim 57, wherein the Poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis, the second axis, or both.

60. The article of footwear of claim 57, wherein a Poisson's ratio of the knitted textile is greater than or equal to zero when measured in the first axis and in the second axis.

61. The article of footwear of any of claims 59-60, wherein the first layer is disposed on an exterior surface of the article of footwear.

Technical Field

The present disclosure relates to textiles, in particular knitted textiles (knit textile) having two or more integrally formed knitted layers, a first layer comprising yarns comprising a first thermoplastic composition and a second layer comprising yarns having a second composition; and articles of apparel (apparel) and athletic equipment (sport equipment) incorporating the knitted textile. Methods of making knitted textiles, articles of apparel, and athletic equipment are also disclosed.

Description of the related Art

Modern textile manufacturing and materials make it possible to produce textiles with improved fit and comfort. Significant improvements in knitting techniques, such as those disclosed in WO2014/081680, allow for the formation of a single integrally formed knitted textile having different properties in different regions of the knitted textile while reducing material waste. Using this technique, it is possible to reduce the number of material elements required to manufacture textiles and articles of apparel incorporating such textiles, while also reducing labor costs and manufacturing time.

The use of yarns having different material compositions also allows for different regional behaviors in the integrally formed knitted textile. For example, a knitted textile may have multiple layers, each incorporating a different yarn construction and knitting type. Thus, these properties can be exploited to introduce variations in the behavior of the finished product.

Many articles of apparel are designed to fit closely to the body. In view of the diversity of body types and shapes, it is challenging to design a garment that takes into account regional contour (regional contour) and interspecies differences. In addition, certain areas of the article of footwear, such as the toe and heel areas, require increased wear resistance, while other areas, such as the waist area of a shirt or the tongue area of the article of footwear, require increased flexibility. The "one size fits all" strategy may allow many users to experience excessive tightening and discomfort in certain areas and excessive wear or slack in other areas. Similarly, while a material such as cotton may be comfortable against the skin, it may not be suitable for abrasion resistance and tends to retain too much moisture, which makes it undesirable in many applications.

It would be desirable to provide improved integrally formed knit textiles and articles of apparel with specifically tailored regional and directional properties (zonal and directional properties) that allow for enhanced stretch properties, for example, in desired regions and directions, and improved wear resistance or comfort in other regions, while reducing cost and material waste.

Brief summary

In one aspect, a knitted textile having a knitted structure including a first layer having a first yarn having a first thermoplastic composition and a second layer opposite and integrally formed with the first layer, the second layer including a second yarn formed from a second composition is disclosed.

In some embodiments, the first yarn forms an array of knitting patterns in the first layer, the array of knitting patterns defining voids in the first layer; the second layer has a second yarn, and the void passes through the first layer and to the second layer.

In some embodiments, the first layer has a first surface comprising a film comprising first yarns in remelted form (refluwedform), the film forming an array of fused patterns (fused patterns) on the first surface, the array of fused patterns defining voids in the first surface, the voids passing through the first layer and reaching the second layer.

In one aspect, an article of footwear having an upper with a knit textile having a knit structure and a sole structure is disclosed.

In some embodiments, a knit structure has a first layer including first yarns having a first thermoplastic composition, the first layer having a first surface including a film, the film including the first yarns in remelted form, the film forming an array of fused patterns on the first surface, the array of fused patterns defining voids in the first surface, a second layer opposite the first layer and formed integrally with the first layer, the second layer having second yarns formed from a second composition; the void passes through the first layer and reaches the second layer.

In one aspect, a method of forming a knitted textile is disclosed.

In some embodiments, the method includes knitting a knit structure having a first layer with a first yarn having a first thermoplastic composition having a first melting temperature and a second layer opposite and integrally formed with the first layer, the second layer including a second yarn formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn and the second yarn forming an interlocking knit stitch; and forming an array of knitting patterns in the first layer having the first yarn, the array of knitting patterns defining voids in the first layer, the voids passing through the first layer to the second layer, wherein a portion of the yarn of the second layer is exposed through the voids in the first layer.

In one aspect, a method of manufacturing a knitted textile is disclosed.

In some embodiments, the method includes providing a knit structure having a first layer having a first yarn having a first thermoplastic composition and a second layer opposite and integrally formed with the first layer having a second yarn having a second composition, the first layer comprising an array of knit patterns formed from the first yarn, the array of knit patterns defining voids in the first layer, the voids passing through the first layer and reaching the second layer, wherein a portion of the yarns of the second layer are exposed through the voids in the first layer; and heating the first layer to at least partially melt the first thermoplastic composition.

In some embodiments, the first thermoplastic composition has a first melting temperature and the second composition has a second melting temperature or a second decomposition temperature or both.

In an embodiment, the first melting temperature is at least 5 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature. In an embodiment, the first melting temperature is at least 10 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature. In an embodiment, the first melting temperature is at least 15 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature. In an embodiment, the first melting temperature is at least 20 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

In certain embodiments, the method further comprises heating the first layer to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition.

In one aspect, a method of manufacturing an article of footwear is disclosed.

In some embodiments, the method includes providing a knit structure having a first layer including a first yarn including a first thermoplastic composition having a first melting temperature and a second layer on an opposite side of the knit textile from the first layer and integrally formed with the first layer. The second layer includes a second yarn formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn and the second yarn forming an interlocking knit stitch. The first layer includes an array of knit patterns formed from the first yarn, the array of knit patterns defining voids in the first layer. The void passes through the first layer and to the second layer, wherein a portion of the yarns of the second layer are exposed through the void in the first layer. The first melting temperature is lower than the lowest temperature of the second melting temperature and the second decomposition temperature. The method also includes forming the knitted structure into an upper, heating a portion of the first layer to a temperature above the first melting temperature and below a lowest temperature of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition and form a film on the first layer. The method also includes attaching the upper to an outsole to form an article of footwear.

In an embodiment, the first melting temperature is at least 5 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature. In an embodiment, the first melting temperature is at least 10 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature. In an embodiment, the first melting temperature is at least 15 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature. In an embodiment, the first melting temperature is at least 20 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

In some embodiments, the method includes providing a knit structure having a first layer and a second layer, the first layer including first yarns, the first yarns including a first thermoplastic composition, the first layer having a first surface including a film, the film including the first yarns in remelted form, the film forming an array of fused patterns on the first surface, the array of fused patterns defining voids in the first surface, the second layer being located on an opposite side of the knit structure from the first layer and integrally formed with the first layer, the second layer including second yarns formed from a second composition; the first and second yarns form interlocking knit stitches in the second layer and/or in the first layer beneath the film, the voids passing through the first layer and reaching the second layer, wherein a portion of the yarns of the second layer are exposed through the voids in the first layer; forming the knit structure into an upper; and attaching the upper to the outsole to form an article of footwear.

In some embodiments, the first layer is disposed on an exterior surface of the article of footwear.

Brief description of several views of the drawings

The following drawings are provided to illustrate various embodiments of the present disclosure and are not intended to limit the scope of the invention. The components in the drawings are not necessarily to scale.

Fig. 1A, 1B, and 1C illustrate various knitting patterns used in embodiments of the knitted textiles herein.

Fig. 2A illustrates an unstretched knitted textile according to certain embodiments herein.

Fig. 2B illustrates a stretched knitted textile according to certain embodiments herein.

Fig. 3 illustrates a perspective view of a medial side of an article of footwear incorporating a knitted textile upper.

Fig. 4 illustrates a perspective view of a lateral side of an article of footwear incorporating a knitted textile upper.

Fig. 5 is an exemplary knitted textile showing a cut pattern/direction pattern for tensile and strain testing at various orientations according to certain embodiments herein.

Fig. 6 illustrates a schematic diagram illustrating stress and strain testing of a knitted textile according to certain embodiments herein.

Fig. 6A illustrates the steps of obtaining a textile sample for testing.

Fig. 6B illustrates the step of cutting and positioning one or more textile samples for tensile and strain testing.

Fig. 6C illustrates the step of evaluating the load versus axial displacement of the textile sample.

Fig. 6D illustrates an equation for determining Poisson's ratio for various textile samples.

Figure 6E illustrates the step of plotting the load versus axial displacement data for the textile sample.

Fig. 6F illustrates the step of determining the poisson's ratio for various textile samples.

Fig. 6G illustrates a textile sample in an unstretched state, with no strain and no displacement.

Detailed Description

Described herein is a textile 2 having a first layer 4 and a second layer 6 integrally formed with the first layer 2, wherein voids 8 are in the first layer 4 to the second layer 6, the textile providing unique tensile properties, particularly in certain orientations. Articles of apparel and athletic equipment incorporating such textiles are also described.

Headings are provided for the convenience of the reader only and should not be construed to limit the scope of the disclosure or the appended claims.

The term "textile" or "textile component" as used herein includes knitted, woven and non-woven fabrics or cloths. Although reference is frequently made herein to "knitted textiles," "knitted uppers," and the like, it should be understood that other textiles may also be employed in certain embodiments.

The term "article of apparel" as used herein refers to any article of footwear or clothing that is configured to be worn on a person. Thus, examples of articles of apparel include shoes, boots, helmets, hat (hat), cap (cap), shirts, pants, shorts, and sleeves, as well as many other products configured to be worn on a person.

The term "athletic equipment" as used herein refers to any article that is primarily used for performing athletic activities and may be formed using textile manufacturing processes similar to or the same as those used for articles of apparel as provided herein. Examples of athletic equipment suitable for particular embodiments include knee pads, soccer balls, baseball balls, elbow pads, backpacks, luggage, dudous (cinchpack), and belts.

In one aspect, a knitted textile 2 having a knitted structure 10 is disclosed.

In an embodiment, the knitted structure 10 includes a first layer 4 including a first yarn 12 and a second layer 6 including a second yarn 14, the first layer 4 being integrally formed with the second layer 6.

As used herein, the term "integrally formed" means that the first and second layers 4, 6 of the textile are formed as part of a substantially continuous mechanical process (i.e., as a one-piece element), rather than the first and second layers 4, 6 being formed as separate structures that are subsequently attached to one another (e.g., by subsequent sewing, bonding, adhering, etc.). The integrally formed textile may be formed as a one-piece element without requiring a large number of additional manufacturing steps or processes. Among other advantages, the process benefits from reduced material waste associated with forming separate knit structures and subsequently attaching them.

In a preferred embodiment, the integrally formed textile is an integrally formed knitted textile 2. Any knitting process known in the art may be used, including flat knitting (flat knitting), circular knitting (circular knitting), and the like. Thus, in some embodiments, first layer 4 and second layer 6 of knitted textile 2 are integrally formed using interlocking knit stitches that include first yarn 12 and second yarn 14. This does not exclude other and further components being integrally formed with the first layer 4 and/or the second layer 6 and/or being attached to the first layer 4 and/or the second layer 6. Similarly, additional yarns may be present in some embodiments of knitted textile 2.

The terms "preferred" and "preferably" refer herein to embodiments of the invention that may provide certain benefits under certain circumstances. However, other embodiments may be preferred, under the same or different circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure.

In some embodiments, the second layer 6 is on the opposite side of the first layer 4. In some embodiments, additional (third, fourth, etc.) layers are present between the first layer 4 and the second layer 6 or adjacent to the first layer 4 and/or the second layer 6. One or more additional layers may be integrally formed with the first layer 4 and/or the second layer 6, such as by using interlocking knit stitches, or one or more additional layers may be subsequently attached to the first layer 4 and/or the second layer 6, such as by subsequently using stitching, adhesives, or other bonding methods.

Because it should be understood that first layer 4 and second layer 6 will have a length (x), a width (y), and a depth (z), various features of first layer 4 or second layer 6 may be characterized by any combination of these dimensions. In some embodiments, the first layer 4 has a first surface 34. As used herein, the term "first surface" means an imaginary flat surface positioned parallel to, for example, the z-axis of the first layer 4 and lying substantially along the outermost boundary of the first layer 4. For example, the first surface 34 of the first layer 4 of the knitted textile 2 may refer to an imaginary plane that lies on the outermost boundaries of the first yarns 12 of the first layer 4. Conversely, the expression "in the first layer" or "in the second layer" may refer to an area within the first layer 4 or the second layer 6 of the knitted textile, the first layer 4 or the second layer 6 including the first yarn 12 or the second yarn 14, respectively.

In the embodiments herein, the first layer 4 is substantially discontinuous. As used herein, when referring to a layer of knitted textile 2, the term "discontinuous" refers to the presence of a significant area in which the yarn is not present in a given layer of the textile (i.e., greater than the area between adjacent stitches of a typical knitted material), or at least in which the yarn is not present in a significant area on first surface 34 of the textile. These regions define voids, for example, in the first layer 4. In the embodiments herein, the voids 8 act as openings or windows to the underlying second layer 6.

In an embodiment, an array of knit patterns 16 is used in the knit textile 2 disclosed herein. Illustrative examples of some of these knit patterns 16 are shown in fig. 1A, 1B, and 1C, including: a rectangular pattern with voids 8 having a slit-like shape (fig. 1A), a bow-tie pattern with voids 8 having a concave shape (fig. 1B), and a polygonal pattern with voids 8 having a generally hexagonal shape (fig. 1C). Various amorphous configurations (amophorusconstruction) are also possible. The term "concave" as used herein refers to a structure having an interior angle greater than 180 degrees. The "bow tie" pattern in FIG. 1B illustrates a concave shape.

The term "array" means that there are a plurality of repeating knit patterns that are particularly visible in the first layer 4 of the knit textile 2. In a preferred embodiment, the array of knit patterns 16 is formed primarily from the first yarns 12 in the first layer 4. Knitted textile 2 in fig. 1A, 1B, and 1C shows different arrays of knit patterns 16, each array illustrating a unique structure and potentially unique directional properties.

In each of the embodiments of fig. 1A, 1B and 1C, the array of knit patterns 16 is continuous and interconnected in the first layer 4. As used herein, when referring to an array of knit patterns, the term "continuous" refers to a knit textile 2 in which adjacent knit patterns 16 are joined in the first layer 4. Thus, in some embodiments, the array of knit patterns 16 is continuous and interconnected in the first layer 4.

In some embodiments, the array of knit patterns 16 is discontinuous in the first layer 4 and is not interconnected. As used herein, the term "discontinuous" when referring to an array of knit patterns refers to a knit textile 2 in which adjacent knit patterns are discrete in the first layer 4, at least as viewed on the first surface 34 of the first layer 4. Thus, the discontinuous array of knit patterns will appear to be non-interconnected in the first layer 4. There may be no physical continuity between adjacent patterns in the first layer 4 or on the first surface 34, even though there may in fact be a continuous course of yarn across the second or further layers that physically connect adjacent knit patterns 16 of the knit textile 2.

The discontinuous array of knit patterns 16 can impart unique properties in both untreated (e.g., unheated) and treated (e.g., heated) knit textiles 2 as compared to knit textiles in which the array of knit patterns is substantially continuous.

Without wishing to be bound by any particular theory, the structure of the array of knit patterns 16 (and the array of fused patterns after melting) may generally be responsible for the unique tensile properties, anisotropic behavior, and poisson's ratio of the disclosed knit textile 2. As seen in fig. 1A, 1B, and 1C, the various arrays of knit pattern 16 have a direction-specific geometry. For example, the bow tie configuration in the intermediate image of fig. 1B includes a plurality of horizontal rows of connected knit patterns offset from adjacent rows (above and below). The stretch properties of knitted textile 2 in one axis (i.e., direction or orientation) may differ from the stretch properties in a second axis due to these unusual geometries in first layer 4. Moreover, the unique properties of the disclosed knit textile 2, apparel item, and athletic equipment may be due in part to the interaction of two or more layers of the knit textile 2, unusual material compositions, and subsequent processing steps (e.g., heating and remelting).

In some embodiments, as shown in fig. 5, for example, knitted textile 2 has a first axis 18 and a second axis 20, first axis 18 being perpendicular to second axis 20. As used herein, the first axis 18 and the second axis 20 are understood to describe different imaginary reference lines on which forces, such as tensile forces, may be applied to the disclosed textile, article of apparel, and/or athletic equipment. The orientation of the disclosed textile, article of apparel, and/or athletic equipment may also be changed with respect to the applied tensile force to assume different axes. In some embodiments, the first axis 18 and the second axis 20 are perpendicular to each other. In some embodiments, the first axis 18 is offset from the second axis 20 by about 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, or 90 degrees as measured from a minimum interaxial angle (i.e., angle). In particular embodiments, the first axis 18 is substantially parallel (0 degrees) to the knit or fused pattern 16 in the knit textile 2 and the second axis 20 is substantially perpendicular (90 degrees) to the knit or fused pattern 16 in the knit textile 2, as generally shown in fig. 5.

It is to be understood that, where a range is disclosed herein, the disclosure covers all values up to and including the explicitly disclosed values, as well as all values between those explicitly disclosed values. For example, the disclosed range of 20.0mm to 30.0mm includes 20.0mm, 30.0mm, and all values therebetween.

In certain embodiments, when tension in first axis 18 and/or second axis 20 is applied to knitted structure 10, the area of void 8 in knitted textile 2 increases to expose more of second layer 6. This effect is illustrated in the unstretched state (fig. 2A) and the stretched state (fig. 2B). In the figure, the first layer 4 has been heat treated to form a film 24 on the first surface 34 (fig. 2A). The voids 8 may appear to have different visual properties, such as different colors or hues (shades). In one example, this may be a lighter color or other contrasting color or texture (texture) due to the presence of the second yarn 14 of the underlying second layer 6. The first yarns 12 form a substantially continuous knit/fuse pattern 16 on the first surface 34 of the first layer 4, which knit/fuse pattern 16 is defined by the perimeter of the knit pattern 16 defining the void 8 in this example. It should be appreciated that the knit pattern 16 in the knit textile 2 becomes a fused pattern 16 after heat treatment.

In some embodiments, the voids 8 are about four ranks wide.

In embodiments, the first yarns 12 comprise a thermoplastic composition. As used herein, a "thermoplastic composition" is a composition that softens or melts when heated at a relatively low temperature and returns to a solid state when cooled. More particularly, the thermoplastic composition (a) transforms from a solid state to a softened state when heated to the softening temperature of the thermoplastic composition, and (b) transforms from a solid state to a substantially liquid state when heated to the melting temperature of the thermoplastic composition. When sufficiently cooled, the thermoplastic composition transitions from a softened or liquid state back to a solid state. Thus, the thermoplastic composition can be softened or melted, molded, cooled, re-softened or re-melted, re-molded, and re-cooled through multiple cycles. The thermoplastic composition may also be welded, fused or heat bonded to other materials when heated to at least the softening temperature. As used herein, the term "remelt" may refer to a yarn and/or thermoplastic composition that has been heated above its melting point, which is sufficient to allow the thermoplastic composition to melt and flow before potentially returning to a solid state. Various constructions of knitted textile 2, yarns with thermoplastic compositions and thermal bonding are described in US2013/0255103, the contents of which are incorporated by reference in their entirety.

Examples of suitable thermoplastic compositions include thermoplastic polyurethanes, polyamides, polyesters, polypropylenes, and polyolefins. Many, but not all, thermoplastic compositions are polymeric materials.

The first yarns 12 may be partially or entirely formed of a thermoplastic composition. In certain embodiments, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 99%, or all (100%) of the first yarns 12 are comprised of the thermoplastic composition. Advantages of forming the first yarns 12 substantially entirely of a thermoplastic composition are uniform properties, the ability to easily form thermal bonds, efficient manufacturing, elastomeric stretch, and relatively high stability or tensile strength.

While the first yarn 12 may comprise any of these thermoplastic compositions, the use of thermoplastic polyurethane imparts various advantages. For example, various compositions of thermoplastic polyurethanes are elastomeric and stretch over one hundred percent of their resting length while exhibiting relatively high stability or tensile strength. Thermoplastic polyurethanes are susceptible to forming thermal bonds with other components, as compared to some other thermoplastic polymer materials.

Thus, in some embodiments, the thermoplastic composition comprises at least one thermoplastic polyurethane. In certain embodiments, the first yarns 12 may be formed primarily (at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 99%) or entirely (100%) of thermoplastic polyurethane.

Although a single thermoplastic composition may be used, the first yarns 12 may also be formed from multiple thermoplastic compositions. As an example, the filaments of the first yarn 12 may have a sheath-core construction, wherein the outer sheath of a single filament is formed from the first thermoplastic composition and the inner core of a single filament is formed from the second thermoplastic composition. Conversely, the outer sheath of the individual filaments may be formed from a first thermoplastic composition and the inner core of the individual filaments may be formed from a second non-thermoplastic composition.

As a similar example, the individual filaments of the first yarn 12 may have a bicomponent configuration, wherein one half (or portion) of the individual filaments are formed from the first thermoplastic composition and the opposite half (or another portion) of the individual filaments are formed from the second thermoplastic composition. Conversely, one half (or portion) of a single filament may be formed from a first thermoplastic composition and the opposite half (or another portion) of the single filament may be formed from a second non-thermoplastic composition.

Various other configurations, yarn types, and knitting methods of knit pattern 16 may be used to form knitted textile 2, including those discussed in WO2014/081680, which is incorporated by reference in its entirety.

In some embodiments, the yarn comprising the thermoplastic composition is treated (e.g., by heat) to melt the thermoplastic composition, forming a film 24 comprising the yarn in remelted form. The film 24 comprising such remelted yarns may be non-filamentous, at least in the layer or region where the melting of the yarns comprising the thermoplastic composition is complete. In addition to forming film 24, the remelted yarns may be thermally bonded with other portions of knitted textile 2, such as non-remelted areas of first layer 4, second layer 6, or other components associated with knitted textile 2. For example, the thermal bond may be formed from yarns comprising a thermoplastic composition (in non-filamentous form) that penetrates into portions of the second layer 6.

In embodiments, the second yarn 14 comprises a second composition. The second composition may be a higher melting point composition relative to the first (thermoplastic) composition. For example, the second composition may be a thermosetting composition. The thermosetting composition may not melt upon heating, but rather degrade or decompose. Representative examples of the second composition include cotton, wool, elastic fiber, and nylon.

In embodiments, the first melting temperature is substantially lower than the second melting temperature or the second decomposition temperature. This ensures that the treatment (e.g., heat treatment) of the first yarns 12 comprising the first thermoplastic composition also does not cause melting or decomposition of the second yarns 14 comprising the second composition. In certain embodiments, the first melting temperature is at least 5 degrees celsius, at least 10 degrees celsius, at least 15 degrees celsius, or at least 20 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

In some embodiments, the second composition comprises a thermoset that decomposes rather than melts when it is heated. Thus, in certain embodiments, the first melting temperature is at least 5 degrees celsius, at least 10 degrees celsius, at least 15 degrees celsius, or at least 20 degrees celsius lower than the second decomposition temperature.

In some embodiments, the second composition comprises a thermoplastic material that melts when it is heated, rather than (or at a temperature below) decomposing. Thus, in certain embodiments, the first melting temperature is at least 5 degrees celsius, at least 10 degrees celsius, at least 15 degrees celsius, or at least 20 degrees celsius lower than the second melting temperature.

Various methods may also be used to reduce the effect of exposing the second yarns 14 to the heat-treated first yarns 12, including screening, masking, applying a chemical (e.g., water or oil) to one or the other of the yarns, and the like.

Untreated knitted textile

In certain embodiments, a knitted textile 2 having a first layer 4 and a second layer 6 has unique directional stretch properties (directional stretch properties) without further processing, the first layer 4 having an array of knit patterns 16 defining voids 8 in the first layer 4, the voids 8 extending to the second layer 6. In certain of these embodiments, the disclosed knitted textile 2 has different properties, such as modulus of elasticity and poisson's ratio, when measured in the first axis 18 (or orientation) than when measured in the second axis 20. Accordingly, the disclosed knitted textile 2 may have anisotropic properties.

As used herein, the term "anisotropic" refers to a material (e.g., a textile) that has physical properties of different values when measured in different directions. A common example is wood, which is stronger along the grain (grain) than across the grain. Conversely, the term "isotropic" refers to a material (e.g., a textile) having physical properties that have the same or similar values when measured in different directions. As used herein, the term "elastic modulus" may be used interchangeably with the terms "young's modulus" or "tensile modulus" and is generally the ratio of stress (force per unit area) along an axis relative to strain (proportional deformation) along that same axis.

The anisotropic properties are particularly useful when the disclosed knit textile 2 is incorporated into an article of apparel, such as an article of footwear or an article of clothing. In such cases, such anisotropic properties may impart a tailored stiffness to the article, with particular regions and stress directions stiffer than other regions and directions. Accordingly, articles of apparel incorporating knitted textile 2 exhibit enhanced and dynamic fit, zone support, better conformance, and user comfort.

Fig. 3 and 4 illustrate two perspective views of an article of footwear 26 incorporating a knit textile upper 28 according to certain embodiments herein. Fig. 3 illustrates a perspective view of the medial side of the article of footwear 26, while fig. 4 illustrates the lateral side. The knitted textile 2 shown in fig. 3 and 4 has a stitch-like knit pattern 16 formed by the first layer 4, the first layer 4 defining the void 8 to expose the underlying second layer 6.

Thus, in a particular embodiment, a knitted textile 2 having a knitted structure 10 is disclosed, the knitted structure 10 comprising: a first layer 4 of the knitted construction 10, the first layer 4 comprising a first yarn 12, the first yarn 12 comprising a first thermoplastic composition having a first melting temperature, the first yarn 12 forming an array of knit patterns 16 in the first layer 4, the array of knit patterns 16 defining voids 8 in the first layer 4; a second layer 6 of knitted construction 10, the second layer 6 being located on an opposite side of knitted textile 2 from the first layer 4 and being integrally formed with the first layer 4, the second layer 6 comprising a second yarn 14, the first yarn 12 and the second yarn 14 forming an interlocking knit stitch; a void 8, the void 8 passing through the first layer 4 and to the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the void 8 in the first layer 4; the second yarns 14 are formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first melting temperature being lower than the lowest of the second melting temperature and the second decomposition temperature.

Treated knitted textile

In embodiments, the treatment of knitted textile 2 facilitates melting/remelting of the first thermoplastic composition. In a preferred embodiment, this treatment is accomplished by applying heat to the first layer 4. Various methods of applying heat to textiles are known in the art, including hot pressing.

In some embodiments, the properties of knitted textile 2 change as a result of the heat treatment of first layer 4. For example, the heat treatment to form a film in the first layer 4 may protect the second layer 6 from abrasion, while the heat treated first layer 4 may provide improved water resistance.

In a particular embodiment, the first layer 4 of the knit textile 2 has a first surface 34 that includes the film 24, the film 24 including the first yarns 12 in remelted form, the film 24 forming an array of fused patterns 16 on the first surface 34, the array of fused patterns 16 defining voids 8 in the first surface 34.

As used herein, the term "remelted" means that the yarn and/or composition (e.g., thermoplastic composition) is present in a non-filamentous form. For example, the remelted yarn and/or composition may be heated such that individual filaments of the yarn and/or composition at least partially melt or fuse, and the individual filaments lose their filamentous character. Other methods of forming the remelted composition may be envisioned by those skilled in the art.

Because second layer 6 of knitted textile 2 may be integrally formed with first layer 4, at least some of second yarns 14 may be present in first layer 4, or even on the first/outer surface of first layer 4. When the first layer 4 is heat treated, some or all of the first yarns 12 having the thermoplastic composition may melt and remelt, while the second yarns 14 present in the first layer 4 do not melt. When tension is applied in one or more axes, these unmelted second yarns 14 may pull apart to separate adjacent remelted portions of the first layer 4, exposing a larger area of the void 8 to the second layer 6. The voids 8 also allow breathability and fabric stretch. Furthermore, voids 8 may be directed downward to direct water in specific areas, as shown by the generally downward sloping orientation of more than one void 8 extending from the ankle opening toward the forefoot structure and/or sole structure 22 as seen in fig. 2A and 2B.

In certain embodiments, the heat treatment significantly increases the stiffness of the knitted textile 2 in the first axis 18, but has a negligible effect on the stiffness in the second, different axis. In particular embodiments, heat treatment of the first layer 4 of the knitted textile 2 results in an increase in the modulus of elasticity in the first axis 18, the second axis 20, or both of at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 100%. In embodiments, knitted textile 2 is therefore anisotropic after treatment.

In other embodiments, the textile is isotropic.

In some embodiments, the textile is anisotropic in one region (i.e., zone) and isotropic in another region.

In certain embodiments, the heat treatment significantly increases the poisson's ratio of knitted textile 2 in first axis 18, but has a negligible effect on poisson's ratio in a second, different axis. Poisson's Ratio (PR) is the ratio of transverse strain to axial strain. Most materials expand perpendicular to the direction of compression and contract perpendicular to the direction of extension. For example, when a rubber band is stretched, it becomes significantly thinner in a direction perpendicular to the stretching direction. Stable, isotropic, linear elastic materials have a poisson's ratio between-1.0 and 0.5, but most materials have a poisson's ratio between 0.0 and 0.5 (i.e., zero or positive poisson's ratio). An incompressible material that deforms elastically at small strains has a poisson's ratio of exactly 0.5. The rubber has a poisson's ratio of almost 0.5. Steel and rigid polymer (before yielding) have a PR of about 0.3. The cork's PR is close to 0, indicating little lateral expansion upon compression.

According to certain embodiments, knitted textile 2 after heat treatment may have a measured poisson's ratio in first axis 18 close to zero, but a significantly higher (more positive) poisson's ratio in the same axis after heat treatment of first layer 4. After heat treating the first layer 4, the same knitted textile 2 may also become substantially stiffer in at least the first axis 18. Thus, in particular embodiments, heat treatment of the first layer 4 of the knitted textile 2 causes the poisson's ratio in the first axis 18, the second axis 20, or both to change (increase or decrease) by at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 100%.

Thus, in a particular embodiment, a knitted textile 2 having a knitted structure 10 is disclosed, the knitted structure 10 comprising: a first layer 4 of the knit structure 10, the first layer 4 including first yarns 12, the first yarns 12 including a first thermoplastic composition, the first layer 4 having a first surface 34 including a film 24, the film 24 including the first yarns 12 in remelted form, the film 24 forming an array of fused patterns 16 on the first surface 34, the array of fused patterns 16 defining voids 8 in the first surface 34; a second layer 6 of knitted construction 10, second layer 6 being located on an opposite side of knitted textile 2 from first layer 4 and being integrally formed with first layer 4, second layer 6 comprising a second yarn 14 formed from a second composition; the first yarn 12 and the second yarn 14 form interlocking knit stitches in the second layer 6 and/or in the first layer 4 underlying the film 24; voids 8, the voids 8 passing through the first layer 4 and reaching the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4.

In the embodiments herein, knitted textile 2 has no auxetic property (auxetic property) before or after heat treatment. Conversely, in some embodiments, knitted textile 2 may have auxetic properties in at least first axis 18 before and/or after heat treating first layer 4. In certain embodiments, knit textile 2 and/or an article of apparel 26 incorporating knit textile 2 have auxetic properties before and/or after heat treatment.

As used herein, the term "auxetic" generally means a material having a negative poisson's ratio. In some cases, the material will contract in the transverse direction when compressed (or will expand in the transverse direction when stretched), resulting in a negative poisson's ratio. When stretched, the auxetic material thus becomes thicker perpendicular to the applied force. This typically occurs due to the way the internal structure of the auxetic material deforms when the sample is loaded uniaxially.

The auxetic behavior may be useful in areas where curtain-like fit (drape-like fit) is desired, but not pleated or folded at irregular contours. Auxetic materials may be particularly suitable for areas of an article of apparel where conforming to irregular shapes is desired.

In this manner, the particular knit pattern 16, the different yarns and compositions, and the use of different thermal treatments to knit textile 2 (e.g., the first layer) in a given orientation allows an operator to customize the region-specific properties and direction-specific properties in knit textile 2. For example, an operator may modify any of these conditions and locally control compliance, modulus/stiffness, or drape property.

In some embodiments, the first layer 4 is treated only in a portion of the knitted textile 2, wherein other portions remain untreated. In this way, significant anisotropy can be created between different portions of knit textile 2 (or an article of apparel or athletic equipment incorporating the knit textile).

In further embodiments, texture may be added to the first layer 4. For example, a different release paper may be used to prevent the pressing member from adhering to the first layer during the hot pressing process. The release paper may include a texture or design (waves, ribs, etc.) that may be pressed into the first layer 4 and thereby impart a texture.

Each of these properties of knitted textile 2 before and after heat treatment can be incorporated into articles of apparel and athletic equipment. For example, a knit textile 2 incorporated into an upper 28 of an article of footwear 26 may be heat treated such that the upper 28 has a negative poisson's ratio in the toe-to-heel direction, but is very stiff from the bite line to the collar.

Alternative constructions

It is also possible to form a knitted textile 2, an item of clothing or sports equipment having a first layer 4 and a second layer 6 using only one yarn having a thermoplastic composition instead of two or more yarns in the knitted textile 2. In embodiments, heat treating only the first layer 4 of the knitted textile 2 causes the thermoplastic composition (and yarns) in only the first layer 4 to melt or remelt, and minimally involves the underlying second layer 6.

Thus, in one aspect, a knitted textile 2 includes a knitted structure 10 formed from yarns having a thermoplastic composition, the knitted structure 10 having a first layer 4 and a second layer 6, the yarns forming an array of knitting patterns 16 in the first layer 4, the array of knitting patterns 16 defining voids 8, the voids 8 being in the first layer 4 and passing through the first layer 4 and reaching the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4.

In embodiments, heating the first layer 4 above the melting temperature or decomposition temperature of the thermoplastic composition causes the yarns in the first layer 4 to at least partially melt.

In another aspect, a knitted textile 2 includes a knitted structure 10 formed from yarns having a thermoplastic composition, the knitted structure 10 having a first layer 4 and a second layer 6, the first layer 4 having a first surface 34 including a film 24, the film 24 including first yarns 12 in remelted form, the film 24 forming an array of fused patterns 16 in the first layer 4, the array of fused patterns 16 defining voids 8, the voids 8 being in the first layer 4 and through the first layer 4 and to the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4.

Various methods for selectively heat treating only a portion, a section, or a depth of a textile are also known in the art, including blocking, masking, and using chemicals that promote or minimize temperature changes in the textile. Using a single yarn type may simplify the manufacturing process and reduce some of the waste associated with knitting textile 2 incorporating multiple yarn types.

Layered textile

In one aspect, the textile is formed by layering, embroidering, printing, bonding, strapping, masking, laminating or otherwise attaching (collectively "layered textiles") the material of the second layer 6 onto the first layer 4, the first layer 4 comprising first yarns 12 comprising a first thermoplastic composition, the second layer 6 comprising second yarns 14 comprising a second composition.

In this regard, the first layer 4 and the second layer 6 of the layered textile are not integrally formed, but are formed as separate structures that are subsequently attached. In an embodiment, the second layer 6 of the layered textile is positioned after being attached on the opposite side of the layered textile from the first layer 4.

Each of the first layer 4 and the second layer 6 may be separately formed through a knitting process, a weaving process, or a non-weaving process. In an embodiment, the first yarns 12 form an array of knit patterns 16 in the first layer 4, the array of knit patterns 16 defining voids 8 in the first layer 4, the voids 8 passing through the first layer 4 and reaching the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4.

In embodiments, the heat treatment of the first layer 4 of the layered textile causes the first thermoplastic composition to reflow, forming the film 24 on the first surface 34 of the first layer 4. In some embodiments, the heat treatment of the layered textile significantly increases the poisson's ratio of the layered textile in the first axis 18, but has a negligible effect on the poisson's ratio in the second different axis. Similarly, in certain embodiments, the heat treatment of the layered textile significantly increases the stiffness of the layered textile in the first axis 18, but has a negligible effect on the stiffness in the second, different axis. In this manner, the use of specific knit patterns 16, different yarns and compositions, and different heat treatments for first layer 4 in a given orientation allows an operator to customize the area-specific and direction-specific properties in knitted textile 2.

Article of apparel and sporting equipment

In some embodiments, knitted textile 2 is incorporated into an article of apparel 26. In an embodiment, the article of apparel is an article of footwear or an article of clothing. In some embodiments, knitted textile 2 forms a portion of article of footwear 26. In certain embodiments, knit textile 2 forms all or a portion of upper 28 of article of footwear 26. In some embodiments, knitted textile 2 forms a portion of athletic equipment. The term "portion" means that the knitted textile 2 may represent 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 100% of an item of apparel or sports equipment.

Thus, in a particular embodiment, an article of footwear 26 includes an upper 28 and a sole structure 22, the upper 28 including a knit textile 2 having a knit structure 10, the knit structure 10 including: a first layer 4 of the knit structure 10, the first layer 4 including first yarns 12, the first yarns 12 including a first thermoplastic composition, the first layer 4 having a first surface 34 including a film 24, the film 24 including the first yarns 12 in remelted form, the film 24 forming an array of fused patterns 16 on the first surface 34, the array of fused patterns 16 defining voids 8 in the first surface 34; a second layer 6 of knitted construction 10, second layer 6 being located on an opposite side of knitted textile 2 from first layer 4 and being integrally formed with first layer 4, second layer 6 comprising a second yarn 14 formed from a second composition; the first yarn 12 and the second yarn 14 form interlocking knit stitches in the second layer 6 and/or in the first layer 4 underlying the film 24; voids 8, the voids 8 passing through the first layer 4 and reaching the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4.

In some embodiments, the article of footwear 26 has a first footwear axis 30 and a second footwear axis 32, the first footwear axis 30 being oriented on the article of footwear 26 from the medial side to the lateral side, and the second footwear axis 32 being oriented on the article of footwear 26 from the toe to the heel.

In some embodiments, first layer 4 is disposed on an exterior surface of article of footwear 26.

Method of forming textiles and articles

In one aspect, a method for forming a knitted textile 2 is disclosed.

In some embodiments, the method includes knitting a knitted structure 10 including a first layer 4 and a second layer 6, the first layer 4 including a first yarn 12, the first yarn 12 having a first thermoplastic composition, the first thermoplastic composition having a first melting temperature, the second layer 6 being located on an opposite side of the knitted textile 2 from the first layer 4 and being integrally formed with the first layer 4, the second layer 6 including a second yarn 14 formed from a second composition, the second composition having a second melting temperature or a second decomposition temperature or both, the first yarn 12 and the second yarn 14 forming interlocking knit stitches; and forming an array of knit patterns 16 in the first layer 4 with the first yarns 12, the array of knit patterns 16 defining voids 8 in the first layer 4, the voids 8 passing through the first layer 4 and reaching the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4.

In embodiments, the first melting temperature is at least 5 degrees celsius, at least 10 degrees celsius, at least 15 degrees celsius, or at least 20 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

In some embodiments, the first layer 4 is heated to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition.

In certain embodiments, the molten first thermoplastic composition forms a film 24 on the first layer 4.

In one aspect, a method of manufacturing a knitted textile 2 is disclosed.

In an embodiment, the method comprises: providing a knit structure 10, the knit structure 10 including a first layer 4 and a second layer 6, the first layer 4 including a first yarn 12, the first yarn 12 including a first thermoplastic composition having a first melting temperature, the second layer 6 being located on an opposite side of the knit textile 2 from the first layer 4 and being integrally formed with the first layer 4, the second layer 6 including a second yarn 14 formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn 12 and the second yarn 14 forming interlocking knit stitches, the first layer 4 including an array of knit patterns 16 formed from the first yarn 12, the array of knit patterns 16 defining voids 8 in the first layer 4, the voids 8 passing through the first layer 4 and to the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the voids 8 in the first layer 4, the first melting temperature being lower than the lowest of the second melting temperature and the second decomposition temperature; and heating the first layer 4 to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition.

In some embodiments, the first layer 4 of the knitted textile 2 is thus raised to a temperature at or above the melting temperature of the first thermoplastic material. For example, heat (or heat and pressure) can be applied directly to first layer 4 of knitted textile 2 by contacting first layer 4 of knitted textile 2 with a heated plate. In an embodiment, the temperature of the first layer 4 of the knitted structure 10 is raised for a duration sufficient to form a non-filamentous film 24 on at least a portion of the first layer 4. Thus, in some embodiments, the molten first thermoplastic composition forms a film 24 on the first layer 4.

In particular embodiments, knit textile 2 is also incorporated into an article of apparel, such as an article of footwear or an article of clothing. In particular embodiments, knit textile 2 is also incorporated into upper 28 of article of footwear 26. In particular embodiments, upper 28 is further attached to sole structure 22 of article of footwear 26. Various methods of attaching the upper 28 to the sole are known in the art, but it is also possible to thermally bond the upper 28 to the sole by hot melting the thermoplastic composition.

In one aspect, a method for manufacturing an article of footwear 26 is disclosed.

In some embodiments, the method comprises: providing a knit structure 10, the knit structure 10 including a first layer 4 and a second layer 6, the first layer 4 including a first yarn 12, the first yarn 12 including a first thermoplastic composition having a first melting temperature, the second layer 6 being located on an opposite side of the knit textile 2 from the first layer 4 and being integrally formed with the first layer 4, the second layer 6 including a second yarn 14 formed from a second composition having a second melting temperature or a second decomposition temperature or both, the first yarn 12 and the second yarn 14 forming interlocking knit stitches, the first layer 4 including an array of knit patterns 16 formed from the first yarn 12, the array of knit patterns 16 defining voids 8 in the first layer 4, the voids 8 passing through the first layer 4 and to the second layer 6, wherein a portion of the yarn of the second layer 6 is exposed through the voids 8 in the first layer 4; forming knitted structure 10 into upper 28; heating a portion of the first layer 4 to a temperature above the first melting temperature and below the lowest of the second melting temperature and the second decomposition temperature to at least partially melt the first thermoplastic composition and form a film 24 on the first layer 4; and attaching the upper 28 to the outsole to form the article of footwear 26.

In embodiments, the first melting temperature is lower than the lowest of the second melting temperature and the second decomposition temperature. In certain embodiments, the first melting temperature is at least 5 degrees celsius, at least 10 degrees celsius, at least 15 degrees celsius, or at least 20 degrees celsius lower than the lowest of the second melting temperature and the second decomposition temperature.

In some embodiments, the first axis 18 is oriented on the article of footwear 26 from the medial side to the lateral side, and the second axis 20 is oriented on the article of footwear 26 from the toe to the heel.

In particular embodiments, the poisson's ratio of knitted textile 2 is greater than or equal to zero when measured in first axis 18, second axis 20, or both.

In some embodiments, first layer 4 is disposed on an exterior surface of article of footwear 26.

In one aspect, a method of forming an article of footwear 26 is disclosed.

In some embodiments, the method includes providing a knit structure 10, the knit structure 10 including a first layer 4 and a second layer 6, the first layer 4 including first yarns 12, the first yarns 12 including a first thermoplastic composition, the first layer 4 having a first surface 34 including a film 24, the film 24 including the first yarns 12 in remelted form, the film 24 forming an array of fused patterns 16 on the first surface 34, the array of fused patterns 16 defining voids 8 in the first surface 34, the second layer 6 being located on an opposite side of the knit structure 10 from the first layer 4 and integrally formed with the first layer 4, the second layer 6 including second yarns 14 formed from a second composition; the first yarn 12 and the second yarn 14 form an interlocking knit stitch in the second layer 6 and/or in the first layer 4 underlying the film 24, the void 8 passing through the first layer 4 and to the second layer 6, wherein a portion of the yarns of the second layer 6 are exposed through the void 8 in the first layer 4; forming knitted structure 10 into upper 28; and attaching the upper 28 to the outsole to form the article of footwear 26.

In some embodiments, the first axis 18 is oriented on the article of footwear 26 from the medial side to the lateral side, and the second axis 20 is oriented on the article of footwear 26 from the toe to the heel.

In particular embodiments, the poisson's ratio of knitted textile 2 is greater than or equal to zero when measured in first axis 18, second axis 20, or both.

In some embodiments, first layer 4 is disposed on an exterior surface of article of footwear 26.

The following examples are provided to illustrate certain specific features and/or aspects. These examples should not be construed as limiting the present disclosure to the particular features or aspects described therein.

Examples

Knitted textile 2 is formed with an array of knit patterns 16 in first layer 4 and voids 8 passing from first layer 4 to second layer 6. Knitted textile 2 may be incorporated into footwear (e.g., uppers), clothing, athletic equipment, and the like.