Knitted Component with an Inner Layer Having a Thermoplastic Material and Related Method

This application is a continuation of co-pending U.S. patent application Ser. No. 18/228,521, filed on Jul. 31, 2023, which is a continuation application of U.S. patent application Ser. No. 16/887,674, filed on May 29, 2020, now issued as U.S. Pat. No. 11,739,448, which claims the benefit of priority of U.S. provisional app. No. 62/855,486, filed May 31, 2019. The contents of all of these applications are incorporated herein by reference in the entirety.

The present disclosure relates generally to knitted components and methods of manufacturing knitted components, for example, knitted components for use in footwear applications, apparel applications, or the like.

The present disclosure relates generally to a knitted component having a selected region of macro-texture and the method for forming a method a knitted component having a selected region of macro-texture. The disclosure also relates to an article of footwear having an upper made in accordance with this disclosure.

A variety of material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing knitted items such as knitted uppers. In athletic footwear, for example, the upper may have multiple layers that each include a variety of joined material elements. As examples, the material elements may be selected to impart stretch-resistance, cushion, low-friction, wear-resistance, flexibility, air-permeability, compressibility, comfort, water-resistance, and moisture-wicking to different areas of the upper. Moreover, the material elements are often joined in a layered configuration to impart multiple properties to the same areas.

Wearers of articles of footwear may desire articles of footwear that are durable for functionality, precisely shaped for comfort of wear, decoration, or aerodynamics, and soft-textured for comfort of wear. Such users may seek to maximize these properties and characteristics. Many construction techniques have been employed to achieve such a result. Examples of such construction include use of multiple layers of soft material for comfort, waterproof or high-tensile strength materials for durability, are applied items for shape and marking.

However, as those with skill in the art recognize, combining disparate materials is such a way creates additional steps, as well as waste, in the manufacturing process. Also, layers of materials or joints between different materials of construction may present assembly and maintenance burdens.

Therefore, there exists a need in the art for a method for manufacturing uppers for articles of footwear that minimize the number of manufacturing steps while reducing raw material waste.

While various embodiments of the present disclosure have been described, the present disclosure is not to be restricted except in light of the attached claims and their equivalents. Moreover, the advantages described herein are not necessarily the only advantages of the present disclosure and it is not necessarily expected that every embodiment of the present disclosure will achieve all of the advantages described.

The disclosure will be described in detail as it relates to a region or regions of structural stiffness. Structural stiffness may be described or characterized as resistance to permanent deformation, akin to more traditional measures of material properties such as the Young's modulus measure of resilience, but specific to the ability of the component to retain or return to a given morphology of its maco-texture after loading. In this disclosure, the regions may be described as providing or having different rigidity, resilience, structure, structural stiffness, or bending resistance, for example. These and other words or phrases that have essentially the same meanings and indicate or describe similar phenomena in the disclosure.

Low-melt thermoplastic yarn imparts structural stiffness to a section of the knitted component after heat or pressure processing by anchoring a plurality of knit layers together over the area where the area where the processed low-melt thermoplastic yarn has been processed. By softening and reforming the thermoplastic yarn in a new morphology, or “macro-texture,” the processed low-melt thermoplastic layer imparts to the anchored knit layers the new macro-texture. By anchoring the layers together, the processed section of the knitted component demonstrates increased structural stiffness compared with the unprocessed knitted component. Thus, a knitted component section stiffened with processed low-melt thermoplastic yarn will resist permanent deformation of the new macro-texture.

One aspect of this disclosure is directed to a method for creating an integrally formed knitted componenthaving a selected region of macro-textureafter heat or pressure processing and a method for creating such a knitted component. Herein, a “macro-texture” may be referred to as a shape or texture extending through multiple layers of a textile such that it is discernable from both sides of the textile (e.g., opposite textile faces), whereas a “micro-texture” is generally isolated to one textile face. In the knitted component, a first knit layercomprising a first high-melting point yarnis located on the opposite side of the knitted componentfrom a second knit layercomprising a second high-melting point yarn. The first yarn and the second yarn,form interlocking knit stitches within the knitted component(e.g., such that one or more loops forming the first knit layeris interlooped with at least one loop forming the second knit layer). Thus, the majority of the yarn present in the first knit layeris the first high-melting point yarnand the majority of the yarn present in the second knit layeris the second high-melting point yarn, although owing to the nature of the knitting process, a small amount of the first yarnwill be present in the second layer(forming interlocking stitches) and a small amount of the second yarnwill be present in the first layer. While any specific yarn may be used as the first yarnand/or the second yarn, in certain exemplary embodiments the first yarnand/or the second yarnmay be primarily comprised of a polyester. A low-melting point thermoplastic inlaid strand(which may be partially or fully formed of a thermoplastic material) is inlaid in the direction of the courses of the interlocked knit layers and may run the entire length of the knit layers, or may be inlaid in courses over only a selected portion of the knit layers. Notably, when referring to the inlaid strand. The number and direction of strands of low-melting point thermoplastic yarn are selected to yield the controlled structural stiffness after heat or pressure processing so as to maintain a macro-texture. The low-melting point thermoplastic strandis softened through either applying heat or pressure to the knitted component.

In one aspect, the disclosure provides a method for creating a knitted componenthaving a selected region of controlled stiffness after heat or pressure processing. One such knitted component is depicted in. In accordance with the method, a knitted componentcomprising high-melting point polymer yarnis knitted. A low-melting point thermoplastic strandis inlaid in the selected regionof the knitted componentin a number and direction sufficient to yield the controlled stiffness after processing. In another aspect, the knitted component may be formed by more three or more knit layers and two or more layers of low-melting point thermoplastic inlaid yarn.

In another aspect depicted in, the disclosure provides a method for knitting a knitted componenthaving a first selected regionof a first controlled stiffness after processing and a second selected regionof a second controlled stiffness after processing. In accordance with the method, a knitted componentcomprising high-melting point yarnis knitted. A first low-melting point thermoplastic strandis inlaid into the first selected regionof the knitted componentin a number and direction sufficient to yield a first controlled stiffness after processing. A second low-melting point thermoplastic yarnis inlaid into the second selected regionof the knitted componentin a number and direction sufficient to yield a first controlled stiffness after processing.

In another aspect depicted in, the disclosure provides a method for creating a knitted componenthaving a selected region of macro-textureand controlled stiffness after heat or pressure processing.

One such knitted componentis depicted in. In accordance with the method, a knitted componentcomprising high-melting point polymer yarnis knitted. A low-melting point thermoplastic strandis inlaid in the selected regionof the knitted componentin a number and direction sufficient to yield the controlled stiffness after processing. The knitted component is processed to soften the low-melting point thermoplastic strand.

In one aspect, as depicted in, the inlaid strandmay be softened by applying heat to the knitted component. The knitted componentis heated to soften the low-melting point thermoplastic strand. The knitted component may be heated by omnidirectional means, such as the use of steam, an oven, or equivalent, or by directional means, such as a hot surface, heat gun, or equivalent. Depending on the crystallinity or general characteristics of the yarn, to soften the low-melting point thermoplastic strand, the knitted componentcan either be heated to or above the inlaid yarn's melting point, above the inlaid yarn's glass transition temperature, or to or above the inlaid yarn's softening point for a given processing pressure. When the softened inlaid strandis cooled to a temperature below its softening point, the material becomes firm.

While the low-melting point thermoplastic yarn is softened, the knitted component is shaped using a mold press(also referred to as a “mold press”) having a macro-texture feature. Notably, the mold pressmay be relatively cool relative to the melting temperature of one or more yarns in the knitted component (e.g., it may be maintained at room temperature). The mold pressgenerally either has a top portion and a bottom portion. The mold press can be a clamshell design, where the top portion and the bottom portion are hinged along one edge so that the knitted component may be insert between the top portion and the bottom portion and the mold press closed down on the knitted component. Alternatively, the top portion and bottom portion of the mold pressmaybe be two independent plates that are not otherwise connected. In this alternative design the knitted component is positioned on top of the bottom portion of the mold pressand the top portion is then positioned on top of the knitted component. The top portion may be of similar size as the bottom portion, or may be larger or smaller. Although it is typical for the top portion and bottom portion to align so that macro-texture featureson the bottom portion align with corresponding macro-texture featureson the top portion, there is not a requirement. The top portion and bottom portions may have distinctly different macro-texture features, or the portions may be flat, thus without macro-texture features. As indicated in, the macro-texture featureson the mold pressmay be of a variety of shapes and patterns including, but not limited to, letters, words, phrases, numbers, logos, three-dimensional geometric designs, line drawings or sketches, signatures, or a combination of features.

As depicted in, after the knitted componentwith softened low-melting point thermoplastic strandis positioned into the mold pressand the mold pressis engaged, a sufficient amount of pressure is applied to the mold presssuch that the softened low-melting point thermoplastic stranddeforms and the knitted componentconforms to the macro-texture featurein the mold press. The amount of pressure will vary depend on the amount and temperature of the thermoplastic strand, the desired amount of infiltration of low-melt thermoplastic strandinto the knit layers,, among other factors. In one embodiment, the inherent weight of the top portion of the mold press will provide sufficient pressure to achieve the desired results, and no additional pressure is required. In another embodiment, additional pressure is applied to the press mold. As depicted inC, additional pressure may cause the low-melting point thermoplastic strandto infiltrate the knit layers,more than if only the inherent weight of the top portion of the mold press is applied, as depicted in.

After the knitted componentconforms to the macro-texture features, the knitted componentis allowed to cool. This cooling allows the low-melt thermoplastic strandto transition from its softened state to its firm state. Cooling may be accomplished by a variety of means including, but not limited to, allowing the knitted component to cool in the ambient, cooling one of both of the portions of the mold press(and/or simply relying on conduction through the mold presswhen the mold press is below the melting temperature of the thermoplastic strand, such as at room temperature), exposing the knitted componentto fluid that is at a lower temperature than the temperature of the softened low-melting point thermoplastic strandincluding liquids and gasses, or other means. As depicted in, after the knitted componenthas the low melting point thermoplastic strandhas firmed, the knitted componentis removed from the mold press.

In another aspect depicted in, the disclosure provides a method for creating a knitted componenthaving a multiple selected regions of macro-texturesand controlled stiffness after heat or pressure processing. In accordance with the method, a knitted componentcomprising high-melting point polymer yarnis knitted. A low-melting point thermoplastic strandis inlaid in the selected regionof the knitted componentin a number and direction sufficient to yield the controlled stiffness after processing. The knitted componentis processed to soften the low-melting point thermoplastic strand. While the low-melting point thermoplastic yarn is softened, the knitted component is shaped using a mold presshaving multiple macro-texture features. A sufficient amount of pressure is applied to the mold presssuch that the softened low-melting point thermoplastic stranddeforms and the knitted componentconforms to the macro-texture featuresin the mold press. After the knitted componentthe low-melting point thermoplastic strandhas firmed, the knitted componentis removed from the mold press.

In another aspect depicted inthe knitted componentis heated to soften the low-melting point thermoplastic strandand positioned over a slump moldhaving a macro-texture. As depicted in, while the low-melting point thermoplastic strandis softened, the knitted component is placed onto the slump mold. After the knitted componentcools so that the low-melting point thermoplastic strandhas firmed, the knitted componentis removed from the slump mold, as indicated in.

In another aspect depicted inthrough, varying amounts of low-melting point thermoplastic strandor varying amounts of pressure can be applied to the heated knitted componentin the engaged mold pressto achieve varying levels of low-melting point thermoplastic yarn penetration into the knit layers,. Additional pressure applied to the cold press will allow the low-melting point thermoplastic strandto penetrate the knit layers to a greater depth. This may result is negligible penetration, significant penetration, or complete penetrationas the amount of pressure increases or the amount of time pressure is applied increases. Similarly, using a higher volume ratio of low-melting point thermoplastic yarn to high-melting point thermoplastic yarn will allow the low-melting point thermoplastic yarn to penetrate into the knit layers at a greater depth, as depicted in. As the volume amount ratio of material increases, the low-melting point thermoplastic yarn can occupy a larger percentage of the empty space surrounding the high-melting point yarn of the knit layers, thus allowing for greater degrees of penetration.

When the thermoplastic strandmelts between the first layerand the second layer, it may form a “third layer” comprised primarily of the thermoplastic material, as shown in. When melted sufficiently, the third layer may form a water-resistant and/or waterproof barrier between the first layerand the second layer. Advantageously, the knitted component may include outer surfaces that have a knit texture (often desirable in footwear for its soft/comfortable surface characteristics and aesthetics, for example) while also having desirable water-resistant properties. Further, it is contemplated that the thermoplastic material of the third layer may be primarily contained between the first layerand the second layersuch that it is substantially absent from the outer surfaces of the knitted component.

The yarns used in embodiments may be selected from monofilament and multifilament yarns formed from synthetic materials. High-melting point polymer yarns,also may be made from natural materials. Natural materials are not practical for low-melting point polymer yarns because the low-melting point polymer yarns must at least partially soften to be festively molded. Natural materials typically do not soften as synthetic thermoplastics do, but rather char; therefore, the use of natural materials may limit the range of processing temperatures that may be used in order to ensure that the knitted component is processed below the scorching temperature of the natural material. However, natural materials may be incorporated with a low-melting point thermoplastic yarn may be used as a low-melting point thermoplastic strandlayer.

Low-melting point thermoplastic yarntypically is synthetic polymeric material formed from a polymer that melts at a relatively low temperature, generally below 150 C. The melting temperature of the low-melting point thermoplastic strandmay be sufficiently different from the melting temperature of the high-melting point polymer yarns,that the low-melting point polymer strandmay be essentially completely melted without melting or adversely affecting the characteristics of the high-melting point polymer yarns,.

In some embodiments, the melting temperature of low-melting point polymer yarn is less than about 115° C., typically less than about 110° C., and more typically less than about 100° C. Synthetic polymer yarns that may be suitable as low-melting point polymer yarn include TPU yarns, low-melting point temperature PET, or low-melting point temperature nylon yarns. For example, low-melting point temperature nylon, which may be nylon-6, nylon-11, or nylon-12, may have a melting point of about 85° C. In some embodiments, polyurethane and polypropylene yarns may be used. In some embodiments, thermoplastic polyurethane (TPU) yarn may be used.

High-melting point polymer yarn, by definition, has a higher melting temperature than low-melting point thermoplastic yarns. The melting points of high-melting point polymer yarns typically greater than about 185° C., more typically greater than about 200° C., and even more typically greater than about 210° C. For example, nylon-6/11 has a melting point of at least about 195° C.; nylon-6/10 has a melting point of about 220° C., and nylon-6/6 has a melting point of at least about 255° C. These and other high-melting point polymer yarns may be used.

The yarns may be any color, and may be transparent, translucent, or opaque. These color and light properties and characteristics may be used to provide pleasing designs and color combinations. When the low-melting point polymer yarn is softened, the softened yarn may partially or fully surround the high-melting point polymer yarn. Thus, the colors of the yarns may combine where the yarns coincide. Examples of articles of footwear of the disclosure thus may be transparent, translucent, or opaque, depending most strongly on the properties and characteristics of the low-melting point polymer yarn. Softening the yarn typically does not change the color or light transmission properties of the resultant solid layer. In some embodiments, color and light transmission properties may be selected to provide selected effects.

The yarns may be selected from yarns that meet design criteria and may incorporate yarns made with different deniers and compositions of matter, for example. Also, typically, the high-melting point polymer yarns,comprise different polymers from the low-melting point polymer yarns. More typically, the high-melting point polymer yarns,will be different compositions of matter from the low-melting point polymer yarns. However, low-melting point polymer yarn made from low-melting point nylon may be used with high-melting point nylon yarns, with melt temperature difference sufficient to ensure that only the low-melting point polymer yarn melts when the knitted component is heated. In some embodiments, a composite material may be incorporated into a knitted componenteither in one of the high-melting point yarns,or in the low-melting point thermoplastic strand. Such a composite material typically comprises fibers in a binder.

Additionally, the inlaid strandcan be of a composite material to provide additional properties to the knitted componentsuch as strength, rigidity, elasticity, water-resistance, among others. The inlaid strandmay incorporate materials that are not low-melting point thermoplastics. However, to maintain the characteristics of the knit layers,, including the micro-texture of the knit layers, the knitted componentshould not be heated above either the scorching or softening temperature of either of the high-melting point polymer yarns,which comprise the knit layers. The inlaid strandmay also incorporate multiple strands and/or yarn. These multiple inlaid strandsmay have similar or disparate properties, although at least one of the strands may incorporate a low-melting point thermoplastic material.

In another aspect depicted in, the knitted component can be incorporated into an upper for a shoe or other wearable item. An article of footwear is depicted inas including a sole structureand an upper. Although the article of footwear is illustrated as having a general configuration suitable for running, concepts associated with footwear may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, training shoes, walking shoes, and hiking boots, for example. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed with respect to footwear apply to a wide variety of footwear types.

Although the disclosure is described in detail as it relates to a knitted component for an upperfor an article of footwear, the principles described herein may be applied to any textile element to provide a region of stiffness and macro-structureto an object. For example, the principles may be applied to textiles including, but not limited to, knitted textiles, and woven textiles. Knitted textiles include textiles formed by way of warp knitting, weft knitting, flat knitting, circular knitting, and other suitable knitting operations. The knitted textile may have a plain knit structure, a mesh knit structure, or a rib knit structure, for example. Woven textiles include, but are not limited to, textiles formed by way of any of the numerous weave forms, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weaves, and double cloth weaves, for example.

Having described various aspects of the subject matter above, additional disclosure is provided below that may be consistent with the claims originally filed with this disclosure. In describing this additional subject matter, reference may be made to the previously described figures.

One general aspect includes a method of manufacturing a knitted component, including: knitting a first knit layer and a second knit layer on a knitting machine, where the first knit layer and the second knit layer each include a plurality of intermeshed loops, and where at least one loop of the first knit layer is intermeshed with at least one loop of the second knit layer; inlaying an inlaid strand between the first knit layer and the second knit layer during the knitting of the first knit layer and the second knit layer, where the inlaid strand includes a thermoplastic material having a melting point; applying heat to at least a portion of the thermoplastic material of the inlaid strand such that the portion of the thermoplastic material rises to a temperature at or above the melting point; applying a pressure to at least one side of the knitted component with a mold press to form a molded shape; and cooling the portion of the thermoplastic material to a temperature below the melting point during or after application of the pressure such that the molded shape is retained on at least one side of the knitted component.

Optionally, the step of cooling the portion of the thermoplastic material is at least partially executed by the mold press. The step of applying heat to the portion of the thermoplastic material may be executed prior to the step of applying the pressure to the at least one side of the knitted component. The mold press may include a temperature of less than the melting point during the step of applying the pressure to the at least one side of the knitted component. The portion of the thermoplastic material may form a barrier between the first knit layer and the second knit layer once the portion of the thermoplastic material is cooled, and where the barrier is water-resistant or waterproof. At least one of the first knit layer and the second knit layer may include a yarn having a melting point above the melting point of the thermoplastic material. At least one of the first knit layer and the second knit layer may include a polyester yarn.

Another general aspect includes a method of manufacturing a knitted component, including: knitting a first knit layer and a second knit layer on a knitting machine, where the first knit layer and the second knit layer each include a plurality of intermeshed loops, and where at least one loop of the first knit layer is intermeshed with at least one loop of the second knit layer; inlaying an inlaid strand between the first knit layer and the second knit layer during the knitting of the first knit layer and the second knit layer, where the inlaid strand includes a thermoplastic material having a melting point; applying heat to at least a portion of the thermoplastic material of the inlaid strand such that the portion of the thermoplastic material rises to a temperature at or above the melting point; and cooling the portion of the thermoplastic material to a temperature below the melting point such a barrier is formed between the first knit layer and the second knit layer, the barrier being water resistant or waterproof (e.g., as tested under ISO-11092 (7.4)).

Another general aspect includes a knitted component, including: a first knit layer located on a first side of the knitted component; a second knit layer located on a second side of the knitted component that is opposite the first side, where the first knit layer includes at least one loop that is intermeshed with at least one loop of the second knit layer; and a third layer formed between the first knit layer and the second knit layer, where the third layer includes a thermoplastic material that is substantially contained between the first knit layer and the second knit layer.

Optionally, the knitted component may further include a molded shape located on at least one of the first side and the second side of the knitted component. At least one of the first knit layer and the second knit layer may include a yarn having a melting point that is higher than a melting point of the thermoplastic material. At least one of the first knit layer and the second knit layer may include a polyester yarn. The third layer may form a barrier between the first knit layer and the second knit layer that is water-resistant or waterproof. The thermoplastic material of the third layer may be provided via at least one inlaid strand that is inlaid between the first knit layer and the second knit layer.

While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.