具体实施方式：
[0042]The present disclosure is directed to embellished articles, and embellished elements such as embellished shaped components, embellished films, embellished textiles, embellished yarns or embellished fibers which can be combined to form embellished articles. The embellishments or the embellished elements can comprise a low processing temperature composition, or can comprise a high processing temperature composition. In some aspects, a single element can include both the low and high processing temperature compositions. The present disclosure is also directed to methods of thermoforming on a molding surface one or more elements to re-shape the element, to affix an embellishment to an element, to affix an embellished element to another element using re-flown polymeric materials, or any combination thereof. In some cases, the thermoforming process may alter the embellishment (e.g., by reflowing it), or may apply the embellishment (e.g., by activating a sublimation ink). The thermoforming process involves placing at least a portion of at least a first element on a molding surface, and, while the first element remains in contact with the molding surface, increasing the temperature of the entire first element to a first temperature, and then decreasing the temperature of the entire first element to a second temperature. The first temperature is a temperature above the melting point of the low processing temperature composition, but is below the below at least one of: 1) the creep relaxation temperature Tcr; 2) the heat deflection temperature Thd; or 3) the Vicat softening temperature Tvs of the high processing temperature polymeric composition. Thus, using the disclosed process, the portions of the embellishment or element which comprises the low processing temperature composition will melt, re-flow and then re-solidify into a new shape or conformation, while the portions formed high processing temperature composition will retain their original shape or conformation. Using shaped components, films, textiles, yarns and/or fibers from the low processing temperature composition to form embellishments, or by printing, embroidering, or dyeing other elements, and thermoforming these elements to change their conformation or combine them with other elements during the thermoforming process, is a particularly efficient and effective way to incorporate embellishments into the thermoformed article and to use these low processing temperature compositions to achieve unique effects on the thermoformed article. For example, use of the disclosed textiles and processes make it possible to use only a single embellished textile to produce a thermoformed article which includes integrally formed embellished areas. Alternatively or additionally, the thermoformed articles can be dyed. Due to the presence of both the low processing temperature composition and the high processing temperature composition in the thermoformed article, dyeing the thermoformed article can be used to produce unique effects on the dyed thermoformed article with only a few processing steps and without the need to mask portions of the thermoformed article, as the dye selected can preferentially bind with only one of the low processing temperature composition or the high processing temperature composition. For example, anionic dyes bind particularly well to polyurethanes and polyamides. One way of producing a dyed thermoformed article in which only portions of the article are dyed is to immerse the entire thermoformed article in an anionic dye solution, where the low processing temperature composition comprises a polyurethane or a polyamide or both but is substantially free of polyester polymers, and the high processing temperature composition comprises a polyester such as polyethylene terephthalate but is substantially free of polyurethane or polyamide polymers. In this example, only the portions of the article comprising the low processing temperature composition will take up the dye while the portions comprising the high processing temperature composition will remain substantially free of dye, making it possible to produce a partially dyed article without needing to apply and removing masking.
[0043]In various aspects, the present disclosure pertains to articles comprising: a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; and/or a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymeric composition exhibits a creep relaxation temperature Tcr that is greater than a melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, or the second textile, or combinations thereof, comprising embroidery on at least a portion thereon; and 3) the article comprises a dyed first element, a dyed second element, or combinations thereof.
[0044]In an aspect, the present disclosure pertains to articles comprising: a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; and/or a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymeric composition exhibits a heat deflection temperature Thd that is greater than a melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, or the second textile, or combinations thereof, comprising embroidery on at least a portion thereon; and 3) the article comprises a dyed first element, a dyed second element, or combinations thereof.
[0045]In an aspect, the present disclosure pertains to articles comprising: a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; and/or a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymeric composition exhibits a Vicat softening temperature Tvs that is greater than a melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, or the second textile, or combinations thereof, comprising embroidery on at least a portion thereon; and 3) the article comprises a dyed first element, a dyed second element, or combinations thereof.
[0046]In an aspect, the present disclosure pertains to articles comprising: a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; and/or a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymeric composition exhibits at least one of: 1) a creep relaxation temperature Tcr; 2) a heat deflection temperature Thd; or 3) a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, or the second textile, or combinations thereof, comprising embroidery on at least a portion thereon; and 3) the article comprises a dyed first element, a dyed second element, or combinations thereof.
[0047]In an aspect, the present disclosure pertains to articles comprising: a first reflowed material; and a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymeric composition exhibits a creep relaxation temperature Tcr that is greater than a melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, the second textile, the first reflowed material, or combinations thereof, comprising embroidery on at least a portion thereon; 3) the article comprises a dyed first element, a dyed second element, or a combination thereof; and 4) a first reflowed material comprising a second printed marking on at least a portion thereof.
[0048]In an aspect, the present disclosure pertains to articles comprising: a first reflowed material; and a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymeric composition exhibits a heat deflection temperature Thd that is greater than a melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, the second textile, the first reflowed material, or combinations thereof, comprising embroidery on at least a portion thereon; 3) the article comprises a dyed first element, a dyed second element, or a combination thereof; and 4) a first reflowed material comprising a second printed marking on at least a portion thereof.
[0049]In an aspect, the present disclosure pertains to articles comprising: a first reflowed material; and a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymeric composition exhibits a Vicat softening temperature Tvs that is greater than a melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, the second textile, the first reflowed material, or combinations thereof, comprising embroidery on at least a portion thereon; 3) the article comprises a dyed first element, a dyed second element, or a combination thereof; and 4) a first reflowed material comprising a second printed marking on at least a portion thereof.
[0050]In an aspect, the present disclosure pertains to articles comprising: a first reflowed material; and a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers; and wherein the high processing temperature polymeric composition exhibits at least one of: 1) a creep relaxation temperature Tcr; 2) a heat deflection temperature Thd; or 3) a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymeric composition the melting temperature Tm of the low processing temperature polymeric composition; and wherein the article comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a first printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, the second textile, the first reflowed material, or combinations thereof, comprising embroidery on at least a portion thereon; 3) the article comprises a dyed first element, a dyed second element, or a combination thereof; and 4) a first reflowed material comprising a second printed marking on at least a portion thereof.
[0051]In an aspect, the present disclosure pertains to processes for manufacturing an article comprising: providing a disclosed article; and combining the article with one or more additional materials to form an article of footwear, apparel or sporting equipment.
[0052]In an aspect, the present disclosure pertains to process for manufacturing an article, the process comprising: receiving a first element selected from a first shaped component, a first film, a first textile, a first yarn, and a first fiber; and/or receiving a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers, wherein the second element comprises a high processing temperature polymeric composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymeric composition exhibits at least one of: 1) a creep relaxation temperature Tcr; 2) a heat deflection temperature Thd; or 3) a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymeric composition; placing at least a portion of the first element and at least a portion of the second element on a molding surface; while the at least a portion of the first element and the at least a portion of the second element is on the molding surface, increasing a temperature of the entire article to a temperature that is above the melting temperature Tm of the low processing temperature polymeric composition and below at least one of: 1) the creep relaxation temperature Tcr; 2) the heat deflection temperature Thd; or 3) the Vicat softening temperature Tvs of the high processing temperature polymeric composition; and subsequent to the increasing the temperature of the entire article, while the at least a portion of the article remains on the molding surface, decreasing the temperature of the entire article to a temperature below the melting temperature Tm of the low processing temperature polymeric composition; thereby forming an article comprising a first reflowed material; wherein the first reflowed material is a melted and re-solidified product of the first element selected from the first shaped component, the first film, the first yarn, the first fiber, the first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers.
[0053]In an aspect, the present disclosure pertains to combination uppers and outsoles for an article of footwear, comprising: a first re-flowed material; and a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first reflowed material is a melted and re-solidified product of a first element selected from a first shaped component, a first film, a first yarn, a first fiber, a first textile, or any combination thereof; wherein the first reflowed material comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers; wherein the second element comprises a high processing temperature composition, the high processing temperature composition comprising one or more second thermoplastic polymers; wherein the high processing temperature polymeric composition exhibits at least one of: 1) a creep relaxation temperature Tcr; 2) a heat deflection temperature Thd; or 3) a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymeric composition; wherein the combination upper and outsole includes a medial midfoot area, a lateral midfoot area, a ground-facing outsole area, and at least a portion of the first re-flowed material is present on the ground-facing outsole area; and wherein the combination upper and outsole comprises one or more of: 1) the first film, the first textile, the second shaped component, the second film, or the second textile, or combinations thereof, comprising a printed marking on at least a portion thereof; 2) the first film, the first textile, the second film, or the second textile, or combinations thereof, comprising embroidery on at least a portion thereon; 3) the article comprises a dyed first element, a dyed second element, or combinations thereof; and 4) the first reflowed material comprising a printed marking on at least a portion thereof or embroidery on at least a portion thereon.
[0054]In an aspect, the present disclosure pertains to processes for manufacturing a combination upper and outsole for an article of footwear, the process comprising: receiving a first element selected from a first shaped component, a first film, a first textile, a first yarn, and a first fiber; receiving a second element selected from a second shaped component, a second film, a second textile, a second yarn, or a second fiber; wherein the first element comprises a low processing temperature polymeric composition, the low processing temperature polymeric composition comprising one or more first thermoplastic polymers, wherein the second element comprises a high processing temperature polymeric composition, the high processing temperature polymeric composition comprising one or more second thermoplastic polymers, and wherein the high processing temperature polymeric composition exhibits at least one of: 1) a creep relaxation temperature Tcr; 2) a heat deflection temperature Thd; or 3) a Vicat softening temperature Tvs that is greater than the melting temperature Tm of the low processing temperature polymeric composition; placing at least a portion of the first element and at least a portion of the second element on a molding surface; while the at least a portion of the first element and the at least a portion of the second element are on the molding surface, increasing a temperature of the entire first element and the entire second element to a temperature that is above the melting temperature Tm of the low processing temperature polymeric composition and below at least one of: 1) the creep relaxation temperature Tcr; 2) the heat deflection temperature Thd; or 3) the Vicat softening temperature Tvs of the high processing temperature polymeric composition; and subsequent to the increasing the temperature of the entire first and second articles, while the at least a portions of the first and second articles remain on the molding surface, decreasing the temperature of the entire first and second elements to a temperature below the melting temperature Tm of the low processing temperature polymeric composition, thereby forming a article.
[0055]The present disclosure is directed to materials and processes for making textiles, articles of sporting equipment, and articles of wear, including articles of footwear and articles of apparel. It should be understood that a variety of articles of sporting equipment are contemplated by the present disclosure, including backpacks, equipment bags, hats, protective gear, and the like. It should be understood that a variety articles of wear are contemplated by the present disclosure, including knit articles. A non-limiting list of articles of wear contemplated by the present disclosure includes footwear, shirts, pants, socks, jackets or other outerwear, protective equipment, hats, and undergarments, e.g., brassieres. In certain aspects, the article of wear is an article of footwear. “Article of footwear” is used to refer to an article intended for wear on a human foot, e.g., in some aspects, an article of footwear can be a shoe. In some aspects, the disclosed materials and processes can be used in the manufacture of a component used in an article of wear, such as an article of footwear. An exemplary component of an article of wear include, but are not limited to, an upper for an article of footwear.
[0056]An exemplary article of footwear is athletic or sports footwear, including, but not limited to, running shoes, basketball shoes, soccer shoes, baseball shoes, football shoes, tennis shoes, rugby shoes, cross-training shoes, walking shoes, hiking boots, golf shoes, sneakers, and the like. Alternatively, the article of footwear can be non-athletic footwear, including, but not limited to, dress shoes, loafers, casual wear shoes, sandals, and boots, including work boots. A shoe can or cannot enclose the entire foot of a wearer. For example, a shoe could be a sandal or other article that exposes large portions of a wearing foot. The person of ordinary skill in the art can appreciate, therefore, that the materials and processes disclosed herein apply to a wide variety of footwear types or styles, in addition to the specific type or style discussed in the following material and depicted in the accompanying figures.
[0057]The disclosed textiles and articles can include yarns, fibers, or a combination of yarns and fibers that comprise a low processing temperature polymeric composition (described below) and yarns, fibers, or a combination of yarns and fibers that comprises a high processing temperature polymeric composition (also described below). The disclosed textiles and articles comprise at least two yarns that balance a number of material properties as described herein. Moreover, the yarns and fibers used in the disclosed materials and processes will be selected based on a variety of factors, including the type of the footwear to be manufactured, e.g., whether it is an article of athletic or non-athletic footwear, and the typical use of the article of footwear. For example, in considering the types of yarns and fibers to use in an article of athletic footwear, the type of sport an article of athletic footwear is used for and/or the conditions (e.g., indoor or outdoor) the article of athletic footwear is to be worn on can be considered.
[0058]The disclosed articles can include shaped components, films, fibers, yarns, or a combination thereof that comprise a low processing temperature polymeric composition (described below) and shaped components, films, fibers, yarns, or a combination thereof that comprises a high processing temperature polymeric composition (also described below). The disclosed articles comprise at least two polymeric compositions that balance a number of material properties as described herein. Moreover, the compositions and processes used to form these articles will be selected based on a variety of factors, including the type of the article to be manufactured, and the typical use of the article.
[0059]In various aspects, the disclosed shaped component, films, textiles and articles comprise two distinct polymeric compositions, where one of the polymeric compositions can melt or deform in a thermoforming process performed over a first temperature range (referred to herein as the low processing temperature polymeric composition), while the other polymeric composition maintains its shape over the first temperature range (referred to herein as the high processing temperature polymeric composition). It is to be understood that reference to a “polymeric composition” is intended to refer to a composition comprising at least one polymer. Optionally, additional ingredients such as pigments, dyes, fillers, processing aids, and the like, can be present in the polymeric composition. The low processing temperature composition comprises one or more first thermoplastic polymers. The high processing temperature composition comprises one or more second polymers. In some examples, the high processing temperature polymeric composition is a thermoplastic composition, and comprises one or more second thermoplastic polymers. The polymeric compositions of the present disclosure can be used to form shaped components, films, and/or fibers. The shaped components and/or films can in turn be incorporated into articles as described herein. The fibers can in turn be used to form yarns and textiles as described herein, and these yarns and textiles can also be incorporated into articles as described herein. In a further aspect, the disclosed textiles and articles comprise a first film, fiber or yarn comprising a low processing temperature polymeric composition and a second film, fiber or yarn comprising a high processing temperature polymeric composition.
[0060]As mentioned above, the articles described herein can include materials, such as a shaped component, a film, a fiber, a yarn and/or a textile, wherein the article is at least partly formed of a low processing temperature polymeric composition and a high processing temperature polymeric composition. In some examples, the material is at least partly formed of a low processing temperature polymeric composition and a high processing temperature polymeric composition. As used herein, a “low processing temperature polymeric composition” and a “high processing temperature polymeric composition” are relative terms with regard to the relative creep relaxation temperature (Tcr), Vicat softening temperature (Tvs), heat deflection temperature (Thd), and/or melting temperature (Tm) of each of these compositions. The creep relaxation temperature (Tcr), Vicat softening temperature (Tvs), heat deflection temperature (Thd), and melting temperature (Tm) of the low processing temperature polymeric composition are also understood to be lower than the decomposition temperature of the high processing temperature polymeric composition. These parameters are further described in detail below. It should be understood that other properties and parameters can differ between the low processing temperature polymeric composition and the high processing temperature polymeric composition, as discussed in detail below. In various aspects, the low processing temperature polymeric composition and/or the high processing temperature polymeric composition or both can be present in a shaped component, film, textile, yarn or fiber.
[0061]In various aspects, when both the low processing temperature polymeric composition and the high processing temperature polymeric composition are thermoplastic compositions, the melting temperature (Tm) of a low processing temperature polymeric composition is below at least one of the following properties of the high processing temperature polymeric composition: (1) creep relaxation temperature (Tcr); (2) Vicat softening temperature (Tvs); (3) heat deflection temperature (Thd); or (4) melting temperature (Tm). That is, for example, the low processing temperature polymeric composition exhibits a melting temperature (Tm) that is below the temperature of one or more of a creep relaxation temperature (Tcr), a Vicat softening tempera