Knitted textile and method of forming

Patent metadata

Field	Value
Publication number	US-11788219-B2
Application number	US-202217982873-A
Country	US
Kind code	B2
Filing date	Nov 8, 2022
Priority date	Apr 7, 2017
Publication date	Oct 17, 2023
Grant date	Oct 17, 2023

Abstract

A knitted textile having a first layer including a first yarn with a thermoplastic composition integrally formed with a second layer including a second yarn, the first yarn forming an array of knitted patterns defining voids through the first layer to the second layer. The first layer may be heat treated to form a film. Treatment of the first layer may change zonal and directional tensile properties of the knitted textile. The Poisson's ratio of the knitted textile may be greater than or equal to zero in a first axis and/or a second axis, before and/or after treatment. Articles of apparel, including articles of footwear and garments incorporating the knitted textile, and methods of forming the knitted textiles and articles are disclosed.

First claim

What is claimed is:

1. A knitted textile with a knitted structure, comprising:
a first layer of the knitted structure comprising a first yarn, the first layer having a first surface comprising a film, the film comprising the first yarn in reflowed 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 located on the opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn;
the first yarn and the second yarn forming interlocking knit stitches in the second layer and/or in the first layer adjacent the film;
the voids passing through the first layer and to the second layer, wherein a portion of the second yarn of the second layer is exposed through the voids in the first layer,
wherein the first yarn has a first melting temperature, and the second yarn has a second melting temperature or a second decomposition temperature, and the first melting temperature is 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 lower of the second melting temperature and the second decomposition temperature.

3. The knitted textile of claim 1 , wherein at least 90% of the first yarn is formed from a first thermoplastic composition, and wherein the second yarn is formed from a second composition.

4. The knitted textile of claim 1 , wherein a surface area of the voids increases to expose more of the second layer when tension is applied to the knitted structure.

5. The knitted textile of claim 1 , wherein the array of fused patterns are discontinuous in the first layer.

6. The knitted textile of claim 1 , wherein the knitted structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

7. The knitted textile of claim 6 , wherein a Poisson's ratio of the knitted textile is greater than or equal to zero when measured along the first axis, along the second axis, or along both.

8. The knitted textile of claim 6 , wherein a Poisson's ratio of the knitted textile is less than zero when measured along the first axis or along the second axis.

9. An article of footwear comprising an upper and a sole structure, the upper comprising a knitted textile with a knitted structure, the knitted structure comprising:
a first layer of the knitted structure comprising a first yarn,
the first layer having a first surface comprising a film, the film comprising the first yarn in reflowed 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 located on the opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn;
the first yarn and the second yarn forming interlocking knit stitches in the second layer and/or in the first layer adjacent the film;
the voids passing through the first layer and to the second layer, wherein a portion of the second yarn of the second layer is exposed through the voids in the first layer,
wherein the first yarn has a first melting temperature, and the second yarn 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.

10. The article of footwear of claim 9 , wherein the knitted structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

11. The article of footwear of claim 10 , wherein the first axis is oriented medial-to-lateral on the article of footwear, and the second axis is oriented from toe-to-heel on the article of footwear.

12. The article of footwear of claim 10 , wherein a Poisson's ratio of the knitted textile is greater than or equal to zero when measured along the first axis, along the second axis, or along both.

13. The article of footwear of claim 10 , wherein a Poisson's ratio of the knitted textile is less than zero when measured along the first axis or along the second axis.

14. The article of footwear of any one of claim 9 , wherein the first layer is disposed on an exterior surface of the article of footwear.

15. A method of manufacturing an article of footwear, the method comprising:
forming a knitted structure of a knitted textile, the knitted structure comprising:
a first layer comprising a first yarn, the first yarn comprising a first melting temperature, and
a second layer located on the opposite side of the knitted textile from the first layer and integrally formed with the first layer, the second layer comprising a second yarn comprising 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 knitted patterns formed with the first yarn, the array of knitted patterns defining voids in the first layer, the voids passing through the first layer and to the second layer, wherein a portion of the second yarn of the second layer is exposed through the voids in the first layer,
the first melting temperature being lower than the lowest of the second melting temperature and the second decomposition temperature;
forming the knitted 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 yarn to form a film on the first layer; and
attaching the upper to an outsole.

16. The method of claim 15 , wherein the knitted structure has a first axis and a second axis, the first axis being perpendicular to the second axis.

17. The method of claim 16 , wherein the first axis is oriented medial-to-lateral on the article of footwear, and the second axis is oriented from toe-to-heel on the article of footwear.

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

19. The method of claim 17 , wherein a Poisson's ratio of the knitted textile is less than zero when measured along the first axis or along the second axis.

20. The method of claim 15 , 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.

Assignees

• Nike Inc

Inventors

• Macgilbert John S
• Mcfarland Ii William C

Classifications

• D04B21/165 Primary

  with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics (layered products not united by stitch loops B32B5/22) · CPC title

• A43B1/04

  braided, knotted, knitted or crocheted · CPC title

• D04B1/16 Primary

  synthetic threads · CPC title

• D04B1/24

  wearing apparel · CPC title

• D04B21/207

  Wearing apparel or garment blanks · CPC title