Nonwoven Material, Method Of Making Same, And Articles Incorporating The Nonwoven Material

Patent metadata

Field	Value
Publication number	US-2016168774-A1
Application number	US-201514932702-A
Country	US
Kind code	A1
Filing date	Nov 4, 2015
Priority date	Dec 16, 2014
Publication date	Jun 16, 2016
Grant date	—

Abstract

A method for making a nonwoven material includes dispensing fiber particles onto a substrate. The substrate may be shaped or flat. A separate substance may be utilized to enhance the adhesion of the fiber particles onto the substrate. The substrate may be charged to enhance the adhesion of the fiber particles onto the substrate. The articles resulting from this process have the same contours as the substrate as the fiber particles are matted and cured on the substrate prior to removing the nonwoven fabric from the substrate. The resultant articles may be monofabric articles, including only the fiber particles and a binder.

First claim

What is claimed is:

1 . A method of making a nonwoven article, the method comprising:
preparing a substrate to receive fiber particles; depositing a first plurality of fiber particles onto the substrate; applying an adhesive to the plurality of fiber particles; depositing a second plurality of fiber particles onto the substrate; matting the first plurality of fiber particles and the second plurality of fiber particles together to form a matted ply of a resultant nonwoven article; curing the resultant nonwoven article; and removing the resultant nonwoven article from the substrate.

2 . The method according to claim 1 , wherein the substrate is configured to produce an article having curvature along at least two axes.

3 . The method according to claim 2 , wherein the substrate is a last for an article of footwear.

4 . The method according to claim 1 , wherein the substrate is substantially flat to produce a sheet of fabric.

5 . The method according to claim 1 further comprising the steps of
applying a second adhesive to the matted ply;
depositing a third plurality of fiber particles onto the matted ply; and
matting the third plurality of fiber particles together to form a second matted ply of the resultant nonwoven article.

6 . The method according to claim 5 further comprising the step of applying a mask to a portion of the matted ply prior to depositing at least one of the second adhesive and the third plurality of fiber particles onto the matted ply.

7 . The method according to claim 1 further comprising the step of applying a mask to a portion of the substrate prior to depositing the plurality of fiber particles onto the substrate.

8 . The method according to claim 1 , wherein the step of preparing the substrate includes applying to the substrate a substance designed to capture the fiber particles.

9 . The method of claim 1 , wherein the step of preparing the last includes applying a charge to the substrate.

10 . The method according to claim 1 , wherein depositing the first plurality of fiber particles to the substrate includes blowing the first plurality of fiber particles onto the substrate.

11 . The method according to claim 1 , wherein applying the adhesive includes spraying the adhesive onto the fiber particles.

12 . The method according to claim 1 , wherein matting the fiber particles includes a mechanical compressing of the first plurality of fiber particles and second plurality of fiber particles.

13 . The method according to claim 12 , wherein the mechanical compressing includes using a roller to entangle the first plurality of fiber particles and the second plurality of fiber particles.

14 . A method of making a nonwoven upper, the method comprising:
preparing a last to receive a plurality of fiber particles; depositing the plurality of fiber particles onto the last in the shape of an upper, including a throat opening; applying an adhesive to the plurality of fiber particles; matting the fiber particles to form a matted layer of the upper; curing the adhesive; and removing the resultant upper from the last.

15 . The method according to claim 14 , wherein the step of preparing the last includes applying to the last a substance designed to capture the plurality of fiber particles.

16 . The method according to claim 15 , wherein the substance is applied to the last to form an outline of the throat opening of the upper.

17 . The method according to claim 15 , wherein the substance facilitates removing the upper from the last.

18 . The method according to claim 17 , wherein the substance is petroleum jelly.

19 . The method according to claim 17 , wherein the substance is silicone.

20 . The method according to claim 17 , wherein the step of preparing the last includes applying a release film to the last.

21 . The method according to claim 14 , wherein the step of preparing the last includes applying a charge to the last.

22 . The method according to claim 21 , wherein the last has a negative charge when the charge is applied to the last and each fiber in the plurality of fiber particles has a positive charge.

23 . The method according to claim 14 further comprising removing a completed upper from the last after neutralizing the charge to the last.

24 . The method according to claim 14 further comprising the step of incorporating the resultant upper into an article of footwear.

25 . The method according to claim 24 further comprising associating the resultant upper with a sole.

26 . The method according to claim 24 further comprising finishing the throat opening with at least one of a tongue and a securing system.

27 . A method of making a nonwoven fabric, the method comprising:
preparing a substantially flat substrate to receive a plurality of fiber particles; depositing the plurality of fiber particles onto the substantially flat substrate; applying an adhesive to the plurality of fiber particles; matting the fiber particles to form a matted layer of the nonwoven fabric; curing the adhesive; and removing the resultant nonwoven fabric from the substantially flat substrate.

28 . The method according to claim 27 , wherein the step of preparing the substantially flat substrate includes applying to the substantially flat substrate a substance designed to capture the plurality of fiber particles.

29 . The method according to claim 28 , wherein the substance facilitates removing the upper from the substantially flat substrate.

30 . The method according to claim 28 , wherein the substance is one of petroleum jelly and silicone.

31 . The method according to claim 28 , wherein the step of preparing the substantially flat substrate includes applying a release film to the substantially flat substrate.

32 . The method according to claim 27 , wherein the step of preparing the substantially flat substrate includes applying a charge to the substantially flat substrate.

33 . The method according to claim 32 , wherein the substantially flat substrate has a negative charge when the charge is applied to the substantially flat substrate and each fiber in the plurality of fiber particles has a positive charge.

34 . The method according to claim 27 , wherein removing the resultant fabric from the substantially flat substrate occurs after neutralizing the charge to the substantially flat substrate.

35 . The method according to claim 27 further comprising incorporating the nonwoven fabric into an article.

36 . The method according to claim 35 , wherein incorporating the nonwoven fabric into an article includes cutting the nonwoven fabric into a pattern.

37 . The method according to claim 35 , wherein the article is an article of apparel.

38 . An article incorporating a nonwoven fabric, the article comprising:
a first layer incorporating a first plurality of matted fiber particles and an adhesive, wherein each fiber in the first plurality of matted fiber particles is a monofilament, and where all of the fibers in the first plurality of matted fiber particles is the same monofilament; and a second layer incorporating a second plurality of matted fiber particles

Assignees

• Nike Inc

Inventors

• Breithaupt Chris
• Wood Christina M

Classifications

• D04H1/645 Primary

  Impregnation followed by a solidification process · CPC title

• A43B7/125

  provided with a vapour permeable member, e.g. a membrane (A43B23/022 takes precedence) · CPC title

• D04H1/76

  otherwise than in a plane, e.g. in a tubular way · CPC title

• A43D25/183

  by nozzles · CPC title

• D10B2501/043

  Footwear · CPC title