# US 11,998,080 B2 · Textiles and articles and processes for making the same

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- Number: US 11,998,080 B2
- Document ID: US11998080B2
- Status: Granted
- Kind: B2
- Application number: 16/945,441
- Filed: 2020-07-31
- Published: 2021-02-04
- Granted: 2024-06-04
- Earliest claimed: 2019-08-02
- Assignees: NIKE, Inc.
- Applicants: NIKE, Inc.
- Inventors: Devon Frazier; Walter M. Hancock; Dave Klinger; Robert Mervar; Brian G. Prevo; Hilary Walker
- Web page: https://patentgrep.com/patent/US11998080B2

## CPC

- A43B 1/028: Synthetic or artificial fibres
- A43B 13/122: {characterised by the outsole or external layer}
- A43B 1/04: braided, knotted, knitted or crocheted
- A43B 5/02: Football boots {or shoes, i.e. for soccer, football or rugby}
- A43B 5/06: Running shoes; Track shoes
- A43B 13/02: characterised by the material
- A43B 13/026: {Composites, e.g. carbon fibre or aramid fibre; the sole, one or more sole layers or sole part being made of a composite}
- A43B 13/04: Plastics, rubber or vulcanised fibre
- A43B 13/12: Soles with several layers of different materials
- A43B 13/22: Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer
- A43B 13/223: {Profiled soles}
- A43B 13/26: projecting beyond the sole surface
- A43B 23/0205: {characterised by the material (material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08)}
- A43B 23/0215: {Plastics or artificial leather}
- A43B 23/0225: {Composite materials, e.g. material with a matrix}
- A43B 23/0235: {Different layers of different material}
- A43B 23/0245: {characterised by the constructive form}
- A43B 23/0255: {assembled by gluing or thermo bonding}
- A43B 23/026: {Laminated layers}
- A43B 23/0265: {having different properties in different directions}
- B29C 51/12: of articles having inserts or reinforcements
- B29C 51/145: {having at least one layer of textile or fibrous material combined with at least one plastics layer}
- B29D 35/122: {Soles}
- B29D 35/126: {Uppers}
- B29D 35/146: {Uppers}
- B32B 5/026: {Knitted fabric}
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/40: comprising polyurethanes
- D02G 3/36: Cored or coated yarns or threads ({D02G3/34, D02G3/40 take precedence}; elastic yarns or threads D02G3/32)
- D04B 1/16: synthetic threads
- D06M 15/233: aromatic, e.g. styrene
- D06M 15/70: combined with mechanical treatment
- B29K 2009/06: SB polymers, i.e. butadiene-styrene polymers
- B29L 2031/504: {Soles}
- B29L 2031/505: {Uppers}
- B32B 2307/536: Hardness
- B32B 2437/02: Gloves, shoes
- D06M 2101/32: Polyesters
- D06M 2101/34: Polyamides
- D06M 2200/35: Abrasion, pilling or fibrillation resistance
- D06M 2200/40: Reduced friction resistance, lubricant properties; Sizing compositions
- D10B 2331/02: polyamides (D10B2331/08 takes precedence)
- D10B 2331/04: polyesters, e.g. polyethylene terephthalate [PET]
- D10B 2331/10: polyurethanes
- D10B 2401/041: thermoplastic; thermosetting
- D10B 2401/06: Load-responsive characteristics
- D10B 2401/061: elastic
- D10B 2401/063: high strength
- D10B 2501/043: Footwear
- A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D02G: CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D04B: KNITTING
- D06M: TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES

## Abstract

Films, fibers, filaments, yarns and textiles including thermoplastic elastomeric compositions are described, as are methods of making the films, fibers, filaments, yarns and textiles. These films, fibers, filaments, yarns and textiles can be used to make articles of apparel, footwear, and sporting equipment. When thermoformed, the thermoplastic elastomeric compositions can impart abrasion resistance, traction, and other advantageous properties to the articles. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

## Claims

### Claim 1

An outsole for an article of footwear, comprising:
a textile comprising a thermoformed network of yarns comprising a first core yarn and a first polymeric composition, wherein the first polymeric composition consolidates the thermoformed network of yarns by surrounding at least a portion of the first core yarn and occupying at least a portion of spaces between yarns in the thermoformed network of yarns, and wherein the first polymeric composition comprises a thermoplastic elastomeric polyurethane, wherein the thermoplastic elastomeric polyurethane is a thermoplastic elastomeric polyester polyurethane, a thermoplastic elastomeric polyether polyurethane, or any combination thereof, wherein the first polymeric composition has a Durometer Hardness of from about 70 to about 80 Shore A, as determined using the Durometer Hardness Test;
wherein the thermoformed network of yarns is a thermoformed product of a first textile comprising a first network of yarns including a first coated yarn comprising the first core yarn and a first coating, the first coating comprising the first polymeric composition, the first core yarn comprising a second polymeric composition, wherein the first coating is axially centered surrounding the core yarn, the first coating has a nominal average outer diameter of the coated yarn is up to about 1.0 millimeter, the first coating has an average radial coating thickness of about 50 micrometers to about 200 micrometers, and wherein, in the thermoformed network of yarns, the first polymeric composition consolidating the thermoformed network of yarns is a re-flowed and re-solidified product of the first polymeric composition of the first coating of the first coated yarn;
wherein, in the first coated yarn, the first polymeric composition has a first melting temperature greater than about 110 degrees Celsius and less than about 190 degrees Celsius, the second polymeric composition of the first core yarn has a second deformation temperature, and the second deformation temperature is at least 50 degrees Celsius greater than the first melting temperature of the first polymeric composition;
wherein a first side of the thermoformed network defines at least a portion of a surface of the outsole configured to be externally-facing or ground-facing or ground-contacting when the outsole is part of a finished article of footwear, and
the first polymeric composition when thermoformed has a cold Ross flex of about 120,000 to about 180,000.

### Claim 2 (depends on 1)

The outsole of claim 1, wherein the thermoformed network of yarns defines at least a portion of the surface of the outsole configured to be ground-contacting when the outsole is part of the finished article of footwear, and the thermoformed network further comprises a layer of a third polymeric composition, wherein the third polymeric composition is a thermoplastic elastomeric composition comprising thermoplastic elastomeric polyurethane; wherein a first side of the layer defines the surface of the outsole configured to be ground-contacting when the outsole is part of a finished article of footwear, and a second side of the layer opposite the first side is thermally bonded to a first side of the textile via the first polymeric composition of the textile.

### Claim 3 (depends on 2)

The outsole of claim 2, wherein the layer of the third polymeric composition is an extruded layer or an injection molded layer or a film layer.

### Claim 4 (depends on 2)

The outsole of claim 2, wherein the thermoplastic elastomeric polyurethane of the first polymeric composition and the thermoplastic elastomeric polyurethane of the third polymeric composition each have the same chemical structure, or wherein the first polymeric composition and the third polymeric composition each have melting temperatures within about 10 degrees Celsius of each other, or both.

### Claim 5 (depends on 2)

The outsole of claim 2, wherein the layer of the third polymeric composition has a thickness of from about 0.1 millimeter to about 5 millimeters.

### Claim 6 (depends on 1)

The outsole of claim 1, wherein the textile is bonded to a foam sole component.

### Claim 7 (depends on 1)

The upper of claim 1, wherein the thermoplastic elastomeric polyurethane is a thermoplastic elastomeric polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof.

### Claim 8 (depends on 1)

The upper of claim 1, wherein the thermoplastic elastomeric polyurethane comprises an aromatic polyester thermoplastic elastomeric polyurethane, an aliphatic polyester thermoplastic elastomeric polyurethane, or a combination thereof.

### Claim 9 (depends on 1)

The outsole of claim 1, wherein the first polymeric composition has a melt flow index of about 2 grams/10 minutes to about 50 grams/10 minutes at 160 degrees Celsius using a test weight of 2.16 kilograms as determined using ASTM D1238-13, or a melt flow index greater than about 2 grams/10 minutes at 190 degrees centigrade or 200 degrees Celsius when using a test weight of 10 kilograms as determined using the Melt Flow Index Test.

### Claim 10 (depends on 1)

The outsole of claim 1, wherein the first core yarn comprises a polyester or a polyamide having a linear density from about 100 denier to about 300 denier.

### Claim 11 (depends on 2)

The outsole of claim 2, wherein the first polymeric composition or the third polymeric composition has a dry dynamic coefficient of friction (COF) of greater than 1.0 as determined against dry smooth concrete using the Coefficient of Friction Test.

### Claim 12 (depends on 2)

The outsole of claim 2, wherein the first polymeric composition or the third polymeric composition has a wet dynamic coefficient of friction (COF) of greater than 0.3 as determined against wet smooth concrete using the Coefficient of Friction Test.

### Claim 13 (depends on 2)

The outsole of claim 2, wherein, for the first polymeric composition or the third polymeric composition, a difference between a wet dynamic coefficient of friction and a dry dynamic coefficient of friction is less than 40 percent as determined using the Coefficient of Friction Test.

### Claim 14 (depends on 1)

The outsole of claim 1, wherein, for the thermoformed network of yarns, a difference between a dry dynamic coefficient of friction and a wet coefficient of friction is less than 55 percent as determined using the Coefficient of Friction Test.

### Claim 15 (depends on 1)

The outsole of claim 1, wherein a difference between a static coefficient of friction of a dry surface and a wet surface of the textile is less than 40 percent as determined using the Coefficient of Friction Test.

### Claim 16 (depends on 1)

The outsole of claim 1, wherein the textile has a dry shoe traction of greater than 6 and a wet shoe traction of greater than 5 as determined using the Method to Determine Whole Shoe Traction after Biomechanical Abrasion.

### Claim 17 (depends on 1)

The outsole of claim 1, wherein the textile has an abrasion loss of less than 0.50 cubic centimeters lost after 3,000 cycles as determined using the Akron Abrasion Test.

### Claim 18 (depends on 1)

The outsole of claim 1, wherein the textile has an abrasion loss of less than 0.30 cubic centimeters lost as determined using the DIN Abrasion Test.