US20160168774A1 - Nonwoven Material, Method Of Making Same, And Articles Incorporating The Nonwoven Material - Google Patents

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.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 62/092,517, entitled “NONWOVEN MATERIAL AND METHOD OF MAKING SAME AND ARTICLES INCORPORATING THE NONWOVEN MATERIAL”, and filed on Dec. 16, 2014, which application is hereby incorporated by reference.
BACKGROUND
• The present invention relates generally to nonwoven materials, methods of making nonwoven materials, and articles made from nonwoven materials. In particular, the present invention relates to a breathable nonwoven material, methods of making the nonwoven material, and articles incorporating the nonwoven material.
• Fabrics may be incorporated into a variety of products for both personal and industrial purposes. Nonwoven fabrics may be used in various products, and nonwoven fabrics may be manufactured for incorporation into a particular type of article. Breathable nonwoven fabrics may be desirable for articles of footwear and articles of apparel. Certain types of conventional nonwoven materials made with a backing material may not be sufficiently breathable for incorporation into articles of footwear and articles of apparel, while other types of conventional nonwoven material made without a backing material may not be sufficiently durable for incorporation into articles of footwear and articles of apparel.
SUMMARY
• A nonwoven fabric may form an article, a component of an article, or form a material that can be used to form an article or a component of an article. A method of making the nonwoven fabric includes depositing a plurality of fiber particles onto a substrate. The fiber particles may be relatively long compared to the industry standard. The substrate may have any shape, including a flat surface, a curved surface, or a three-dimensional surface. The shape of the substrate is imparted to the resultant fabric, so the resultant fabric can be formed into the shape of the desired article or a component of the desired article in addition to a sheet of fabric from which components of the desired article may be cut.
• The substrate may be prepared to accept the fiber particles, such as by spreading a gelatinous substance on the surface of the substrate to which the fiber particles may temporarily adhere or by charging the substrate with an electromagnetic charge. The fiber particles are then deposited onto the substrate using any method known in the art, such as by blowing the fiber particles onto the substrate. An adhesive is applied to the fiber particles prior to matting the fiber particles into a nonwoven fabric layer.
• This process of depositing fiber particles, applying adhesive, and matting the fiber particles may be repeated until a desired number of layers or a desired thickness of the resultant nonwoven fabric is achieved. Optionally, some layers may include a mask to prevent fiber particles from accumulating in selected areas to manipulate the thickness, flexibility, breathability, and other properties of the nonwoven fabric in those selected areas. The adhesive is then cured, and the resultant nonwoven fabric is removed from the substrate and optionally sent for additional processing. Nonwoven articles made using this method include articles of apparel and articles of footwear.
• In one aspect, the invention provides a method of making a nonwoven article, the method comprising the steps of: preparing a substrate to receive a plurality of fiber particles, depositing the 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 adhesive and the first plurality of fiber particles, matting the fiber particles to form a matted layer, and removing the resultant nonwoven article from the substrate.
• In one aspect, the invention provides a method of making a nonwoven upper, the method comprising the steps of 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, depositing a second plurality of fiber particles onto the adhesive and the first 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.
• In one aspect, the invention provides a method of making a nonwoven fabric, the method comprising the steps of 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, depositing a second plurality of fiber particles onto the adhesive and the first 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 last.
• In one aspect the invention provides an article incorporating a nonwoven fabric. The article includes 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. The article also includes a second layer incorporating a second plurality of matted fiber particles and the adhesive, wherein each fiber in the second plurality of matted fiber particles is a monofilament, and where all of the fibers in the second plurality of matted fiber particles is the same monofilament.
• Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
• The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
• FIG. 1 is a perspective view of an embodiment of an article of footwear having a nonwoven upper;
• FIG. 2 is a perspective, exploded view of the embodiment of the article of footwear having a nonwoven upper shown inFIG. 1;
• FIG. 3 is a perspective view of an embodiment of a nonwoven upper;
• FIG. 4 is a flowchart of an embodiment of a method of making a nonwoven upper;
• FIG. 5 shows a last for use in the embodiment of a method of making a nonwoven upper;
• FIG. 6 shows the last ofFIG. 5 being prepared to receive a first layer of fiber particles;
• FIG. 7 shows an embodiment of the depositing of the first layer of fiber particles onto the last;
• FIG. 8 shows an embodiment of applying an adhesive to the first layer of fiber particles;
• FIG. 9 shows an embodiment of applying a second layer of fiber particles onto the first layer of fiber particles and adhesive;
• FIG. 10 shows an embodiment of mechanically matting the first and second layers of fiber particles to form a first ply of nonwoven material;
• FIG. 11 shows an embodiment of applying an adhesive to the third layer of fiber particles, using a mask to inhibit the application of adhesive in a selected location;
• FIG. 12 shows an embodiment of depositing a third layer of fiber particles onto the last and the first ply of nonwoven material, using a mask to inhibit the deposition of fiber particles in a selected location;
• FIG. 13 shows an embodiment of mechanically matting the third layer of fiber particles to form a second ply of nonwoven material and curing the nonwoven material;
• FIG. 14 shows an embodiment of removing the completed seamless nonwoven upper from the last;
• FIG. 15 shows an embodiment of a nonwoven upper with void areas due to the masking;
• FIG. 16 shows a perspective view of an embodiment of a flat substrate;
• FIG. 17 shows an embodiment of preparing the flat substrate to receive fiber particles;
• FIG. 18 shows an embodiment of the depositing of a fourth layer of fiber particles onto the flat substrate;
• FIG. 19 shows an embodiment of applying an adhesive to the fourth layer of fiber particles;
• FIG. 20 shows an embodiment of applying a fifth layer of fiber particles onto the fourth layer and the adhesive binder;
• FIG. 21 shows an embodiment of mechanically matting the fourth and fifth layers of fiber particles to form a first ply of nonwoven material;
• FIG. 22 shows an embodiment of applying an adhesive to the first ply of nonwoven material;
• FIG. 23 shows an embodiment of depositing a sixth layer of fiber particles onto the first ply of nonwoven material and the applied adhesive;
• FIG. 24 shows an embodiment of matting the sixth layer of fiber particles to form a second ply of nonwoven material interconnected with the first ply of nonwoven material;
• FIG. 25 shows an embodiment of curing the nonwoven material in a convection oven;
• FIG. 26 shows an embodiment of removing the resultant nonwoven fabric from the substrate;
• FIG. 27 shows an embodiment of a resultant nonwoven fabric;
• FIG. 28 shows a charged last for use in the embodiment of a method of making a seamless nonwoven upper;
• FIG. 29 shows an embodiment of the depositing of a seventh layer of fiber particles onto the charged last;
• FIG. 30 shows an embodiment of applying an adhesive to the seventh layer of fiber particles;
• FIG. 31 shows an embodiment of applying an eighth layer of fiber particles onto the seventh layer of fiber particles and the charged last;
• FIG. 32 shows an embodiment of mechanically matting the seventh and eighth layers of fiber particles to form a ply of nonwoven material;
• FIG. 33 shows an embodiment of applying an adhesive to the ply of nonwoven material;
• FIG. 34 shows an embodiment of applying a ninth layer of fiber particles onto the ply of nonwoven material and the adhesive binder;
• FIG. 35 shows an embodiment of mechanically matting the ninth layer of fiber particles to form a second ply of nonwoven material;
• FIG. 36 shows an embodiment of removing the completed seamless nonwoven upper from the uncharged last;
• FIG. 37 shows a perspective view of an embodiment of a seamless nonwoven upper;
• FIG. 38 shows a perspective view of an embodiment of a charged flat substrate;
• FIG. 39 shows an embodiment of the depositing of a tenth layer of fiber particles onto the charged substrate;
• FIG. 40 shows an embodiment of applying an adhesive to the tenth layer of fiber particles;
• FIG. 41 shows an embodiment of depositing an eleventh layer of fiber particles onto the charged substrate, tenth layer of fiber particles, and adhesive binder;
• FIG. 42 shows an embodiment of mechanically matting the tenth and eleventh layers of fiber particles to form a ply of nonwoven material;
• FIG. 43 shows an embodiment of applying an adhesive to the ply of nonwoven material;
• FIG. 44 shows an embodiment of depositing a twelfth layer of fiber particles onto the first ply of nonwoven material and the adhesive binder;
• FIG. 45 shows an embodiment of mechanically matting the twelfth layer of fiber particles to form a second layer of nonwoven material and curing the nonwoven material;
• FIG. 46 shows an embodiment of removing the completed seamless nonwoven fabric from the uncharged substrate;
• FIG. 47 shows an embodiment of an article of apparel being made from a nonwoven material on a body last; and
• FIG. 48 shows an embodiment of an article of apparel and its pattern on a nonwoven material.
DETAILED DESCRIPTION
• A variety of products are at least partially formed from fabrics. As examples, articles of apparel (e.g., shirts, pants, socks, jackets, undergarments, footwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats) are often formed from various fabric elements that are joined through stitching or adhesive bonding. Fabrics may also be utilized in bed coverings (e.g., sheets, blankets), table coverings, towels, flags, tents, sails, and parachutes. Fabrics utilized for industrial purposes are commonly referred to as technical fabrics and may include structures for automotive and aerospace applications, filter materials, medical fabrics (e.g. bandages, swabs, implants), and industrial apparel that protects or insulates against heat and radiation.
• Although some products are formed from one type of fabric, many products may also be formed from two or more types of fabrics in order to impart different properties to different areas. As an example, shoulder and elbow areas of a shirt may be formed from a fabric that imparts durability (e.g., abrasion-resistance) and stretch-resistance, whereas other areas may be formed from a fabric that imparts breathability, comfort, stretch, and moisture-absorption. As another example, an upper for an article of footwear may have a structure that includes numerous layers formed from various types of fabrics and other materials (e.g., polymer foam, leather, synthetic leather), and some of the layers may also have areas formed from different types of fabrics to impart different properties. As yet another example, straps of a backpack may be formed from non-stretch fabric elements, lower areas of a backpack may be formed from durable and water-resistant fabric elements, and a remainder of the backpack may be formed from comfortable and compliant fabric elements. Accordingly, many products may incorporate various types of fabrics in order to impart different properties to different portions of the products.
• In order to impart the different properties to different areas of a product, fabric elements or components formed from the materials may be cut to desired shapes and then joined together, usually with stitching or adhesive bonding. As the number and types of fabric elements incorporated into a product increases, the time and expense associated with transporting, stocking, cutting, and joining the fabric elements may also increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and types of fabric elements incorporated into a product increases. Moreover, products with a greater number of fabric elements and other materials may be more difficult to recycle than products formed from few elements and materials. By decreasing the number of elements and materials utilized in a product, therefore, waste may be decreased while increasing the manufacturing efficiency and recyclability.
• Fabrics may be defined as any manufacture from fibers, filaments, or yarns having a generally two-dimensional structure (i.e., a length and a width that are substantially greater than a thickness). In general, fabrics may be classified as mechanically-manipulated fabrics or non-woven fabrics. Mechanically-manipulated fabrics are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines. Non-woven fabrics are webs or mats of filaments that are bonded, fused, interlocked, or otherwise joined. Felt and nonwoven material are common examples of non-woven fabrics.
• Flocking, generally, is the process of depositing many small fiber particles, called fiber particles, onto a surface or backing layer. The fiber particles affix onto the surface. However, flocking includes retaining the surface or backing layer as part of the resultant article. The technique described below for making nonwoven material is inspired by conventional flocking techniques, but no backing layer remains in the resultant nonwoven material; the fiber particles and binder are matted to produce a flexible fabric. The resultant nonwoven material may have enhanced breathability as compared to other types of woven or nonwoven materials because the process of depositing fiber particles and matting those particles together allows for large pores or air gaps between the fiber particles. This breathability may be desirable for articles of footwear and articles of apparel.
• FIGS. 1 and 2 show an embodiment of one type of article offootwear100 incorporating a nonwoven material. Nonwoven upper101 is a breathable seamless upper. For the purposes of this disclosure, a seamless upper means that the upper lacks overlapping edges or portions that are joined together by any conventional method, such as stitching, welding, or with adhesives. A seamless upper may be joined to another component, such as a sole124 and other finishing or decorative elements, such as aneyestay reinforcing element130, a first protective portion ortoe counter125 disposed on a toe of nonwoven fabric upper101, a second protective portion or heel counter126 disposed on a heel of nonwoven fabric upper101. In the embodiment shown inFIG. 2, finishingelement130 includes atongue135 and aportion132 configured to accommodate a fastening system133 (shown inFIG. 1).Fastening system133 may includeeyelets132 and alace134. In other embodiments, nonwoven fabric upper101 may include additional components or nonwoven fabric upper101 may eliminate one or more of these described components.
• As shown inFIGS. 2 and 3, nonwoven fabric upper101 may be made from a nonwoven material. The nonwoven material may be shaped with curvature along one or more axes of nonwoven fabric upper101 so that the nonwoven material is produced in the shape of nonwoven fabric upper101. As shown inFIG. 3, nonwoven fabric upper101 includes curvature along each of alongitudinal axis170 that extends in a heel-to-toe direction, atransverse axis172 that extends in a medial-to-lateral direction, and avertical axis174 that extends in through nonwoven fabric upper101 in a direction that is substantially orthogonal tolongitudinal axis170 andtransverse axis172.
• In the embodiment shown inFIG. 2, nonwoven fabric upper101 includes athroat opening112, where the throat opening is defined by aheel edge113, amedial edge114, and alateral edge115. In the embodiment shown in FIG.2, nonwoven fabric upper101 also includes an optionallower opening116 defined by amedial edge118 and alateral edge119.Lower opening116 is disposed opposite tothroat opening112. When nonwoven fabric upper101 is associated with anupper surface122 of sole120 to produce article offootwear100, sole120 closes and sealslower opening116. In other embodiments, nolower opening116 is provided; nonwoven fabric upper101 may include a solid portion of material connectingmedial edge118 tolateral edge119 across the bottom of nonwoven fabric upper101. In such embodiments, sole120 is affixed to this solid portion of material. These components of article offootwear100 may be attached to each other using any method known in the art, such as with adhesives, stitching, and/or welding.
• The material for a nonwoven article may be made according to the method shown inFIG. 4. By utilizing the method shown in the flow diagram ofFIG. 4, the nonwoven material may be made so that the entire thickness of the nonwoven material is made from fiber particles and binder. No additional backing or substrate needs to be incorporated into the final material, though a substrate may be used during the method to support the uncured layers of fiber particles and binder. Further, in some embodiments of the method, a substrate shaped in all three dimensions may be used so that the nonwoven material may be manufactured in the shape of the article to avoid the need for additional processing steps or to limit the number of additional processing steps. Conventional methods for making articles such as an article of footwear generally include multiple preparation and cuttings steps to shape the article and to form multiple seams to hold the shape. The article may then be sent for additional finishing work, such as associating a sole with an upper or adding other finishing elements or components to the article. One embodiment of the method ofFIG. 4 is shown inFIGS. 5-13, and the method is described below with reference toFIGS. 4-13.
• The method described inFIG. 4 for making the nonwoven material occurs on a substrate. In some embodiments, the method ofFIG. 4 allows for a shaped nonwoven article to be made on the shaped substrate. In some embodiments, the substrate may be a last for an article of footwear or a body last. In other embodiments, the method ofFIG. 4 allows for a substantially flat portion of nonwoven material to be made on a substantially flat substrate. When a flat substrate is used, the resultant nonwoven material may then be finished into a flat article or cut and/or shaped to form a shaped article.
• Generally, the method described inFIG. 4 begins by preparing a substrate to receive fiber particles in afirst step200. The substrate may be any type of surface capable of supporting fiber particles and binder. In some embodiments, the substrate may be a non-porous surface. In some embodiments, the substrate may be made from thermoplastic materials, such as various types of known polymers, thermoset materials, such as rubber or various types of known polymers, ceramic materials, metals, composite materials, or combinations thereof.
• The resultant nonwoven fabric will take on the shape of the substrate. In some embodiments, the substrate may be a substantially flat surface so that the resultant nonwoven fabric is also substantially flat. In some embodiments, the substrate may include a surface shaped with curvature along at least two axes so that the resultant nonwoven fabric is formed with the same curvature. In some embodiments, the substrate may include multiple shaped and/or curved surfaces so that the resultant nonwoven fabric is formed into a shaped, three-dimensional article.
• FIG. 5 shows an embodiment of asubstrate300 used in an embodiment of a method of making a nonwoven upper301 (shown inFIGS. 13 and 14). In the embodiment shown inFIG. 5,substrate300 is a last for an article of footwear.Substrate300 may be supported on a manufacturing floor, preparation table, or otherwise in a manufacturing facility by abase310.Base310 may be any type of structure capable of supporting and stabilizingsubstrate300, such as a weighted plate. In some embodiments, apole312 may be associated withbase310 so thatsubstrate300 may be positioned at a predetermined height abovebase310. In some embodiments,pole312 may positionsubstrate300 so thatsubstrate300 is positioned at a comfortable working height for a user standing or sitting on the manufacturing floor. In other embodiments,pole312 may positionsubstrate300 so that all sides ofsubstrate300 are accessible to the manufacturing process. In some embodiments,substrate300 may include provisions for associating withpole312. For example, in oneembodiment substrate300 may include a recess or hole configured to receive a free end ofpole312. The free end ofpole312 may be inserted intosubstrate300 and fitted there by an interference fit or with threading. In other embodiments,pole312 may be an integral extension ofsubstrate300.
• Substrate300 may be any type of last known in the art. In some embodiments,substrate300 may be a solid, rigid material but in other embodiments may be made of any substrate material discussed above. In other embodiments,substrate300 may be an inflatable last.Substrate300 may be a last configured for any type of foot in terms of size or shape, such as shapes and sizes for adult males, adult females, and children.
• Substrate300 may be a material to which fiber particles may not adhere without an additional adhesive or other substance to which the fiber particles may temporarily adhere. The fiber particles may be any types of fiber particle known in the art, but are, in general, small pieces of cut fiber. In some embodiments, the fiber particles may be natural or synthetic fibers, yarns, or threads. In some embodiments, the fiber particles may be wool, cotton, Nylon, Polyester, Rayon, Kevlar, or combinations of these materials. In some embodiments, only one type of fiber particle is used in the manufacture of the nonwoven material. In other embodiments, different types of fiber particle may be used in the manufacture of the nonwoven material.
• Fiber particles are generally small cut pieces of fiber. While the fiber particles may have any denier known in the art, in some embodiments, the denier may be less than 100. In some embodiments, the denier of the fiber particles may be less than about 75. In some embodiments, the denier of the fiber particles may be less than about 50. In some embodiments, the denier of the fiber particles may be less than about 20. In some embodiments, the fiber particles have a length of 1 mm or less. In other embodiments, however, the fiber particles may be longer than 1 mm. In some embodiments, the fiber particles may be 1.5 mm or less in length. In some embodiments, the fiber particles may be at least 2 mm in length. In some embodiments, the fiber particles may be between 0.25 mm and 5 mm in length. In some embodiments, the fiber particles may be between 0.5 mm and 4 mm in length. In some embodiments, the fiber particles may be about 2 mm in length. Fiber particles having a length of 2 mm or greater may produce articles that have enhanced durability over articles produced with fiber particles having a length of less than 2 mm. Fiber particles having a length of less than 2 mm may produce articles with less porosity than articles produced with fibers having a length of 2 mm or greater.
• In some embodiments, all of the fiber particles used to make a single nonwoven fabric may have substantially the same length. In other embodiments, the fiber particles used to make a single nonwoven fabric may have different lengths. In one embodiment, the fiber particles are a mix of lengths between about 0.5 mm and about 4 mm. In one embodiment, the fiber particles are a mix of lengths between about 0.5 mm and about 4 mm with a denier of less than 20.
• In order to receive the fiber particles and hold the fiber particles in position on the surface ofsubstrate300,substrate300 may be prepared with a substance to which the fiber particles may temporarily adhere. In the embodiment shown inFIG. 6,substrate300 is prepared by spreading asubstance320 onto the surface ofsubstrate300.Substance320 may be any type of substance to which the fiber particles may adhere and may be cleaned off ofsubstrate300 and the resultant article when the article is removed fromsubstrate300. In some embodiments,substance320 may be a gelatinous substance such as silicone or petroleum jelly. In other embodiments,substance320 may be a release film, such as polyurethane film.
• Substance320 may be applied onto the surface ofsubstrate300 using any method known in the art. In one embodiment, such as the embodiment shown inFIG. 6,substance320 is dispensed from acontainer324 and spreads ontosurface330 ofsubstrate300, with or without additional mechanical manipulation such as with a brush. A mask or masking agent such asmask309 may be placed ontosubstrate300 prior to the application ofsubstance320 ontosubstrate300. In some embodiments, such as the embodiment shown inFIG. 6,mask309 may be used to provide a shape to the edges ofsubstance320 so that the resultant nonwoven material has edges with a specific contour. For example,mask309 may be provided onsubstrate300 so that a resultant nonwoven upper301 (shown inFIG. 16) has a throat opening302 (shown inFIG. 16) without a subsequent cutting step, as anedge303 ofthroat opening302 may be adequately finished without any subsequent cutting or trimming steps.
• Mask309 may be any type of material capable of blocking the application ofsubstance320 to a selected or predetermined area ofsubstrate300. In some embodiments,mask309 may be a flexible sheet, screen, or film so thatmask309 may be wrapped around or otherwise fitted tosubstrate300. For example,mask309 may be a sheet or film of thermoset material, such as rubber, a thermoplastic material, such as polyurethane, paper, a fabric, or a metal. In other embodiments,mask309 may be a hard or relatively rigid piece of material that is formed to fit ontosubstrate300 in the desired configuration. For example,mask309 may be cardboard, a molded thermoplastic or thermoset material, metal, glass, composite material, ceramic, or any other kind of material.Mask309 may be positioned proximate tosubstrate300 or affixed tosubstrate300.
• In other embodiments,first step200 may include other ways to preparesubstrate300 to receive the fiber particles. For example, in the electrostatic embodiments discussed below with respect toFIGS. 30-50,first step200 may be achieved by applying a charge to the substrate.
• Asecond step210 of the method shown inFIG. 4 includes dispensing or depositing a plurality of the fiber particles onto the substrate.FIG. 7 shows an embodiment ofsecond step210. In the embodiment shown inFIG. 7,substrate300 has been prepared withsubstance320. Adispenser342 is associated with areservoir340 containing a plurality offiber particles341, which may be any type of fiber particle as discussed above.Reservoir340 may be any container capable of holding a desired quantity offiber particle341 and communicating that fiber particle todispenser342.Dispenser342 is configured to dispensefiber particles341 ontosubstance320.Dispenser342 may be any type of dispenser capable of propellingfiber particles341 fromreservoir340 ontosubstance320.Dispenser342 may be manual or automated.
• In the embodiment shown inFIG. 7,dispenser342 is a blower or other type of pneumatic device equipped with anozzle343.Dispenser342 may be any type of blower known in the art.Dispenser342 is configured to drawfiber particles341 fromreservoir340 and expel the fiber particles throughnozzle343 towardssubstance320 andsubstrate300. Once expelled, the fiber particles becomeambient fiber particles346.Ambient fiber particles346 are carried along streams of flowingair344 propelled fromdispenser342.Ambient fiber particles346 move towardssubstance342 until theambient fiber particles346 alight on tosubstance320. Onceambient fiber particles346 come into contact withsubstance320, the fiber particles become embeddedfiber particles350. In some embodiments, embeddedfiber particles350 are positioned withinsubstance320 so that embeddedfiber particles350 are substantially normal to the surface ofsubstrate300. In other embodiments, embeddedfiber particles350 are embedded at other angles with respect to the surface ofsubstrate300. In some embodiments, embeddedfiber particles350 are positioned at random angles with respect to the surface ofsubstrate350.
• Dispenser342 andsubstrate300 may move relative to one another to ensure that the entire surface ofsubstrate300 is exposed toambient fiber particles346. In one embodiment,dispenser342 may move around astationary substrate300. In another embodiment,substrate300 may move and rotate relative to astationary dispenser342. In some embodiments, more than onedispenser342 may be positioned at various locations aroundsubstrate300.
• In some embodiments,dispenser342 may be configured to dispensefiber particles341 untilambient fiber particles346 no longer adhere tosubstance320. In some embodiments, the duration of dispensing may be controlled by one or more sensors positionedproximate substrate300 that may send a signal todispenser342 to cease dispensing fiber particles. In some embodiments, the duration of dispensing may be determined by an operator visually inspectingsubstrate300 andambient fiber particles346. Excessambient fiber particles346 may be removed from the proximity ofsubstrate300 by additional blowing air or a vacuum.
• Athird step220 of the method shown inFIG. 4 includes applying an adhesive to the embedded fiber particles. The applied adhesive enhances the matting of the fiber particles in subsequent manufacturing steps and enhances the ability of each layer of the matted fiber particles to accept an additional layer of fiber particles. The adhesive may be any type of adhesive known in the art. In some embodiments, the adhesive may be an aerosolized adhesive configured to spray small droplets of adhesive onto the embedded fiber particles. In some embodiments, the adhesive may be a liquid adhesive that may be brushed or rolled onto the embedded fiber particles or into which the substrate and embedded fibers may be dipped. In some embodiments, the adhesive may be water based. In other embodiments, the adhesive may be polyvinyl acetate based. In other embodiments, the adhesive may be rubber based. In some embodiments, the adhesive may be LocTite® spray adhesive or liquid adhesive, 3M® spray or liquid adhesives, KIWO® fiber particles adhesive, and/or spray or liquid Plasti Dip®.
• FIG. 8 shows an embodiment ofthird step220. In the embodiment shown inFIG. 8, asprayer360 is configured to apply an adhesive362 onto embeddedfiber particles350.Sprayer360 may be any kind of spray device known in the art capable of aerosolizing and propelling adhesive362 towards embeddedfiber particles350. In some embodiments,sprayer360 may be a trigger-type intermittent sprayer, such as a manual spray bottle or handheld spray unit. In some embodiments,sprayer360 may be a compressor-driven continuous sprayer, such as a power sprayer. In some embodiments,sprayer360 may be a manually operated sprayer. In other embodiments, such as the embodiment shown inFIG. 8,sprayer360 may be automated. In some embodiments,sprayer360 may include anozzle364 is configured to expelaerosolized adhesive362. In some embodiments,sprayer360 may be a robot programmed to operate and manipulate the position ofnozzle364. The general operation of a robotic arm is well known in the art.Sprayer360 may in some embodiments be an articulated robotic arm connected to a controller, such as a processor with associated memory, and a power source such as a battery or a connection to a power grid via a power cord such ascord825. In some embodiments,nozzle364 may be associated with a source of adhesive, such assource820. In some embodiments, afeeder tube821 may establish a fluid connection betweenadhesive source820 andnozzle364. In some embodiments,feeder tube821 may be exposed, such as in the embodiment shown inFIG. 8. In other embodiments,feeder tube821 may be integrated intosprayer360 and may be threaded throughsprayer360 to connectsource820 tonozzle364.
• Sprayer360 may include multiple members and joints so that the height and/or orientation ofnozzle364 may be manipulated. Whilesprayer360 may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 8,sprayer360 may include abase806, afirst member807, asecond member809, athird member811, and agrip805. A first joint801 may connectthird member811 andsecond member809. A second joint802 may connectsecond member809 andfirst member807. A third joint803 may connectfirst member807 andbase806. Each member such asbase806,first member807,second member809,third member811, andgrip805, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members. Each joint such as first joint801, second joint802, and third joint803 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height ofsprayer360. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Sprayer360 andsubstrate300 may move relative to one another to ensure that adhesive362 is applied to the entire surface ofsubstrate300. In one embodiment,sprayer360 may move around astationary substrate300. For example, in the embodiment shown inFIG. 8,sprayer360 may be mounted onto atrack810 that encircles, surrounds, or partially surroundssubstrate300. Aconnector815 may be attached tobase806 and slidably positioned withintrack810.Connector815 may be actuated by the controller and the power source using known techniques to translateconnector815, and, by extension,sprayer360, alongtrack810. In this manner,sprayer360 may move to multiple positions aroundsubstrate300. Further,base360 may be configured to rotate with respect toconnector815 to allownozzle364 to facesubstrate300 regardless of the position ofsprayer360 ontrack810. In another embodiment,substrate300 may move and rotate relative to astationary sprayer360. In some embodiments, more than onesprayer360 may be positioned at various locations aroundsubstrate300. The operation of robotic arms for manufacturing
• In some embodiments, a large amount of adhesive may be applied to embeddedfiber particles350, such as when a dip-type adhesive is used. In other embodiments, such as shown in the enlarged view inFIG. 8, a relatively light coating of adhesive is applied to embeddedfiber particles350. The enlarged view inFIG. 8 showsadhesive droplets366 dispersed within embeddedfiber particles350.Adhesive droplets366 may be adhered to anindividual fiber particle346 oradhesive droplets366 may be adhered to multiple embeddedfiber particles350.Adhesive droplets366 remain uncured at this point in the manufacturing process.
• Afourth step225 of the method shown inFIG. 4 includes dispensing a second layer of fiber particles onto the first layer of fiber particles, the adhesive binder, and the last/substrate. In most respects,fourth step225 is a repetition ofsecond step210.FIG. 9 shows an embodiment offourth step225, in which dispenser342 deposits an additional plurality of fiber particles onto embeddedfiber particles350.Dispenser342 may be manually operated or automated using factory or other robotic mechanisms like an articulated robotic arm.Adhesive particles366 assist in capturing second embeddedfibers355 and holding second embeddedfibers355 to embeddedfibers350.
• Afifth step230 of the method shown inFIG. 4 includes matting the fiber particles. Matting the fiber particles causes the individual fibers to bend, intertwine, and adhere to each other. This matting process transforms the individual fiber particles into a continuous if porous layer of fabric. In some embodiments,fifth step230 involves mechanically manipulating embeddedfiber particles350 and second embeddedfiber particles355 by rubbing, grinding, rolling, compressing, or otherwise moving the embedded fiber particles to entangle the embedded fiber particles together. In other embodiments,fifth step230 may involve a vacuum matting process in which the substrate in positioned in a vacuum chamber to compress the embedded fibers when a vacuum is applied. In other embodiments,fifth step230 may involve a manual matting process in which an operator or technician uses his or her hands to entangle the embedded fiber particles together.
• FIG. 10 shows an embodiment offifth step230 in which aroller370 is passed over embeddedfiber particles350 and second embeddedfiber particles355.Roller370 may be any type of roller known in the art, such as a roller on a robotic arm, as shown inFIG. 10, or a manually-manipulated roller.Roller370 may have a smooth surface or a textured surface. A textured surface, such as with projections, may assist in the matting and entangling of the fiber particles. The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller370.Roller370 compresses and entangles embeddedfiber particles350 and second embeddedfiber particles355 together to form afirst ply375 of nonwoven fabric. As shown in the enlarged portion ofFIG. 10,individual fiber particles346 become entangled at connection points376. The matting process leaves relativelylarge pores378 infirst ply375.Large pores378 may contribute to the breathability of the resultant nonwoven fabric upper301 (shown inFIG. 16).
• Robotic arm1060 may include multiple members and joints so that the height and/or orientation ofroller370 may be manipulated. Whilerobotic arm1060 may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 10,robotic arm1060 may include abase1006, afirst member1007, asecond member1009, a third member1011, and agrip1005. A first joint1001 may connect third member1011 andsecond member1009. A second joint1002 may connectsecond member1009 andfirst member1007. A third joint1003 may connectfirst member1007 andbase1006. Each member such asbase1006,first member1007,second member1009, third member1011, andgrip1005, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members.Grip1005 may be a clamp or similar mechanism. In some embodiments,roller370 may include ahandle379 configured to be securely and optionally removably or interchangeably held bygrip1005. Each joint such as first joint1001, second joint1002, and third joint1003 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height ofrobotic arm1060. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Robotic arm1060 and embeddedfiber particles350 onsubstrate300 may move relative to one another to ensure thatroller370 may contact all of the embeddedfiber particles350 on the surface ofsubstrate300. In one embodiment,robotic arm1060 may move around astationary substrate300. For example, in the embodiment shown inFIG. 10,robotic arm1060 may be mounted onto atrack1010 that encircles, surrounds, or partially surroundssubstrate300. Aconnector1015 may be attached tobase1006 and slidably positioned withintrack1010.Connector1015 may be actuated by the controller and the power source using known techniques to translateconnector1015, and, by extension,robotic arm1060, alongtrack1010. In this manner,robotic arm1060 may move to multiple positions aroundsubstrate300. Further,base360 may be configured to rotate with respect toconnector1015 to allowroller370 to facesubstrate300 regardless of the position ofrobotic arm1060 ontrack1010. In another embodiment,substrate300 may move and rotate relative to a stationaryrobotic arm1060. In some embodiments, more than onerobotic arm1060 may be positioned at various locations aroundsubstrate300.
• An optionalsixth step240 of the method shown inFIG. 4 may be performed.Sixth step240 involves repeatingthird step220 throughsixth step240 to build up additional plies of nonwoven fabric.Sixth step240 may be repeated as many times as desired until the desired number of layers are formed. In some embodiments, the resultant nonwoven fabric material or article may include one to twenty layers. In some embodiments, resultant nonwoven fabric may include two to ten layers.
• The thickness of each ply depends on the type of fiber particles used. In some embodiments, the thickness of each ply may be 0.5 mm or less. In some embodiments, the thickness of each ply may range from about 0.1 mm to about 0.4 mm. In some embodiments, the thickness of each ply may range from about 0.1 mm to about 0.15 mm. In some embodiments, the thickness of each ply may be about 0.138 mm. The overall thickness of the resultant matted fiber fabric is the aggregate of the thickness of the individual plies. In some embodiments, the thickness of the resultant nonwoven fabric may be less than 1 mm. In some embodiments, the thickness of the resultant nonwoven fabric may be between 0.5 mm and 5 mm. In some embodiments, the thickness of the resultant nonwoven fabric may be between 1 mm and 3 mm. In some embodiments, the thickness of the resultant nonwoven fabric may be greater than 5 mm. In one embodiment, the resultant nonwoven fabric includes 10 plies with an overall thickness of about 1.38 mm.
• In some embodiments, when forming the first ply or additional plies of the nonwoven fabric, one or more areas of the substrate or an existing ply of fabric may be masked so that the next ply is not formed or built up in that selected area. Leaving selected areas devoid of additional fiber particles in any given ply or plies may tailor the properties of the resultant fabric ply. For example, in areas devoid of additional fiber particles in a selected region or area of a ply, the thickness of the overall fabric is reduced. In those areas devoid of additional fiber particles, breathability and flexibility may be increased over areas in which the thickness is greater due to the additional material present in completed areas. In those areas which include complete plies and greater thickness, durability, stability, and support may be increased. Creating areas of different thickness in the nonwoven fabric permits a designer to create performance zones to tailor an article for a specific purpose, such as building a thick zone in a heel region to create a stiff heel cup or a building a relatively thin zone proximate a toe box to create a flexible region.
• FIGS. 11-13 show an embodiment of forming a second ply of nonwoven fabric on top offirst ply375 ofnonwoven fabric301. Additionally, amask385 may be employed to prevent additional fiber particles and binder from accumulatingproximate mask385.Mask385 may be any type of mask discussed above, such as a film, screen, paper, or cardboard. In the embodiment shown inFIGS. 11-13,mask385 is positioned centrally along a side ofsubstrate300. This kind of mask creates a zone with increased flexibility and breathability compared to the rest of nonwoven fabric upper301. In other embodiments,mask385 may be positioned in different locations. In some embodiments, more than one mask may be used. In some embodiments, some plies may be masked in first locations while in other plies, the mask may be positioned in different locations. A person of ordinary skill in the art will understand how to use a mask or masks to manipulate the properties of the resultant nonwoven fabric.
• As shown inFIG. 11, aftermask385 has been placed onfirst ply375 in the selected location,third step220 of the method shown inFIG. 4 is essentially repeated. In the embodiment shown inFIG. 11,sprayer360 is configured to apply an adhesive362 ontofirst ply375.Sprayer360 andsubstrate300 may again move relative to one another to ensure that adhesive362 is applied to the entirety offirst ply375. In one embodiment,sprayer360 may move around astationary substrate300. In another embodiment,substrate300 may move and rotate relative to astationary sprayer360. In some embodiments, more than onesprayer360 may be positioned at various locations aroundsubstrate300.Mask385 prevents/inhibits adhesive from being applied underneathmask385 onfirst ply375. As shown,first ply375 may include pile from unmated or loosely matted fibers.
• As in the embodiment shown inFIG. 8,sprayer360 may be automated as an articulated robot as shown inFIG. 8. In some embodiments, such as the embodiment shown inFIG. 11, asecond sprayer1160 may be provided so that the spraying step may be achieved more quickly. Coverage offirst ply375 may also be enhanced with multiple sprayers.Second sprayer1160 may be similar or identical tosprayer1160.
• In some embodiments,second sprayer1160 may include asecondary nozzle1164 is configured to expel aerosolized secondary adhesive1162. In some embodiments,second sprayer1160 may be a robot programmed to operate and manipulate the position ofsecondary nozzle1164. The general operation of a robotic arm is well known in the art.Second sprayer1160 may in some embodiments be an articulated robotic arm connected to a controller, such as a processor with associated memory, and a power source such as a battery or a connection to a power grid via a power cord such assecondary cord1125. In some embodiments,secondary nozzle1164 may be associated with a source of adhesive, such assecondary source1120. In some embodiments, asecondary feeder tube1121 may establish a fluid connection betweensecondary source1120 andsecondary nozzle1164. In some embodiments,secondary feeder tube1121 may be exposed, such as in the embodiment shown inFIG. 11. In other embodiments,secondary feeder tube1121 may be integrated intosecond sprayer1160 and may be threaded throughsecond sprayer1160 to connectsecondary source1120 tosecondary nozzle1164.
• Second sprayer1160 may include multiple members and joints so that the height and/or orientation ofsecondary nozzle1164 may be manipulated. Whilesecond sprayer1160 may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 11,second sprayer1160 may include asecondary base1106, a secondaryfirst member1107, a secondarysecond member1109, a secondarythird member1111, and asecondary grip1105. A secondary first joint1101 may connect secondarythird member1111 and secondarysecond member1109. A secondary second joint1102 may connect secondarysecond member1109 and secondaryfirst member1107. A secondary third joint1103 may connect secondaryfirst member1107 andsecondary base1106. Each member such assecondary base1106, secondaryfirst member1107, secondarysecond member1109, secondarythird member1111, andsecondary grip1105, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members. Each joint such as secondary first joint1101, secondary second joint1102, and secondary third joint1103 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height ofsecond sprayer1160. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Second sprayer1160 andsubstrate300 may move relative to one another to ensure that secondary adhesive1162 is applied to the entire surface ofsubstrate300. In one embodiment,second sprayer1160 may move around astationary substrate300. For example, in the embodiment shown inFIG. 11,second sprayer1160 may be mounted onto asecondary track1110 that encircles, surrounds, or partially surroundssubstrate300. A secondary connector1115 may be attached tosecondary base1106 and slidably positioned withinsecondary track1110. Secondary connector1115 may be actuated by the controller and the power source using known techniques to translate secondary connector1115, and, by extension,second sprayer1160, alongsecondary track1110. In this manner,second sprayer1160 may move to multiple positions aroundsubstrate300. Further,secondary base1160 may be configured to rotate with respect to secondary connector1115 to allowsecondary nozzle1164 to facesubstrate300 regardless of the position ofsecond sprayer1160 onsecondary track1110. In another embodiment,substrate300 may move and rotate relative to a stationarysecond sprayer1160. In some embodiments, more than onesecond sprayer1160 may be positioned at various locations aroundsubstrate300.
• In some embodiments, a relatively light coating of adhesive may be applied tofirst ply375. The enlarged view inFIG. 11 shows second set ofadhesive droplets386 dispersed withinfirst ply375. Second set ofadhesive droplets386 also remain uncured at this point in the manufacturing process.
• FIG. 12 shows an embodiment of repeatingfourth step225 in which a third layer of particles is deposited onto the last. Third embeddedfiber particles380 are deposited onto last300 and intofirst ply375 bydispenser342 in the manner described above with respect to second embeddedfiber particles355. Second set ofadhesive droplets386 assist in retaining third embeddedfiber particles380 in position.
• FIG. 13 shows an embodiment of repeatingfifth step230 in whichroller370 is passed overfirst ply375. As discussed above with respect toFIG. 10,roller370 may be any type of roller known in the art, such as a roller on a robotic arm or a manually-manipulated roller. A controller such as a processor, a computer, or a handheld mobile device that sends signals to theroller370 may guide the movement of a robotic arm.Roller370 compresses and entangles second embeddedfiber particles380 together and tofirst ply375 to form asecond layer390 of nonwoven fabric. In other embodiments, repeatingfifth step230 may involve other methods of mattingfirst ply375, such as vacuum entanglement or manual entanglement.
• Third step220 throughfifth step230 may be repeated in this manner until the desired number of layers and/or thickness of the nonwoven material is achieved. Once the desired number of layers is laid down, aseventh step245 in the method shown inFIG. 4 may be performed: the adhesive may be cured to finish the nonwoven material. Depending upon the type of adhesive, curing may be achieved by exposing the layers to heat, convection, and/or the flow of ambient temperature air over the layers. As shown inFIG. 13,heated air397 may be applied to the nonwoven fabric to cure the adhesive. In some embodiments, the adhesive may be cured at temperatures less than 100 degrees C., less than 120 degrees C., and less than 200 degrees C. In some embodiments, the adhesive may be cured at temperatures between 100 degrees C. and 150 degrees C., between 110 degrees C. and 130 degrees C., or between 115 degrees C. and 125degrees C. Heat397 may be applied using any method known in the art, such as a convection blow heater such asheater398 or an oven (not shown). The heat and/or convection air flow may be applied for any duration. The duration may be influenced by such factors as the type of adhesive, the type of fiber particles, and the thickness of the nonwoven fabric. In some embodiments, the duration of cure may be less than a minute or for longer than a minute.
• In some embodiments, such as the embodiment shown inFIG. 13,heater398 may be mounted on a heater articulatedrobotic arm1360. Heater articulatedrobotic arm1360 may be similar to the articulated robotic arms shown and discussed above with respect toFIGS. 8, 10, and 11. In some embodiments, heater articulatedrobotic arm1360 may include multiple members such as base1306, heaterfirst member1307, and heatersecond member1309. In some embodiments, heater articulatedrobotic arm1360 may include multiple joints connecting the members to each other, such as first heater joint1301, second heater joint1302, and third heater joint1303. As noted above,members1306,1307, and1309 may be any type of member known in the art. Similarly,joints1301,1302, and1303 may be any type of joint known in the art. Heater articulatedrobotic arm1360 may be controlled by a processor with a memory programmed to manipulate articulated robotic arm as is known in the art. Heater articulatedrobotic arm1360 may be powered by a power source such as a battery or a connection to a power grid by aheater cord1314.
• Robotic arm1360 andsubstrate300 may move relative to one another to ensure thatroller370 may contact the entire surface ofsubstrate300. In one embodiment,robotic arm1360 may move around astationary substrate300. For example, in the embodiment shown inFIG. 13,robotic arm1360 may be mounted onto aheater track1310 that encircles, surrounds, or partially surroundssubstrate300. Aheater connector1315 may be attached to base1306 and slidably positioned withintrack1310.Connector1315 may be actuated by the controller and the power source using known techniques to translateconnector1315, and, by extension,robotic arm1360, alongtrack1310. In this manner,robotic arm1360 may move to multiple positions aroundsubstrate300. Further,base1360 may be configured to rotate with respect toconnector1315 to allownozzle364 to facesubstrate300 regardless of the position ofrobotic arm1360 ontrack1310. In another embodiment,substrate300 may move and rotate relative to a stationaryrobotic arm1360. In some embodiments, more than onerobotic arm1360 may be positioned at various locations aroundsubstrate300.
• Once the adhesive is cured, the nonwoven fabric is completed. At this point, aneighth step250 in the method shown inFIG. 4 may be performed.Eighth step250 includes removing the nonwoven fabric from the substrate. Because the layers of the nonwoven fabric were built up and cured directly on the surface of the substrate, the nonwoven fabric will have the same contours as the substrate.
• FIG. 14 shows an embodiment ofeighth step250.Nonwoven fabric301 has conformed to the shape of the last-shapedsubstrate300. In this embodiment,nonwoven fabric301 is a seamless nonwoven upper. Nonwoven fabric upper301 includes athroat opening312 that allows nonwoven fabric upper301 to be pulled off ofsubstrate300 as shown inFIG. 14.Substance320 may facilitate the removal of nonwoven fabric upper301. In addition to makingsubstrate300 able to receive fiber particles,substance320 may lubricate the surface ofsubstrate300 so that nonwoven fabric upper301 slips more easily off ofsubstrate300.
• FIG. 15 shows the completed nonwoven fabric upper301.
• Nonwoven fabric upper301 is seamless, having been made by building up layers onlast substrate300 so that nonwoven fabric upper301 was made in the shape of an upper. No additional cutting or shaping may be required to use nonwoven fabric upper301 in an article of footwear. Abreathable region395 of nonwoven fabric upper301 was formed using the masking technique shown above. A void396 was formed inmatted layer390. Withinvoid396, the no fiber particles accumulated, somatted layer390 is discontinuous. The discontinuity is not reflected in adjacentmatted layer375. Therefore, nonwoven fabric upper301 is continuous throughbreathable region395, but the density of the nonwoven fabric is reduced inbreathable region395. This lower density leads to greater breathability, increased flexibility, and reduced stiffness inbreathable region395 compared to the rest of nonwoven fabric upper301. This type of zonal manipulation of the properties of nonwoven fabric upper301 can be located in different positions in other embodiments of nonwoven fabric upper301, in multiple positions in other embodiments of nonwoven fabric upper301, or eliminated entirely is some embodiments of nonwoven fabric upper301 for an upper having uniform properties throughout.
• In some embodiments, nonwoven fabric upper301 may be made using only one type of fiber particles to produce a monofiber upper nonwoven fabric—a fabric containing only one type of fiber and a binder (the adhesive). For example, nonwoven fabric upper301 may be a mono-polymer upper, composed of a single type of polymeric fiber particle and an adhesive binder. In other embodiments, multiple types of fiber particle and/or multiple types of binder may be used in any given matted layer or in adjacent matted layers.
• An optionalninth step260 of the method ofFIG. 4 includes additional finishing steps for the nonwoven material. Depending upon the final article for which the nonwoven material is intended, no additional finishing steps may be necessary. In some embodiments, an additional finishing step may be washing or otherwise laundering the nonwoven material to remove any remnants of the substance used to coat the substrate. In other embodiments, such as the article shown inFIGS. 1 and 2, components such as a sole, a tongue, or an eyestay reinforcement may be associated with the nonwoven fabric to complete an article like an article of footwear. In other embodiments, such as when making an article of apparel, the additional finishing steps may include cutting the nonwoven fabric and joining the cut pieces to each other or to other pieces of fabric to make another article, like an article of apparel. An embodiment of these types of finishing steps is discussed below with respect toFIGS. 47 and 48.
• FIGS. 16-25 show another embodiment of the method generally set forth inFIG. 4. In this embodiment, a substantially flat substrate is provided to make a substantially flat nonwoven material.
• Generally, the method described inFIG. 4 begins by preparing a substrate to receive fiber particles infirst step200. Thesubstrate400 may be any type of surface capable of supporting fiber particles and binder and may be any type of substrate described above capable of being formed as a flat surface or having a flat surface.FIG. 16 shows an embodiment of aflat substrate400 used in an embodiment of a method of making a nonwoven upper. In the embodiment shown inFIG. 16,flat substrate400 is a substantially flat surface like a table configured to make a substantially flat nonwoven fabric.
• Flat substrate400 may be supported on a manufacturing floor or otherwise a manufacturing facility by asecond base410.Second base410 may be any type of structure capable of supporting and stabilizingflat substrate400, such as a weighted plate. In some embodiments, afirst leg412 and asecond leg413 may be associated withsecond base410 so thatflat substrate400 may be positioned at a predetermined height abovesecond base410. In some embodiments,first leg412 andsecond leg413 may elevateflat substrate400 so thatflat substrate400 is positioned at a comfortable working height for a user standing or sitting on the manufacturing floor. In other embodiments,first leg412 andsecond leg413 may positionflat substrate400 so that all sides offlat substrate400 are accessible to the manufacturing process. In some embodiments,flat substrate400 may include provisions for associating withfirst leg412 andsecond leg413. For example, in one embodimentflat substrate400 may include a recess or hole configured to receive free ends offirst leg412 andsecond leg413. The free end offirst leg412 andsecond leg413 may be inserted intoflat substrate400 and fitted there by an interference fit or with threading. In other embodiments,first leg412 andsecond leg413 may be an extension offlat substrate400.
• In some embodiments,flat substrate400 may be a solid, rigid material.Flat substrate400 may be a table configured for any size of nonwoven fabric in terms of size or shape.
• Likesubstrate300 discussed above,flat substrate400 is generally a material to which fiber particles may not adhere without an additional adhesive or other substance to which the fiber particles may adhere. The fiber particles may be any types of fiber particle discussed above. The fiber particles may have any length or denier discussed above. In order to receive the fiber particles and hold the fiber particles in position on the surface offlat substrate400,flat substrate400 may be prepared with a substance to which the fiber particles may temporarily adhere. In the embodiment shown inFIG. 16,flat substrate400 is prepared by spreading asecond substance420 onto the surface offlat substrate400.Second substance420 may be any type of substance to which the fiber particles may adhere and may be cleaned off offlat substrate400. In some embodiments,second substance420 may be a gelatinous substance such as silicone or petroleum jelly. In other embodiments,second substance420 may be a release film, such as polyurethane film.
• Second substance420 may be applied onto the surface offlat substrate400 using any method known in the art. In one embodiment, such as the embodiment shown inFIG. 17,second substance420 is dispensed from asecond container421 and spreads ontosurface417, with or without additional mechanical manipulation such as with abrush419.Brush419 may be automated, such as with a robotic arm like the robotic arm shown above with respect to, for example,FIGS. 10 and 13. In this embodiment, no mask such asmask309 is provided. In other embodiments, a mask likemask309 may be provided to establish edges of the resultant nonwoven fabric.
• Second step210 of the method shown inFIG. 4 includes dispensing the fiber particles onto the substrate.FIG. 18 shows an embodiment ofsecond step210. In the embodiment shown inFIG. 18,flat substrate400 has been prepared withsecond substance420. Asecond dispenser442 is associated with asecond reservoir440 containing a plurality ofsecond fiber particle441, which may be any type of fiber particle as discussed above.Second reservoir440 may be any container capable of holding a desired quantity ofsecond fiber particle441 and communicating that fiber particle tosecond dispenser442.Second dispenser442 is configured to dispensesecond fiber particles441 ontosecond substance420.Second dispenser442 may be any type of dispenser capable of propellingsecond fiber particle441 fromsecond reservoir440 ontosecond substance420.
• In the embodiment shown inFIG. 18,second dispenser442 is a blower or other type of pneumatic device equipped with asecond nozzle443.Second dispenser442 may be any type of blower known in the art.Second dispenser442 is configured to drawsecond fiber particle441 fromreservoir440 and expel the fiber particles throughsecond nozzle443 towardssecond substance420 andflat substrate400. Once expelled, the fiber particles become secondambient fiber particles446. Secondambient fiber particles446 are carried along streams ofsecond air flow444 propelled fromsecond dispenser442. Secondambient fiber particles446 move towardssubstance420 untilambient fiber particles446 alight uponsecond substance420. Once in contact with and adhered tosecond substance420, the fiber particles become fourth embeddedfiber particles450. In some embodiments, fourth embeddedfiber particles450 are positioned withinsecond substance420 so that fourth embeddedfiber particles450 are substantially normal to the surface offlat substrate400. In other embodiments, fourth embeddedfiber particles450 are embedded at other angles with respect to the surface offlat substrate400. In some embodiments, fourth embeddedfiber particles450 are positioned at random angles with respect to the surface ofsubstrate400.
• Second dispenser442 andflat substrate400 may move relative to one another to ensure that the entire surface offlat substrate400 is exposed to secondambient fiber particles446. In one embodiment,second dispenser442 may move around a stationaryflat substrate400. In another embodiment,flat substrate400 may move and rotate relative to a stationarysecond dispenser442. In some embodiments, more than onesecond dispenser442 may be positioned at various locations aroundflat substrate400.
• Second dispenser442 is configured to dispensesecond fiber particle441 until secondambient fiber particles446 no longer adhere tosecond substance420. In some embodiments, the duration of dispensing may be sensed by one or more sensors positioned proximateflat substrate400. In some embodiments, the duration of dispensing may be determined by an operator visually inspectingflat substrate400 and secondambient fiber particles446. Excess secondambient fiber particles446 may be removed from the proximity offlat substrate400 by additional blowing air or a vacuum.
• Third step220 of the method shown inFIG. 4 includes applying an adhesive to the embedded fiber particles, which is achieved in substantially the same manner as the embodiment ofthird step220 shown inFIG. 8. The types and application styles for the adhesive are also the same.
• FIG. 19 shows an embodiment ofthird step220. In the embodiment shown inFIG. 19, asecond nozzle464 is configured to apply asecond adhesive462 onto fourth embeddedfiber particles450.Second nozzle464 may be any kind of spray device known in the art capable of aerosolizing and propelling second adhesive462 towards fourth embeddedfiber particles450. In some embodiments,second nozzle464 may be a trigger-type intermittent sprayer, such as a manual spray bottle. In some embodiments,second nozzle464 may be a compressor-driven continuous sprayer, such as a power sprayer. In other embodiments, an articulated robotic arm such assprayer360 shown inFIG. 8 may be used. In another embodiment, such as the embodiment shown inFIG. 19, a factory line mechanism may be used to support and controlsecond nozzle464.
• In some embodiments, the factory line mechanism may include afactory track1910 disposed on a ceiling or otherwise suspended aboveflat substrate400. Abase1906 is attached tofactory track1910 so that base1906 may translate alongtrack1910 using known techniques such as servo motors and rollers or wheels. A controller such as a processor with associated memory containing a program for manipulatingbase1906 and/ornozzle464 may be linked wirelessly or via wireline to base1906 or any other part of the factory line mechanism. The factory line mechanism may include any number of members and joints to allownozzle464 to move over the entire surface offlat substrate400. In the embodiment shown inFIG. 19, a first factory joint1901 may attach base1906 to afirst factory member1907. A second factory joint1903 may attachfirst factory member1907 to asecond factory member1909. A third factory joint1902 may attach second factory member tofactory grip1905. Each joint may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by a controller. Moving the joints to push the members apart may control the height of sprayer460. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Second sprayer460 andflat substrate400 may move relative to one another to ensure thatsecond adhesive462 is applied to the entire surface offlat substrate400. In one embodiment, second sprayer460 may move around a stationaryflat substrate400. In another embodiment,flat substrate400 may move and rotate relative to a stationary second sprayer460. In some embodiments, more than one second sprayer460 may be positioned at various locations aroundflat substrate400.
• In some embodiments, a large amount of adhesive may be applied to fourth embeddedfiber particles450, such as when a dip-type adhesive is used. In other embodiments, such as shown in the enlarged view inFIG. 8, a relatively light coating of adhesive is applied to fourth embeddedfiber particles450. The enlarged view inFIG. 19 shows thirdadhesive droplets466 dispersed within fourth embeddedfiber particles450. Thirdadhesive droplets466 may be adhered to anindividual fiber particle446 or thirdadhesive droplets466 may be adhered to multiple fourth embeddedfiber particles450. Thirdadhesive droplets466 remain uncured at this point in the manufacturing process.
• Fourth step225 of the method shown inFIG. 4 includes depositing another layer of fiber particles onto fourth embeddedfiber particles450 and thirdadhesive droplets466.FIG. 20 shows an embodiment offourth step225 for aflat substrate400. Fifth embeddedfiber particles455 are deposited ontosubstrate400 and into fourth embeddedfiber particles450 bydispenser442. Uncured thirdadhesive droplets466 assist in holding fifth embeddedfiber particles455 in position.
• Fifth step230 of the method shown inFIG. 4 includes matting the fiber particles. In this embodiment,fifth step230 may be achieved as discussed above.FIG. 21 shows an embodiment offifth step230 in which asecond roller470 is passed over fourth embeddedfiber particles450 and fifth embeddedfiber particles455.Second roller470 may be any type of roller known in the art, such as a roller on a robotic arm or a manually-manipulated roller. The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to thesecond roller470.Second roller470 compresses and entangles fourth embeddedfiber particles450 together to form aninitial ply475 of nonwoven fabric. Other features of the matting process are similar to those described above with respect toFIG. 9.
• Likeroller370,second roller470 may be automated.Second roller470 may be controlled by a rollerrobotic arm2160, which may be similar to the robotic arm discussed above with respect toroller370. The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller470.Robotic arm2160 may include multiple members and joints so that the height and/or orientation ofroller470 may be manipulated. Whilerobotic arm2160 may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 21,robotic arm2160 may include abase2106, afirst member2107, asecond member2109, athird member2111, and agrip2105. A first joint2101 may connectthird member2111 andsecond member2109. A second joint2102 may connectsecond member2109 andfirst member2107. A third joint2103 may connectfirst member2107 andbase2106. Each member such asbase2106,first member2107,second member2109,third member2111, andgrip2105, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members.Grip2105 may be a clamp or similar mechanism. In some embodiments,roller470 may include ahandle479 configured to be securely and, optionally, removably held bygrip2105. Each joint such as first joint2101, second joint2102, and third joint2103 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height ofrobotic arm2160. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Robotic arm2160 andsubstrate400 may move relative to one another to ensure thatroller470 may contact the entire surface ofsubstrate400. In one embodiment,robotic arm2160 may move around astationary substrate400. For example, in the embodiment shown inFIG. 21,robotic arm2160 may be mounted onto atrack2110 that encircles, surrounds, or partially surroundssubstrate400. A connector2115 may be attached tobase2106 and slidably positioned withintrack2110. Connector2115 may be actuated by the controller and the power source using known techniques to translate connector2115, and, by extension,robotic arm2160, alongtrack2110. In this manner,robotic arm2160 may move to multiple positions aroundsubstrate400. Further,base2106 may be configured to rotate with respect to track2110 to allowroller470 to facesubstrate400 regardless of the position ofrobotic arm2160 ontrack2110. In another embodiment,substrate400 may move and rotate relative to a stationaryrobotic arm2160. In some embodiments, more than onerobotic arm2160 may be positioned at various locations aroundsubstrate400.
• As with the embodiments discussed above, an optionalsixth step240 of the method shown inFIG. 4 involves repeatingthird step220 throughfifth step230 to build up additional plies of nonwoven fabric.Sixth step240 may be repeated until the desired number of plies is formed. The number and thicknesses of the layers are the same as those discussed above.
• FIGS. 22-24 show an embodiment of forming a second ply of nonwoven fabric on top ofinitial ply475 of secondnonwoven fabric401. As shown inFIG. 22,third step220 of the method shown inFIG. 4 is essentially repeated. In the embodiment shown inFIG. 22, a second sprayer460 is configured to apply asecond adhesive462 ontoinitial ply475. Second sprayer460 may be any kind of spray device known in the art capable of aerosolizing and propelling second adhesive462 towardsinitial ply475. In some embodiments, second sprayer460 may be a trigger-type intermittent sprayer, such as a manual spray bottle with athird nozzle464. In some embodiments, second sprayer460 may be a compressor-driven continuous sprayer, such as a power sprayer.
• Second sprayer460 andflat substrate400 may move relative to one another to ensure thatsecond adhesive462 is applied to the entirety ofinitial ply475, which may or may not include a pile from unmated or poorly matted fibers and uncured adhesive. In one embodiment, second sprayer460 may move around a stationaryflat substrate400. In another embodiment,flat substrate400 may move and rotate relative to a stationary second sprayer460. In some embodiments, more than one second sprayer460 may be positioned at various locations aroundflat substrate400.
• FIG. 23 shows an embodiment of repeatingfourth step225 in which another layer of fiber particles is deposited ontosubstrate400, similar to the process discussed above with respect toFIG. 20. Sixth embeddedfiber particles480, once deposited bydispenser442, may be held in position by the geometry of sixth embeddedfiber particles480 and uncuredadhesive droplets486.
• FIG. 24 shows an embodiment of repeatingfifth step230 in whichsecond roller470 is passed over sixth embeddedfiber particles480 to mat the embedded fiber particles together into afourth ply490 and toinitial ply475. As discussed above with respect toFIG. 9,second roller470 may be any type of roller known in the art, such as a roller on a robotic arm or a manually-manipulated roller. A controller such as a processor, a computer, or a handheld mobile device that sends signals to thesecond roller470 may guide the movement of a robotic arm.Second roller470 compresses and entangles sixth embeddedfiber particles480 together to form afourth ply490 of nonwoven fabric. In other embodiments, repeatingfifth step230 may involve other methods of matting sixth embeddedfiber particles480, such as vacuum entanglement or manual entanglement.
• The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller470. The robotic arm may include multiple members and joints so that the height and/or orientation ofroller470 may be manipulated. While the robotic arm may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 24, the robotic arm may include abase2406, afirst member2407, asecond member2409, athird member2411, and agrip2405. A first joint2401 may connectthird member2411 andsecond member2409. A second joint2402 may connectsecond member2409 andfirst member2407. A third joint2403 may connectfirst member2407 andbase2406. Each member such asbase2406,first member2407,second member2409,third member2411, andgrip2405, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members.Grip2405 may be a clamp or similar mechanism. In some embodiments,roller470 may include ahandle479 configured to be securely and optionally removably held bygrip2405. Each joint such as first joint2401, second joint2402, and third joint2403 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height of the robotic arm. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• The robotic arm andsubstrate400 may move relative to one another to ensure thatroller470 may contact the entire surface ofsubstrate400. In one embodiment, the robotic arm may move around astationary substrate400. For example, in the embodiment shown inFIG. 24, the robotic arm may be mounted onto a track2424 that encircles, surrounds, or partially surroundssubstrate400. A connector may be attached tobase2406 and slidably positioned within track2424. The connector may be actuated by the controller and the power source using known techniques to translate the connector, and, by extension, the robotic arm, along track2424. In this manner, the robotic arm may move to multiple positions aroundsubstrate400. Further,base2406 may be configured to rotate with respect to track2410 to allowroller470 to facesubstrate400 regardless of the position of the robotic arm on track2424. In another embodiment,substrate400 may move and rotate relative to a stationary the robotic arm. In some embodiments, more than one the robotic arm may be positioned at various locations aroundsubstrate400.
• Third step220 throughfifth step230 may be repeated in this manner until the desired number of plies or material thickness is achieved. Once the desired number of plies is laid down, aseventh step245 in the method shown inFIG. 4 may be performed: the adhesive may be cured. Depending upon the type of adhesive, curing may be achieved by exposing the layers to heat, convection, and/or the flow of ambient temperature air over the layers.FIG. 25 shows an embodiment of curing utilizing anoven495.Oven495 may be any type of oven known in the art, such as a convection oven or an industrial oven configured to receive a conveyor belt. As shown,oven495 is a convection oven configured so thatuncured fabric401 may be passed intooven495 whereuncured fabric401 is exposed toheat498 andair flow497 at a temperature and for a duration sufficient to cureadhesive particles486. In one embodiment, where the adhesive is LocTite spray adhesive, the adhesive is cured with heat applied at about 120 degrees Celsius for about one minute. Curedfabric402 then exitsoven495.
• Once the adhesive is cured, the nonwoven fabric is completed. At this point, aneighth step250 in the method shown inFIG. 4 may be performed.Eighth step250 includes removing the nonwoven fabric from the substrate. Because the layers of the nonwoven fabric were built up and cured directly on the surface of the substrate, the nonwoven fabric will have the same contours as the substrate.
• FIG. 26 shows an embodiment ofeighth step250. Secondnonwoven fabric402 has conformed to the shape of the substantiallyflat substrate400. In this embodiment, secondnonwoven fabric402 is a two-ply seamless nonwoven sheet of fabric as shown inFIG. 27. Secondnonwoven fabric402 may be pulled off of substantiallyflat substrate400 as shown inFIG. 26.Second substance420 may facilitate the removal of secondnonwoven fabric402. In addition to making substantiallyflat substrate400 able to receive fiber particles,second substance420 may lubricate the surface of substantiallyflat substrate402 so that secondnonwoven fabric402 slips more easily off of substantiallyflat substrate400.
• An optionalninth step260 of the method ofFIG. 4 includes additional finishing steps for the nonwoven material. Depending upon the final article for which the nonwoven material is intended, no additional finishing steps may be necessary. In some embodiments, an additional finishing step may be washing or otherwise laundering the nonwoven material to remove any remnants of the substance used to coat the substrate. In other embodiments, additional components may be associated with the nonwoven fabric to complete an article like an article of footwear or an article of apparel. In other embodiments, such as when making an article of apparel, the additional finishing steps may include cutting the nonwoven fabric and joining the cut pieces to each other or to other pieces of fabric to make another article, like an article of apparel. An embodiment of these types of finishing steps is discussed below with respect toFIGS. 47 and 48.
• FIGS. 28-37 show another embodiment of the method generally set forth inFIG. 4. In this embodiment, a shaped substrate—a last—is provided to make a seamless nonwoven upper.
• FIG. 28 shows an embodiment of a shapedsubstrate500 used in an embodiment of a method of making a nonwoven upper. In the embodiment shown inFIG. 28, shapedsubstrate500 is a last configured to make a nonwoven fabric having the shape of an upper, similar to last300 described above.Shaped substrate500 may be supported on a manufacturing floor or otherwise a manufacturing facility by athird base510.Third base510 may be any type of structure capable of supporting and stabilizingshaped substrate500, such as a weighted plate. In some embodiments, apole512 may be associated withthird base510 so that shapedsubstrate500 may be positioned at a predetermined height abovethird base510. In some embodiments,pole512 may elevate shapedsubstrate500 so that shapedsubstrate500 is positioned at a comfortable working height for a user standing or sitting on the manufacturing floor. In other embodiments,pole512 may position shapedsubstrate500 so that all sides ofshaped substrate500 are accessible to the manufacturing process. In some embodiments, shapedsubstrate500 may include provisions for associating withpole512. For example, in one embodiment shapedsubstrate500 may include a recess or hole configured to receive a free end ofpole512. The free end ofpole512 may be inserted into shapedsubstrate500 and fitted there by an interference fit or with threading. In other embodiments,pole512 may be an extension of shapedsubstrate500.
• In some embodiments, shapedsubstrate500 may be a solid, rigid material.Shaped substrate500 may be last for making an article of footwear, similar tosubstrate300 described above.
• Likesubstrate300 discussed above, shapedsubstrate500 is generally a material to which fiber particles may not adhere without an additional adhesive or other substance to which the fiber particles may adhere. The fiber particles may be any types of fiber particle discussed above. The fiber particles may have any length or denier discussed above. In order to receive the fiber particles and hold the fiber particles in position on the surface of shapedsubstrate500, shapedsubstrate500 may be prepared with a substance to which the fiber particles may temporarily adhere. In the embodiment shown inFIG. 28, shapedsubstrate500 is prepared by applying an electromagnetic charge or field to shapedsubstrate500. The electromagnetic charge may be provided using any method of charging an object known in the art. In some embodiments, the charge may be produced by turning on aswitch514 that controls the flow of power from a power source to shapedsubstrate500. The power source may be any type of power source known in the art, such as a wall outlet connected to the local power grid, a battery, or a generator. In some embodiments, shapedsubstrate500 may include circuitry that produces a charge whenswitch514 is in the ON position. In other embodiments, current from the power source may simply flow through shapedsubstrate500 so that the electromagnetic field of the current produces the charge. In other embodiments, shapedsubstrate500 may include a magnet that spins whenswitch514 is in the ON position to generate the magnetic field. In some embodiments, shapedsubstrate500 may be positioned within a chamber that imparts a charge to the surface of shapedsubstrate500.
• In other electrostatic embodiments,substrate500 may have a positive charge or remain neutral or uncharged. In those embodiments, the fiber particles will have an opposite charge to the substrate or be charged when the substrate is uncharged. The substrate attracts and holds onto the fiber particles due to electrostatic attraction.
• Once shapedsubstrate500 has been charged, the method of making the nonwoven fabric occurs in a substantially similar manner to the embodiments described above.
• Second step210 of the method shown inFIG. 4 includes dispensing the fiber particles onto the substrate.FIG. 29 shows an embodiment ofsecond step210. In the embodiment shown inFIG. 29, shapedsubstrate500 has been prepared with a negative charge. Athird dispenser542 is associated with athird reservoir540 containing a plurality ofthird fiber particles541, which may be any type of fiber particle as discussed above.Third reservoir540 may be any container capable of holding a desired quantity ofthird fiber particle541 and communicating that fiber particle tothird dispenser542.Third dispenser542 is configured to dispensesecond fiber particles441 onto shapedsubstrate500.Third dispenser542 may be any type of dispenser capable of propellingthird fiber particle541 fromthird reservoir540 onto shapedsubstrate500.
• In the embodiment shown inFIG. 29,third dispenser542 is a blower or other type of pneumatic device equipped with athird nozzle543.Third dispenser542 may be automated, such as by using a robot arm such as the robotic arms described above.Third dispenser542 may be any type of blower known in the art.Third dispenser542 is configured to draw a plurality ofthird fiber particles541 fromthird reservoir540 and expel the plurality of fiber particles throughthird nozzle543 towards shapedsubstrate500. Once expelled, the fiber particles become thirdambient fiber particles546. Thirdambient fiber particles546 are carried along streams ofthird air flow544 propelled fromthird dispenser542. Thirdambient fiber particles546 have a positive charge in this embodiment.
• Thirdambient fiber particles546 move towards shapedsubstrate500 until thirdambient fiber particles546 stick to shapedsubstrate500. Once stuck onto the charged surface of shapedsubstrate500, the fiber particles becomeattached fiber particles550. In some embodiments, attachedfiber particles550 are positioned on shapedsubstrate500 so that attachedfiber particles550 are substantially normal to the surface of shapedsubstrate500. In other embodiments, attachedfiber particles550 are positioned at other angles with respect to the surface of shapedsubstrate500. In some embodiments, attachedfiber particles550 are positioned at random angles with respect to the surface of shapedsubstrate500.
• Third dispenser542 and shapedsubstrate500 may move relative to one another to ensure that the entire surface of shapedsubstrate500 is exposed to thirdambient fiber particles546. In one embodiment,third dispenser542 may move around a stationaryshaped substrate500. In another embodiment, shapedsubstrate500 may move and rotate relative to a stationarythird dispenser542. In some embodiments, more than onethird dispenser542 may be positioned at various locations around shapedsubstrate500.
• Third dispenser542 is configured to dispensethird fiber particle541 until thirdambient fiber particles546 no longer adhere tosubstrate500. In some embodiments, the duration of dispensing may be sensed by one or more sensors positioned proximate shapedsubstrate500. In some embodiments, the duration of dispensing may be determined by an operator visually inspectingshaped substrate500 and thirdambient fiber particles546. Excess thirdambient fiber particles546 may be removed from the proximity of shapedsubstrate500 by additional blowing air or a vacuum.
• Third step220 of the method shown inFIG. 4 includes applying an adhesive to the embedded fiber particles, which is achieved in substantially the same manner as the embodiment ofthird step220 shown inFIG. 8. The types and application styles for the adhesive are also the same.
• FIG. 30 shows an embodiment ofthird step220. In the embodiment shown inFIG. 30, athird sprayer3060 is configured to apply a third adhesive562 onto attachedfiber particles550.Third sprayer3060 may be any kind of spray device known in the art capable of aerosolizing and propelling third adhesive562 towards attachedfiber particles550. In some embodiments,third sprayer3060 may be a trigger-type intermittent sprayer, such as a manual spray bottle. In some embodiments,third sprayer3060 may be a compressor-driven continuous sprayer, such as a power sprayer.
• In some embodiments, such as the embodiment shown inFIG. 30,third sprayer3060 may be a factory line mechanism. In some embodiments, the factory line mechanism may include afactory track3010 disposed on a ceiling or otherwise suspended above chargedsubstrate500. Abase3006 may be attached tofactory track3010 so that base3006 may translate alongtrack3010 using known techniques such as servo motors and rollers or wheels. A controller such as a processor with associated memory containing a program for manipulatingbase3006 and/ornozzle564 may be linked wirelessly or via wireline to base3006 or any other part of the factory line mechanism. A spray reservoir may be in fluid communication withnozzle564 throughtrack3010, such as with a tube embedded withintrack3010 or a channel formed intrack3010. In other embodiments, a feeder line may be provided to linknozzle564 to a spray reservoir.
• Third sprayer3060 may include any number of members and joints to allownozzle564 to move over the entire surface ofsubstrate500. In the embodiment shown inFIG. 30, a first factory joint3001 may attach base3006 directly to an articulatedgrip3005 that holdsnozzle564, and, in some embodiments, feeds the spray tonozzle564. Articulatedgrip3005 may include a number of members and joints. A first grip joint3002 may attachfirst grip member3007 to asecond grip member3009. A second factory joint3003 may attachthird grip member3011 tofourth grip member3013. Each joint may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by a controller. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other. By translating alongtrack3010 and by moving the joints, the entire surface ofsubstrate500 may be exposed tospray562.
• Third sprayer560 and shapedsubstrate500 may move relative to one another to ensure that third adhesive562 is applied to the entire surface of shapedsubstrate500. In one embodiment, third sprayer560 may move around a stationaryshaped substrate500. In another embodiment, shapedsubstrate500 may move and rotate relative to a stationary third sprayer560. In some embodiments, more than one third sprayer560 may be positioned at various locations around shapedsubstrate500.
• In some embodiments, a large amount of adhesive may be applied to attachedfiber particles550, such as when a dip-type adhesive is used. In other embodiments, such as shown in the enlarged view inFIG. 30, a relatively light coating of adhesive is applied to attachedfiber particles550. The enlarged view inFIG. 30 shows fifthadhesive droplets566 dispersed within attachedfiber particles550. Fifthadhesive droplets566 may be adhered to anindividual fiber particle546 or fifthadhesive droplets566 may be adhered to multiple attachedfiber particles550. Fifthadhesive droplets566 remain uncured at this point in the manufacturing process.
• Fourth step225 of the method shown inFIG. 4 includes applying a second layer of fiber particles onto attachedfiber particles550 and fifthadhesive droplets566.FIG. 31 shows an embodiment of a layer of second attachedfiber particles555 being deposited onto last500, attachedfiber particles550, and fifthadhesive droplets566. The electrostatic charge, the geometry of attachedfiber particles550, and fifthadhesive droplets566 hold second attachedfiber particles555 in position on last500.
• Fifth step230 of the method shown inFIG. 4 includes matting the fiber particles. In this embodiment,fifth step230 may be achieved as discussed above.FIG. 32 shows an embodiment offifth step230 in which athird roller570 is passed over attachedfiber particles550 and second attachedfiber particles555.Third roller570 may be any type of roller known in the art, such as a roller on a robotic arm or a manually-manipulated roller. The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to thethird roller570.Third roller570 compresses and entangles attachedfiber particles550 and second attachedfiber particles555 together to form abase ply575 of nonwoven fabric.
• Third roller570 may be automated, such as by employing a robotic arm like articulatedrobotic arm3260. The movement of articulatedrobotic arm3260 may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller570. Articulatedrobotic arm3260 may include multiple members and joints so that the height and/or orientation ofroller570 may be manipulated. While articulatedrobotic arm3260 may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 32, articulatedrobotic arm3260 may include abase3206, afirst member3207, asecond member3209, athird member3211, and a grip3205. A first joint3201 may connectthird member3211 andsecond member3209. A second joint3202 may connectsecond member3209 andfirst member3207. A third joint3203 may connectfirst member3207 andbase3206. Each member such asbase3206,first member3207,second member3209,third member3211, and grip3205, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members. Grip3205 may be a clamp or similar mechanism. In some embodiments,third roller570 may include ahandle579 configured to be securely and optionally removably or interchangeably supported by grip3205. Each joint such as first joint3201, second joint3202, and third joint3203 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height of the robotic arm. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other so thatroller570 may have access to the entirety ofsubstrate500 an any particles onsubstrate500.
• The robotic arm andsubstrate500 may move relative to one another to ensure thatroller570 may contact the entire surface ofsubstrate500. In one embodiment, the robotic arm may move around astationary substrate500. For example, in the embodiment shown inFIG. 32, the robotic arm may be mounted onto a track that encircles, surrounds, or partially surroundssubstrate500. A connector may be attached tobase3206 and slidably positioned within the track. The connector may be actuated by the controller and the power source using known techniques to translate the connector, and, by extension, the robotic arm, along the track. In this manner, the robotic arm may move to multiple positions aroundsubstrate500. Further,base3206 may be configured to rotate with respect to track3210 to allowroller570 to facesubstrate500 regardless of the position of the robotic arm on the track. In another embodiment,substrate500 may move and rotate relative to a stationary the robotic arm. In some embodiments, more than one the robotic arm may be positioned at various locations aroundsubstrate500.
• As with the embodiments discussed above, an optionalsixth step240 of the method shown inFIG. 4 involves repeatingthird step220 throughfifth step240 to build up additional plies of nonwoven fabric.Sixth step240 may be repeated as many times as desired until the desired number of plies is formed. The number and thicknesses of the layers are the same as those discussed above.
• FIGS. 33-35 show an embodiment of forming a second ply of nonwoven fabric on top of base ply575 of thirdnonwoven fabric501. As shown inFIG. 33,third step220 of the method shown inFIG. 4 is essentially repeated, using any of the adhesive application techniques shown and/or discussed above.FIG. 33 shows sprayer3364, which may be any type of sprayer discussed above.Sprayer3364 applies sixthadhesive droplets586 to base ply575. InFIG. 33,sprayer3364 is incorporated into a robotic arm similar to the robotic arms discussed above. Multiple members such asbase3306,first member3307, andsecond member3309 are connected together by joints such as first joint3301, second joint3302, and third joint3303. Afeeder line3321 connected to aspray reservoir3320 may feedsprayer3364 so thatspray3362 may be propelled towardssubstrate500. The operation ofsprayer3364 may be the same or similar to any automated sprayer discussed above, such as by changing height or position and controlling the amount and duration of spray.
• Sprayer3364 andsubstrate500 may move with respect to each other so that the entirety ofsubstrate500 may exposed tospray3362. In some embodiments, such as those discussed above,sprayer3364 may move aroundsubstrate500. However, in the embodiment shown inFIG. 33,substrate500 may be configured to spin. For example, a motor andgearbox3310 may be attached toplatform510 and powered by a battery or apowerline3311 controlled byswitch514. Whenswitch514 is in the ON position,gearbox3310 may causesubstrate500 to spin using known techniques. Between the rotating ofsubstrate500 and the ability ofsprayer3364 to change height and other spatial positions, sprayer3364 may be able to expose the entirety ofrotating substrate500 tospray3362.
• Fourth step225 of the method shown inFIG. 4 is also repeated, using any technique forfourth step225 discussed above.FIG. 34 shows an embodiment offourth step225.Dispensers542 deposit chargedfiber particles546 onto last500,base ply575, and sixthadhesive droplets586 until third attachedfiber particles580 attach to base ply575. Sixthadhesive droplets586 assist in maintaining third attachedfiber particles580 in position. As noted above, chargedfiber particles546 are dispensed until no additional fiber particles adhere to last500 and/or a visual inspection of last500 shows the desired level of coverage.
• FIG. 35 shows an embodiment of repeatingfifth step230 in whichthird roller570 is passed over third attachedfiber particles580 to mat and interconnect third attachedfiber particles580. As discussed above with respect toFIG. 10,third roller570 may be any type of roller known in the art, such as a roller on arobotic arm3560 or a manually-manipulated roller. A controller such as a processor, a computer, or a handheld mobile device that sends signals to thethird roller570 may guide the movement of a robotic arm. The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller570. The robotic arm may include multiple members and joints so that the height and/or orientation ofroller570 may be manipulated. While the robotic arm may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 35, the robotic arm may include abase3506, afirst member3507, asecond member3509, athird member3511, and a grip3505. A first joint3501 may connectthird member3511 andsecond member3509. A second joint3502 may connectsecond member3509 andfirst member3507. A third joint3503 may connectfirst member3507 andbase3506. Each member such asbase3506,first member3507,second member3509,third member3511, and grip3505, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members. Grip3505 may be a clamp or similar mechanism. In some embodiments,roller570 may include ahandle579 configured to be securely and optionally removably held by grip3505. Each joint such as first joint3501, second joint3502, and third joint3503 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height of the robotic arm. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• The robotic arm andsubstrate500 may move relative to one another to ensure thatroller570 may contact the entire surface ofsubstrate500. Similar to the embodiment shown inFIG. 33,substrate500 may be configured to rotate or spin to expose the entirety of substrate toroller570.
• Third roller570 compresses and entangles third attachedfiber particles580 together to form anadditional ply590 of nonwoven fabric. Additionally,third roller570 also entangles third attachedfiber particles580 to the fibers ofbase ply575. In other embodiments, repeatingfifth step230 may involve other methods of matting third attachedfiber particles580, such as vacuum entanglement or manual entanglement.
• Third step220 throughfifth step230 may be repeated in this manner until the desired number of layers is achieved. Once the desired number of plies is laid down,seventh step245 in the method shown inFIG. 4 may be performed: the adhesive may be cured. Depending upon the type of adhesive, curing may be achieved by exposing the layers to heat, convection, and/or the flow of ambient temperature air over the layers. In the embodiment shown inFIG. 35, acuring device3565 mounted on atrack3566 propelsheated air3564 towardssubstrate500 at a desired temperature and for a desired duration.Curing device3565 may be a factory line mechanism as discussed above, having a base3561 slidably mounted to track3566. An articulated joint3562 may connect base3561 tobody3563. A controller and power source may feed information and power throughtrack3566 or through other lines connected to curingdevice3565. In one embodiment, where the adhesive is LocTite spray adhesive, the adhesive is cured with heat applied at about 120 degrees Celsius for about one minute. Any of the adhesive curing methods, including temperature and duration, discussed above may be used in this embodiment.
• Once the adhesive is cured, the nonwoven fabric is completed. At this point, aneighth step250 in the method shown inFIG. 4 may be performed.Eighth step250 includes removing the nonwoven fabric from the substrate. Because the layers of the nonwoven fabric were built up and cured directly on the surface of the substrate, the nonwoven fabric will have the same contours as the substrate.
• FIG. 36 shows an embodiment ofeighth step250. Thirdnonwoven fabric501 has conformed to the shape of the substantially shapedsubstrate500. In this embodiment, thirdnonwoven fabric501 is a seamless nonwoven upper. Thirdnonwoven fabric501 includes athroat opening520 that allows thirdnonwoven fabric501 to be pulled off of shapedsubstrate500 as shown inFIG. 36.Switch514 has been turned to the OFF position, which removes or neutralizes the charge on shapedsubstrate500. Neutralizing the charge on shapedsubstrate500 allows thirdnonwoven fabric501 to slip more easily off of shapedsubstrate500. In another embodiment, the charge on shapedsubstrate500 may even switch polarity for this step, so that shapedsubstrate500 and thirdnonwoven fabric501 may have the same polarity and will repel each other for easy removal of the thirdnonwoven fabric501 from shapedsubstrate500.
• An optionalninth step260 of the method ofFIG. 4 includes additional finishing steps for the nonwoven material, which in this embodiment is a seamless nonwoven upper501 as shown inFIG. 37. Depending upon the final article for which the nonwoven material is intended, no additional finishing steps may be necessary. In some embodiments, an additional finishing step may be washing or otherwise laundering the nonwoven material to remove any remnants of the substance used to coat the substrate. In other embodiments, additional components may be associated with the nonwoven fabric to complete an article like an article of footwear or an article of apparel. In other embodiments, such as when making an article of apparel, the additional finishing steps may include cutting the nonwoven fabric and joining the cut pieces to each other or to other pieces of fabric to make another article, like an article of apparel. For example a ragged edge such asthroat opening edge512 may be finished with cutting, sealing, or additional material adhered, welded or sewn into position for a more durable and aesthetically pleasing article. In another example,bottom opening516 may be closed and/or sealed with a sole.
• FIGS. 38-46 show another embodiment of the method generally set forth inFIG. 4. In this embodiment, a charged, substantially flat substrate is provided to make a substantially flat nonwoven material. This method is similar to the method described above with respect toFIGS. 28-37, though the intention is to produce a flat sheet of material as opposed to a shaped, three-dimensional article. Only the shapes of the substrate and the resultant article differ from the embodiment shown and discussed above with respect toFIGS. 28-37.
• The resultant nonwoven fabric will take on the shape of the substrate.FIG. 38 shows an embodiment of a substantially flat chargedsubstrate600 used in an embodiment of a method of making a flat sheet of nonwoven material or fabric. In the embodiment shown inFIG. 38, substantially flat chargedsubstrate600 is a substantially flat surface like a table configured to make a substantially flat nonwoven fabric. Substantially flat chargedsubstrate600 may be supported on a manufacturing floor or otherwise a manufacturing facility by afourth base610.Fourth base610 may be any type of structure capable of supporting and stabilizing substantially flat chargedsubstrate600, such as a weighted plate. In some embodiments, aleg612 may be associated withfourth base610 so that substantially flat chargedsubstrate600 may be positioned at a predetermined height abovefourth base610. In some embodiments,leg612 may elevate substantially flat chargedsubstrate600 so that substantially flat chargedsubstrate600 is positioned at a comfortable working height for a user standing or sitting on the manufacturing floor. In other embodiments,leg612 may position substantially flat chargedsubstrate600 so that all sides of substantially flat chargedsubstrate600 are accessible to the manufacturing process. In some embodiments, substantially flat chargedsubstrate600 may include provisions for associating withleg612. For example, in one embodiment substantially flat chargedsubstrate600 may include a recess or hole configured to receive a free end ofleg612. The free end ofleg612 may be inserted into substantially flat chargedsubstrate600 and fitted there by an interference fit or with threading. In other embodiments,leg612 may be an extension of substantially flat chargedsubstrate600.
• In some embodiments, substantially flat chargedsubstrate600 may be a solid, rigid material. Substantially flat chargedsubstrate600 may have a substantially flat surface, similar to substantiallyflat substrate400 described above.
• Like substantiallyflat substrate400 discussed above, substantially flat chargedsubstrate600 may be a material to which fiber particles may not adhere without a charge. In other embodiments,flat substrate600 may have no charge while the fiber particles are charged. The fiber particles may be any types of fiber particle discussed above. The fiber particles may have any length or denier discussed above. In this embodiment, substantially flat chargedsubstrate600 is prepared by applying an electromagnetic charge or field to substantially flat chargedsubstrate600 so that the fiber particles may attach to chargedsubstrate600 electrostatically. The electromagnetic charge may be provided using any method of charging an object known in the art. In some embodiments, the charge may be produced by turning on asecond switch614 that controls the flow of power from a power source to substantially flat chargedsubstrate600. The power source may be any type of power source known in the art, such as a wall outlet connected to the local power grid, a battery, or a generator. In some embodiments, substantially flat chargedsubstrate600 may include circuitry that produces a charge whensecond switch614 is in the ON position. In other embodiments, current from the power source may simply flow through substantially flat chargedsubstrate600 so that the electromagnetic field of the current produces the charge. In other embodiments, substantially flat chargedsubstrate600 may include a magnet that spins whensecond switch614 is in the ON position to generate the magnetic field.
• Once substantially flat chargedsubstrate600 has been charged, the method of making the nonwoven fabric occurs in a substantially similar manner to the embodiments described above.
• Second step210 of the method shown inFIG. 4 includes dispensing the fiber particles onto the substrate.FIG. 39 shows an embodiment ofsecond step210. In the embodiment shown inFIG. 39, substantially flat chargedsubstrate600 has been prepared with a negative charge. Afourth dispenser642 is associated with afourth reservoir640 containing a plurality offourth fiber particles641, which may be any type of fiber particle as discussed above.Fourth reservoir640 may be any container capable of holding a desired quantity offourth fiber particles641 and communicating that fiber particle tofourth dispenser642.Fourth dispenser642 is configured to dispensefourth fiber particles641 onto substantially flat chargedsubstrate600.Fourth dispenser642 may be any type of dispenser capable of propellingfourth fiber particles641 fromfourth reservoir640 onto substantially flat chargedsubstrate600.
• In the embodiment shown inFIG. 39,fourth dispenser642 is a blower or other type of pneumatic device equipped with afourth nozzle643.Fourth dispenser642 may be any type of blower known in the art.Fourth dispenser642 is configured to drawfourth fiber particles641 fromfourth reservoir640 and expel the fiber particles throughfourth nozzle643 towards substantially flat chargedsubstrate600. Once expelled, the fiber particles become fourthambient fiber particles646. Fourthambient fiber particles646 are carried along streams offourth air flow644 propelled fromfourth dispenser642. Fourthambient fibers646 also carry a positive charge, which is the opposite electromagnetic state as that of substantially flat charged substrate. Fourthambient fiber particles646 are drawn towards substantially flat chargedsubstrate600 due in part to the electromagnetic attraction until fourthambient fiber particles646 stick to substantially flat chargedsubstrate600 due to the electromagnetic attraction. Once positioned onto the charged surface of substantially flat chargedsubstrate600, the fiber particles become fifth attachedfiber particles650. In some embodiments, fifth attachedfiber particles650 are positioned on substantially flat chargedsubstrate600 so that fifth attachedfiber particles650 are substantially normal to the surface of substantially flat chargedsubstrate600. In other embodiments, fifth attachedfiber particles650 are attached at other angles with respect to the surface of substantially flat chargedsubstrate600. In some embodiments, fifth attachedfiber particles650 are positioned at random angles with respect to the surface of substantially flat chargedsubstrate600.
• Fourth dispenser642 and substantially flat chargedsubstrate600 may move relative to one another to ensure that the entire surface of substantially flat chargedsubstrate600 is exposed to fourthambient fiber particles646. In one embodiment,fourth dispenser642 may move around a stationary substantially flat chargedsubstrate600. In another embodiment, substantially flat chargedsubstrate600 may move and rotate relative to a stationaryfourth dispenser642. In some embodiments, more than onefourth dispenser642 may be positioned at various locations around substantially flat chargedsubstrate600.
• Fourth dispenser642 is configured to dispensefourth fiber particles641 until fourthambient fiber particles646 no longer adhere to substantially flat chargedsubstrate600. In some embodiments, the duration of dispensing may be sensed by one or more sensors positioned proximate substantially flat chargedsubstrate600. In some embodiments, the duration of dispensing may be determined by an operator visually inspecting substantially flat chargedsubstrate600 and fourthambient fiber particles646. Excess fourthambient fiber particles646 may be removed from the proximity of substantially flat chargedsubstrate600 by additional blowing air or a vacuum.
• Third step220 of the method shown inFIG. 4 includes applying an adhesive to the embedded fiber particles, which is achieved in substantially the same manner as the embodiment ofthird step220 shown inFIG. 8. The types and application styles for the adhesive are also the same.
• FIG. 40 shows an embodiment ofthird step220. In the embodiment shown inFIG. 40, afourth sprayer4360 is configured to apply afourth adhesive662 onto fifth attachedfiber particles650.Fourth sprayer4360 may be any kind of spray device known in the art capable of aerosolizing and propelling fourth adhesive662 towards fifth attachedfiber particles650. In some embodiments,fourth sprayer4360 may be a trigger-type intermittent sprayer, such as a manual spray bottle. In some embodiments,fourth sprayer4360 may be a compressor-driven continuous sprayer, such as a power sprayer.
• In some embodiments,fourth sprayer4360 may be afactory line mechanism626 that may include afactory track660 disposed on a ceiling or otherwise suspended aboveflat substrate600. A base621 may be attached tofactory track660 so thatbase621 may translate alongtrack660 using known techniques such as servo motors and rollers or wheels. A controller such as a processor with associated memory containing a program for manipulatingbase621 and/ornozzle664 may be linked wirelessly or via wireline tobase621 or any other part of the factory line mechanism. The factory line mechanism may include any number of members and joints to allownozzle664 to move over the entire surface offlat substrate600. In the embodiment shown inFIG. 40, afirst factory joint624 may attach base621 to afirst factory member623. Asecond factory joint622 may attachfirst factory member623 to asecond factory member625 that supportnozzle664. Each joint may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by a controller. Moving the joints to push the members apart may control the height ofsprayer360. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Fourth sprayer4360 and substantially flat chargedsubstrate600 may move relative to one another to ensure thatfourth adhesive662 is applied to the entire surface of substantially flat chargedsubstrate600. In one embodiment,fourth sprayer4360 may move around a stationary substantially flat chargedsubstrate600. In another embodiment, substantially flat chargedsubstrate600 may move and rotate relative to a stationaryfourth sprayer4360. In some embodiments, more than onefourth sprayer4360 may be positioned at various locations around substantially flat chargedsubstrate600.
• In this embodiment, such as shown in the enlarged view inFIG. 40, a relatively light coating of adhesive is applied to fifth attachedfiber particles650. The enlarged view inFIG. 40 shows seventhadhesive droplets666 dispersed within fifth attachedfiber particles650. Seventhadhesive droplets666 may be adhered to anindividual fiber particle646 or seventhadhesive droplets666 may be adhered to multiple fifth attachedfiber particles650. Seventhadhesive droplets666 remain uncured at this point in the manufacturing process.
• Fourth step225 of the method shown inFIG. 4 includes applying a second layer of fiber particles onto fifth attachedfiber particles650 and seventhadhesive droplets666.FIG. 41 shows an embodiment of a layer of sixth attachedfiber particles655 being deposited onto chargedsubstrate600, fifth attachedfiber particles650, and seventhadhesive droplets666. The electrostatic charge, the geometry of fifth attachedfiber particles650, and seventhadhesive droplets666 hold sixth attachedfiber particles655 in position onsubstrate600.
• Fifth step230 of the method shown inFIG. 4 includes matting the fiber particles. In this embodiment,fifth step230 may be achieved as discussed above.FIG. 42 shows an embodiment offifth step230 in which afourth roller670 is passed over fifth attachedfiber particles650 and sixth attachedfiber particles655.Fourth roller670 may be any type of roller known in the art, such as a roller on a robotic arm or a manually-manipulated roller. The movement of a robotic arm such asrobot4236 may be guided by a controller such as a processor, a computer, or a handheld mobile device that sends movement signals to thefourth roller670.
• The movement ofrobot4236 may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller670.Robot4236 may include multiple members and joints so that the height and/or orientation ofroller670 may be manipulated. While the robotic arm may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 42, the robotic arm may include abase4206, afirst member4207, asecond member4209, and athird member4211. A first joint4201 may connectthird member4211 andsecond member4209. A second joint4202 may connectsecond member4209 andfirst member4207. A third joint4203 may connectfirst member4207 andbase4206. Each member such asbase4206,first member4207,second member4209, andthird member4211, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members. In some embodiments,roller670 may include ahandle679 configured to be securely and optionally removably supported bythird member4211. Each joint such as first joint4201, second joint4202, and third joint4203 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height ofrobot4236. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• Fourth roller670 compresses and entangles fifth attachedfiber particles650 and sixth attached fiber particles together to form abottom ply675 of nonwoven fabric. As shown in the enlarged portion ofFIG. 42, the fibers are loosely attached to each other, being attached atvarious points676 while leavingsignificant air gaps678 throughoutbottom ply675.
• As with the embodiments discussed above, an optionalsixth step240 of the method shown inFIG. 4 involves repeatingsecond step210 throughfourth step240 to build up additional plies of nonwoven fabric.Sixth step240 may be repeated as many times as desired until the desired number of plies is formed. The number and thicknesses of the plies are the same as those discussed above.
• FIGS. 43-45 show an embodiment of forming a second ply of nonwoven fabric on top ofbottom ply675 of fourthnonwoven fabric601. As shown inFIG. 43 shows an embodiment of repeatingthird step220. In the embodiment shown inFIG. 43,fourth sprayer4360 is configured to apply anfourth adhesive662 ontobottom ply675. In some embodiments,fourth sprayer4360 may be part of a factory line.
• In some embodiments,fourth sprayer4360 may include atrack4310 disposed on a ceiling or otherwise suspended aboveflat substrate600. Abase4306 may be attached to track4310 so that base4306 may translate alongtrack4310 using known techniques such as servo motors and rollers or wheels. A controller such as a processor with associated memory containing a program for manipulatingbase4306 and/ornozzle4364 may be linked wirelessly or via wireline to base4306 or any other part offourth sprayer4360.Fourth sprayer4360 may include any number of members and joints to allownozzle4364 to move over the entire surface offlat substrate600. In the embodiment shown inFIG. 43, a first joint4301 may attach base4306 to an articulatedgrip4305. Articulatedgrip4305 may include any number of members and joints. A first grip joint4302 may attachfirst grip member4307 to asecond grip member4309. A second factory joint4303 may attachthird grip member4311 tofourth grip member4313. Each joint may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by a controller. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other. By translating alongtrack4310 and by moving the joints, the entire surface ofsubstrate600 may be exposed to fourth adhesive orspray662.
• Fourth sprayer4360 and substantially flat chargedsubstrate600 may move relative to one another to ensure thatfourth adhesive662 is applied to the entirety ofbottom ply675. In one embodiment,fourth sprayer4360 may move around a stationary substantially flat chargedsubstrate600. In another embodiment, substantially flat chargedsubstrate600 may move and rotate relative to a stationaryfourth sprayer4360. In some embodiments, more than onefourth sprayer4360 may be positioned at various locations around substantially flat chargedsubstrate600. Eighth adhesive droplets686 remain uncured and dispersed throughout seventh attachedfiber particles680.
• FIG. 44 shows an embodiment of repeatingfourth step225 of the method shown inFIG. 4, which includes applying another layer of fiber particles ontobottom ply675 and eighth adhesive droplets686. The embodiment shown inFIG. 44 is similar in most respects to the embodiments of repeatingfourth step225 as discussed above with respect to the other embodiments.FIG. 44 shows an embodiment of a layer of seventh attachedfiber particles680 being deposited ontosubstrate600,bottom ply675, and eighth adhesive droplets686.
• FIG. 45 shows an embodiment of repeatingfifth step230 in whichfourth roller670 is passed over seventh attachedfiber particles680. The embodiment shown inFIG. 45 is similar in most respects to the embodiments of repeatingfifth step230 as discussed above with respect to the other embodiments.Fourth roller670 compresses and entangles seventh attachedfiber particles680 together to form an appendedply690 of nonwoven fabric. Additionally,fourth roller670 also entangles seventh attachedfiber particles680 to the fibers ofbottom ply675 to attach appendedply690 tobottom ply675. In other embodiments, repeatingfifth step230 may involve other methods of matting seventh attachedfiber particles680, such as vacuum entanglement or manual entanglement.
• FIG. 45 shows an embodiment of repeatingfifth step230 in whichfourth roller670 is passed over third attachedfiber particles680 to mat and interconnect third attachedfiber particles680. As discussed above with respect toFIG. 10,fourth roller670 may be any type of roller known in the art, such as a roller on a robotic arm or a manually-manipulated roller. A controller such as a processor, a computer, or a handheld mobile device that sends signals to thefourth roller670 may guide the movement of a robotic arm. The movement of a robotic arm may be guided by a controller such as a processor, a computer, or a handheld mobile device that send movement signals to theroller670.
• The robotic arm may be mounted on a track for factory line use, as shown inFIG. 45. While the robotic arm may include any number of members and joint, in some embodiments such as the embodiment shown inFIG. 45, the robotic arm may include abase4506 and afirst member4507. A first joint4501 may connectbase4506 andfirst member4507. Each member such asbase4506 andfirst member4507, may be any type of member known in the art, such as solid rods, hollow tubes, flat bars, and combinations of these types of members. In some embodiments,roller670 may be directly attached tofirst member4507 by aconnector4503.Connector4503 may be a mechanical connector like a pin, a weld, or a joint. First joint4501 andoptionally connector4503 may be any type of joint known in the art, such as hinge joints and rotary joints. Each joint may be independently moved by controller. Moving the joints to push the members apart may control the height of the robotic arm. Each joint may be configured to allow the attached member to move, pivot, swivel, rotate, or otherwise move with respect to each other.
• The robotic arm andsubstrate500 may move relative to one another to ensure thatroller670 may contact the entire surface ofsubstrate500. Similar to the embodiment shown inFIG. 33,substrate500 may be configured to rotate or spin on amotorized gear box627 to expose the entirety ofsubstrate600 toroller670.
• Fourth roller670 compresses and entangles third attachedfiber particles680 together to form anadditional ply690 of nonwoven fabric. Additionally,fourth roller670 also entangles third attachedfiber particles680 to the fibers ofbase ply675. In other embodiments, repeatingfifth step230 may involve other methods of matting third attachedfiber particles680, such as vacuum entanglement or manual entanglement.
• Third step220 throughfifth step230 may be repeated in this manner until the desired number of layers is achieved. Once the desired number of plies is laid down,seventh step245 in the method shown inFIG. 4 may be performed: the adhesive may be cured. Depending upon the type of adhesive, curing may be achieved by exposing the layers to heat, convection, and/or the flow of ambient temperature air over the layers. In the embodiment shown inFIG. 45, acuring device4567 mounted on atrack4510 may propelheated air4597 towardssubstrate600 at a desired temperature and for a desired duration.Curing device4567 may be a factory line mechanism as discussed above, having a base4566 slidably mounted to track4510. An articulated joint4561 may connect base4566 to curingdevice4567. A controller and power source may feed information and power throughtrack4510 or through other lines connected to curingdevice4567. In one embodiment, where the adhesive is LocTite spray adhesive, the adhesive is cured with heat applied at about 120 degrees Celsius for about one minute. Any of the adhesive curing methods, including temperature and duration, discussed above may be used in this embodiment.
• Once the adhesive is cured, the nonwoven fabric is completed. At this point, aneighth step250 in the method shown inFIG. 4 may be performed.Eighth step250 includes removing the nonwoven fabric from the substrate. Because the layers of the nonwoven fabric were built up and cured directly on the surface of the substrate, the nonwoven fabric will have the same contours as the substrate.
• FIG. 46 shows an embodiment ofeighth step250. Fourthnonwoven fabric601 has conformed to the shape of the substantially flat chargedsubstrate600. In this embodiment, fourthnonwoven fabric601 is a sheet of nonwoven material.Second switch614 has been turned to the OFF position, which removes or neutralizes the charge on substantially flat chargedsubstrate600. Neutralizing the charge on substantially flat chargedsubstrate600 allows fourthnonwoven fabric601 to slip more easily off of substantially flat chargedsubstrate600. In some embodiments, switch614 may control the polarity of the charge in addition to or instead of merely controlling the flow of power. If the polarity is reversed, the charge of substantially flat chargedsubstrate600 may repel fourthnonwoven fabric601 for easy removal.
• An optionalninth step260 of the method ofFIG. 4 includes additional finishing steps for the nonwoven material. Depending upon the final article for which the nonwoven material is intended, no additional finishing steps may be necessary. In some embodiments, an additional finishing step may be washing or otherwise laundering the nonwoven material to remove any remnants of the substance used to coat the substrate. In other embodiments, additional components may be associated with the nonwoven fabric to complete an article like an article of footwear or an article of apparel. In other embodiments, such as when making an article of apparel, the additional finishing steps may include cutting the nonwoven fabric and joining the cut pieces to each other or to other pieces of fabric to make another article, like an article of apparel.
• FIGS. 47 and 48 show an embodiment of using a sheet ofnonwoven material770 to make an article ofapparel790 using a body last or a dressmaker'smannequin700. Body last700 may be any type of body last known in the art as long as body last700 is capable of receiving cut portions of material so that a technician or tailor may join the material pieces into an article of apparel. Although shown as a torso-shaped body last, body last700 may in other embodiments be a full body last for making suits that cover both a torso and the legs, or a lower body last for making shorts, pants, trousers, and the like.
• Nonwoven material770 may be made using any method known in the art, including those methods described above. However, the method of makingnonwoven material770 is not restricted to those methods described above.
• FIG. 47 also shows how components of an article of apparel may be associated with body last700 to be joined together into the article of apparel. The components may all be made of the same material, such as is shown in the embodiment ofFIG. 47, or the components may be made of different materials. InFIG. 47, asingle apparel material770 is provided. Outlines of the components to be cut or developed fromapparel material770 are shown on apparel material770: afirst sleeve component771, asecond sleeve component772, afront component773, and aback component774. To associatefirst sleeve component771 with body last700 in the proper position,first sleeve component771 is positioned proximatefirst shoulder721.First sleeve component771 is placed on top of body last700 so thatfirst sleeve component771 covers at least a portion offirst shoulder721. To associatesecond sleeve component772 with body last700 in the proper position,second sleeve component772 is positioned proximatesecond shoulder723.Second sleeve component772 is placed on top of body last700 so thatsecond sleeve component772 covers at least a portion ofsecond shoulder723. In this embodiment, the sleeve components substantially cover the shoulder regions, but do not extend a significant length alongfirst arm710 orsecond arm712. In other embodiments, these coverage amounts could vary, with the shoulders and arms having more or less coverage than shown in this embodiment.
• To associatefront component773 with body last700,front component773 is positionedproximate chest portion702 and abdomen portion714.Front component773 is placed on top of body last700 so that front component covers at least a portion ofchest portion702 and abdomen portion714. In this embodiment,front component773 would substantially cover bothchest portion702 and abdomen portion714. Other embodiments would have varying levels of coverage, either greater than or less than the amount of coverage shown inFIG. 47. To associate backcomponent774 with body last700,back component774 is positioned proximate a back portion of third last (not shown but generally oppositechest portion702 and abdomen714.)Back component774 is placed on top of body last700 so thatback component774 covers at least a portion of the back portion. In this embodiment,back component774 would substantially cover the back portion. Other embodiments would have varying levels of coverage, either greater than or less than the amount of coverage shown inFIG. 47.
• The number of components depends on the design of the article of apparel. For example, in other embodiments, multiple components may be used in place of any single component discussed in this embodiment. Similarly, a single component may be used in place of any two or more components discussed in this embodiment. The embodiment shown inFIG. 47 is of a short-sleeved shirt, but a similar method could be used to make any type of torso-covering garment.FIG. 48 shows how the components correspond to portions of article ofapparel790.
• The components shown inFIG. 47 may be attached directly to body last700 (when the components are touching an outer surface of body last700), or the components may be indirectly attached to body last700 where another layer is positioned between the outer surface of body last700 and the components.) The type of attachment depends on factors including the material(s) used to make body last700. For example, body last700 may include a rigid, inflexible material to withstand the external pressure applied by the pressure applicator. The rigid material may include metals, plastics, ceramics, composites, foam materials, and combinations. Some of these materials may have a smooth surface. In such embodiments, a covering or other material may be included with body last700. In some embodiments, body last700 itself may include a covering, such as a fabric, soft foam, elastomeric material, or the like. The covering layer may be thin enough that any texture on the smooth surface of the rigid material is still able to be imparted to the apparel. However, the covering layer may allow pins or other fasteners to be used to attach the components to body last700. In another embodiment, body last700 may only include the rigid material. A layer of another material may be provided between the outer surface of body last700 and the apparel. For example, a release film may be employed, where one side of the release film is able to stick or adhere to body last700 while the components of the apparel may be positioned on the other side of the release film using a tacky surface, pins or other fasteners, or static electricity. Finally, even if body last700 includes a smooth surface, static electricity, temporary adhesives, or other fasteners may be used to attach the components to body last700. Any of these materials, attachment mechanisms, and configurations may be used with any of the embodiments described herein.
• As will be apparent to a person of ordinary skill in the art, body last700 may be adapted to be a substrate for the method shown inFIG. 4, according to any embodiment discussed above. In such embodiments, the cutting and shaping of the nonwoven material on a separate body last may be eliminated if the nonwoven material itself can be formed and shaped simultaneously on a body last.
• 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. Any feature of any embodiment may be used with and/or substituted for another element of any other embodiment except where specifically restricted. 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.

Claims (53)

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 toclaim 1, wherein the substrate is configured to produce an article having curvature along at least two axes.

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

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

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

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

10. The method according toclaim 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 toclaim 1, wherein applying the adhesive includes spraying the adhesive onto the fiber particles.

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

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

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

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

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

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

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

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

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

26. The method according toclaim 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 toclaim 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 toclaim 28, wherein the substance facilitates removing the upper from the substantially flat substrate.

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

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

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

33. The method according toclaim 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 toclaim 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 toclaim 27 further comprising incorporating the nonwoven fabric into an article.

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

37. The method according toclaim 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 and the adhesive, wherein each fiber in the second plurality of matted fiber particles is a monofilament, and where all of the fibers in the second plurality of matted fiber particles is the same monofilament.

39. The article according toclaim 38, wherein the fabric has curvature along at least two axes.

40. The article according toclaim 39, wherein the article is an upper of an article of footwear.

41. The article according toclaim 40, wherein the upper is seamless.

42. The article according toclaim 41, wherein the upper is associated with a sole.

43. The article according toclaim 41, wherein the upper includes a throat opening.

44. The article according toclaim 41, wherein the upper includes a second material.

45. The article according toclaim 44, wherein the second material is a polymer layer applied to at least one of the toe region and the heel region.

46. The article according toclaim 44, wherein the second material is a reinforcing layer associated with the throat opening.

47. The article according toclaim 46, wherein a first part of a securing system is formed in the reinforcing layer.

48. The article according toclaim 47, wherein the first part of the securing system includes eyelets configured to receive a lace.

49. The article according toclaim 38, wherein the article is an article of apparel.

50. The article according toclaim 49, wherein the nonwoven fabric is associated with a second fabric to form the article of apparel.

51. The article according toclaim 38, wherein the first layer includes a gap devoid of matted fiber particles, and the second layer spans the gap so that the nonwoven fabric is continuous.

52. The article according toclaim 50, wherein the gap is provided to alter at least one performance characteristic of the nonwoven fabric proximate the gap.

53. The article according toclaim 51, wherein the at least one performance characteristic includes at least one of breathability, stiffness, flexibility, and permeability.

Images