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  Article of footwear of nonwoven material and method of manufacturing sameUSPTO Application #: 20060276095Title: Article of footwear of nonwoven material and method of manufacturing same Abstract: A method of forming a portion of an article of footwear includes the steps of providing a last having an exterior surface, extruding a plurality of polymeric fibers, projecting a stream of the extruded polymeric fibers onto the last to form a mat having the shape of the exterior of the last, and subjecting the mat to heat and pressure in a mold. (end of abstract) Agent: Banner & Witcoff, Ltd. - Boston, MA, US Inventors: Bhupesh Dua, Edward N. Thomas Related Keywords: footwear, stream USPTO Applicaton #: 20060276095 - Class: 442400000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Nonwoven Fabric (i.e., Nonwoven Strand Or Fiber Material), Melt-blown Nonwoven Fabric The Patent Description & Claims data below is from USPTO Patent Application 20060276095. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] This invention relates to an article of footwear formed of a nonwoven material and a method of manufacturing an article of footwear formed of a nonwoven material. BACKGROUND OF THE INVENTION [0002] Nonwoven fabrics, herein defined as structures made by bonding and/or interlocking polymeric fibers by mechanical or thermal means, are commonly used in many industries for many applications including, for example: (i) medical products, including surgical gowns, drapes, face masks, bouffant caps, surgical caps, footwear coverings, and slippers; (ii) protective coverings for automobiles, boats, airplanes, bicycles, lawn furniture, lawn mowers, and grills; (iii) apparel, including industrial work wear, pants, shirts, jackets, gloves, headwear, and socks; (iv) personal care products such as diapers, training pants, adult incontinence products, and feminine hygiene products; and (v) filtration. [0003] Two common methods of forming nonwoven fabrics are melt-blowing and spunbonding. The melt-blowing process typically includes extruding a molten thermoplastic material through a plurality of fine die capillaries to form molten fibers. The fibers enter a high velocity gas stream, usually air, which attenuates the fibers so as to reduce their diameters. Thereafter, the high-velocity gas stream deposits the fibers on a collecting surface to form a substantially planar fabric, commonly referred to as a bat, mat web or sheet, which is comprised of randomly disbursed fibers. Patents that are representative of the melt-blowing process include U.S. Pat. No. 3,825,379 to Lohcamp et al. as well as U.S. Pat. No. 4,714,647 to Shipp, Jr. et al. [0004] In contrast, the spunbonding process typically includes extruding a molten thermoplastic material through a plurality of fine spinnerette capillaries to form molten fibers. The fibers then enter a gas stream having less velocity than that of the melt-blowing process. The gas stream reduces the diameters of the fibers and deposits the fibers on a collecting surface, thereby forming a substantially planar fabric. Patents that are representative of the spunbonding process include U.S. Pat. No. 3,692,618 to Dorschner et al. and U.S. Pat. No. 4,340,563 to Appel et al. The difference between melt-blowing and spunbonding relates to the continuity and diameter of the fibers. Whereas melt-blown fibers have diameters that are generally smaller than 10 microns, spunbonded fibers have diameters that are generally between 10 and 30 microns. Melt-blown fibers often include both continuous and discontinuous fibers, since their smaller diameters tends to result in breakage of the continuous fibers, as contrasted with spunbond fibers that include primarily continuous fibers. [0005] The majority of patents relating to the manufacture of nonwoven fabrics focus on the formation of a substantially planar material having a uniform thickness. However, U.S. Pat. No. 6,146,580 to Bontaites, Jr. discloses a method of manufacturing a nonwoven materials in which fibers are deposited on a contoured drum as the drum rotates. The result is a substantially planar material having the contour of the drum imprinted on one surface. Furthermore, the process discloses the manufacture of surgical masks using a form in the shape of a surgical mask. U.S. Pat. No. 5,575,874 to Griesbach, III et al. also discloses a process by which a textured or perforated material is formed. [0006] Melt-blown and spunbonded fabrics have been incorporated into footwear in applications including coverings, composite uppers and insoles, and combination nonwovens. In relation to coverings, the primary use for nonwoven materials appears to be for medical products including footwear coverings and slippers. Patents assigned to Kimberly-Clark Worldwide, Inc., including U.S. Pat. Nos. 5,952,252; 5,939,341; 5,695,377; 5,688,157; and 5,652,051, are exemplary of such uses. In combination with other materials, nonwoven fabrics have been incorporated into shoe uppers and insoles. U.S. Pat. No. 4,603,075 to Dergarabedian discloses an insole composite comprised of a nonwoven fabric and woven polymeric scrim that are saturated with a curable or cross-linkable polymer. U.S. Pat. No. 4,663,222 to Ohue et al. discloses a nonwoven fabric that is heat-bonded to the inner side of a leather shoe to improve comfort and impart resistance to rain and water. U.S. Pat. No. 4,426,420 to Likhyani discloses a spunbonded fabric containing both elastic and non-elastic fibers so as to impart greater stretch and resilience to the fabric. A similar process for melt-blown fibers is disclosed in U.S. Pat. No. 5,238,733 to Joseph et al. [0007] It is an object of the present invention to provide a method of producing an article of footwear formed of nonwoven material that reduces or overcomes some or all of the difficulties inherent in prior known devices. Particular objects and advantages of the invention will be apparent to those skilled in the art, that is, those who are knowledgeable or experienced in this field of technology, in view of the following disclosure of the invention and detailed description of certain preferred embodiments. SUMMARY [0008] The principles of the invention may be used to advantage to provide a method of forming an article of footwear that includes a step of depositing polymeric fibers onto a surface of a last to form a nonwoven material having a shape that corresponds with the surface of the last. The nonwoven material may then be incorporated into an article of footwear. Such footwear provides improved breathability and moldability, abrasion resistance, stretch and recovery, water resistance, and recyclability. [0009] In accordance with a first aspect, a method of forming a portion of an article of footwear includes the steps of providing a last having an exterior surface, extruding a plurality of polymeric fibers, projecting a stream of the extruded polymeric fibers onto the last to form a mat having the shape of the exterior of the last, and subjecting the mat to heat and pressure in a mold. [0010] In accordance with another aspect, a method of forming an article of footwear includes the steps of providing a last having an exterior surface, providing a vacuum at the exterior surface of the last, extruding a plurality of polymeric fibers, depositing at least some of the polymeric fibers onto the last to form a mat having the shape of the exterior of the last, subjecting the mat to heat and pressure in a mold to form an upper, and securing the upper to a sole assembly. [0011] In accordance with yet another aspect, an upper for an article of footwear includes a mat of nonwoven extruded polymeric fibers formed in a shape of an upper for an article of footwear, with the upper being seamless. [0012] In accordance with a further aspect, an article of footwear includes a sole assembly, and an upper secured to the sole assembly, with the upper comprising a mat of nonwoven extruded polymeric fibers and being seamless. [0013] In accordance with yet a further aspect, an upper of an article of footwear is formed by the steps of providing a last having an exterior surface, providing a vacuum at the exterior surface of the last, extruding a plurality of polymeric fibers, projecting a stream of the extruded polymeric fibers onto the last to form a mat having the shape of the exterior of the last, and subjecting the mat to heat and pressure in a mold to form an upper. [0014] Substantial advantage is achieved by forming an article of footwear or an upper of an article of footwear of a nonwoven material. In particular, certain embodiments produce an upper that is breathable and comfortable, with improved moldability, abrasion resistance, stretch and recovery, and recyclability. Such footwear also has unique performance and aesthetic characteristics and reduced waste. [0015] These and additional features and advantages disclosed here will be further understood from the following detailed disclosure of certain embodiments. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIG. 1 is a perspective view of an article of footwear having an upper formed of nonwoven material in accordance with a certain embodiments. [0017] FIG. 2 is a perspective view of a method of forming the upper of FIG. 1 by deposting nonwoven fibers on a last. [0018] FIG. 3 is a perspective view of a mold used in the formation of the upper of the article of footwear of FIG. 1. [0019] The figures referred to above are not drawn necessarily to scale and should be understood to provide a representation of the invention, illustrative of the principles involved. Some features of the article of footwear or upper of nonwoven material and their method of manufacture depicted in the drawings have been enlarged or distorted relative to others to facilitate explanation and understanding. The same reference numbers are used in the drawings for similar or identical components and features shown in various alternative embodiments. Uppers or articles of footwear of nonwoven material and the methods of manufacture as disclosed herein would have configurations and components determined, in part, by the intended application and environment in which they are used. DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS Continue reading... Full patent description for Article of footwear of nonwoven material and method of manufacturing same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Article of footwear of nonwoven material and method of manufacturing same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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