Composite Element With a Polymer Connecting Layer

Abstract

A composite element includes a base or textile layer, a thermoplastic polymer material, a thread, and a cover layer. The base layer has a first surface and an opposite second surface. The polymer material is separate from the base layer, extends into the base layer, and is at least partially located at the first surface. The thread has a section lying adjacent to the first surface layer and substantially parallel to the first surface throughout a distance of at least five centimeters, and the thread is bonded to the base layer with the polymer material. The cover layer is located adjacent to the first surface and bonded to the base layer with the polymer material, and the section of the thread is located between the cover layer and the base layer.

1 . A composite element comprising:
 a textile layer with a first surface and an opposite second surface;   a thermoplastic polymer material separate from the textile layer and extending into the textile layer, the polymer material extending through the textile layer to be located at both the first surface and the second surface;   a thread having a section laying adjacent to the first surface of the textile layer and substantially parallel to the first surface of the textile layer throughout a distance of at least five centimeters; and   a cover layer located adjacent to the first surface of the textile layer and secured to the textile layer with the polymer material, the section of the thread being located between the cover layer and the textile layer.   
     
     
         2 . The composite element recited in  claim 1 , wherein the section of the thread is located between portions of the thread that extend through the textile layer. 
     
     
         3 . The composite element recited in  claim 1 , wherein an end of the section of the thread is located at an edge of the textile layer. 
     
     
         4 . The composite element recited in  claim 1 , wherein the thread includes a plurality of additional sections that lay adjacent to the first surface of the textile layer and are substantially parallel to the first surface of the textile layer throughout the distance of at least five centimeters. 
     
     
         5 . The composite element recited in  claim 4 , wherein the additional sections are oriented to be substantially parallel to each other. 
     
     
         6 . The composite element recited in  claim 4 , wherein the additional sections are oriented to cross each other. 
     
     
         7 . The composite element recited in  claim 1 , wherein a backing layer is located adjacent to the second surface of the textile layer and secured to the textile layer with the polymer material. 
     
     
         8 . The composite element recited in  claim 1 , wherein the thread is secured to the textile layer with the polymer material. 
     
     
         9 . The composite element recited in  claim 1 , wherein the composite element is incorporated into an article of footwear. 
     
     
         10 . A composite element comprising:
 a textile layer with a first surface and an opposite second surface;   a thermoplastic polymer material separate from the textile layer, the thermoplastic polymer material extending into and infiltrating the textile layer, at least a portion of the thermoplastic polymer material being located at the first surface of the textile layer;   a plurality of thread sections laying adjacent to the first surface of the textile layer and substantially parallel to the first surface of the textile layer throughout a distance of at least five centimeters; and   a cover layer located adjacent to the first surface of the textile layer and secured to the textile layer with the polymer material, and the thread sections being located between the cover layer and the textile layer.   
     
     
         11 . The composite element recited in  claim 10 , wherein the plurality of thread sections is secured to the textile layer with the polymer material. 
     
     
         12 . The composite element recited in  claim 10 , wherein at least a portion of the polymer material is located at the second surface of the textile layer, and a backing layer is located adjacent to the second surface of the textile layer and secured to the textile layer with the polymer material. 
     
     
         13 . The composite element recited in  claim 12 , wherein the composite element is incorporated into an article of footwear. 
     
     
         14 . The composite element recited in  claim 13 , wherein the backing layer forms at least a portion of an interior surface of the article of footwear. 
     
     
         15 . A composite element comprising:
 a textile layer with a first surface and an opposite second surface;   a thermoplastic polymer material separate from the textile layer, the thermoplastic polymer material extending into and infiltrating the textile layer, at least a portion of the thermoplastic polymer material being located at the first surface of the textile layer and at least a portion of the thermoplastic polymer material being located at the second surface;   a plurality of thread sections laying adjacent to the first surface of the textile layer and substantially parallel to the first surface of the textile layer throughout a distance of at least five centimeters;   a cover layer located adjacent to the first surface of the textile layer and secured to the textile layer with the polymer material, and the thread sections being located between the cover layer and the textile layer; and   a backing layer located adjacent to the second surface of the textile layer and secured to the textile layer with the polymer material.   
     
     
         16 . The composite element recited in  claim 15 , wherein the plurality of thread sections is secured to the textile layer with the polymer material. 
     
     
         17 . The composite element recited in  claim 15 , wherein the plurality of thread sections comprises at least a first thread group associated with a first portion of the textile layer and a second thread group associated with a second portion of the textile layer. 
     
     
         18 . The composite element recited in  claim 17 , wherein at least one thread associated with the second thread group crosses over at least one thread associated with the first thread group. 
     
     
         19 . The composite element recited in  claim 15 , wherein the portion of the thermoplastic polymer material being located at the first surface of the textile layer is approximately equal to the portion of the thermoplastic polymer material being located at the second surface. 
     
     
         20 . The composite element recited in  claim 15 , wherein the thermoplastic polymer material comprises at least two sheets of thermoplastic polymer material.