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

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.

What is claimed is: 
     
         1 . A method of making a nonwoven article, the method comprising:
 preparing a substrate to receive fiber particles;   depositing a first plurality of fiber particles onto the substrate;   applying an adhesive to the plurality of fiber particles;   depositing a second plurality of fiber particles onto the substrate;   matting the first plurality of fiber particles and the second plurality of fiber particles together to form a matted ply of a resultant nonwoven article;   curing the resultant nonwoven article; and   removing the resultant nonwoven article from the substrate.   
     
     
         2 . The method according to  claim 1 , wherein the substrate is configured to produce an article having curvature along at least two axes. 
     
     
         3 . The method according to  claim 2 , wherein the substrate is a last for an article of footwear. 
     
     
         4 . The method according to  claim 1 , wherein the substrate is substantially flat to produce a sheet of fabric. 
     
     
         5 . The method according to  claim 1  further comprising the steps of
 applying a second adhesive to the matted ply; 
 depositing a third plurality of fiber particles onto the matted ply; and 
 matting the third plurality of fiber particles together to form a second matted ply of the resultant nonwoven article. 
 
     
     
         6 . The method according to  claim 5  further comprising the step of applying a mask to a portion of the matted ply prior to depositing at least one of the second adhesive and the third plurality of fiber particles onto the matted ply. 
     
     
         7 . The method according to  claim 1  further comprising the step of applying a mask to a portion of the substrate prior to depositing the plurality of fiber particles onto the substrate. 
     
     
         8 . The method according to  claim 1 , wherein the step of preparing the substrate includes applying to the substrate a substance designed to capture the fiber particles. 
     
     
         9 . The method of  claim 1 , wherein the step of preparing the last includes applying a charge to the substrate. 
     
     
         10 . The method according to  claim 1 , wherein depositing the first plurality of fiber particles to the substrate includes blowing the first plurality of fiber particles onto the substrate. 
     
     
         11 . The method according to  claim 1 , wherein applying the adhesive includes spraying the adhesive onto the fiber particles. 
     
     
         12 . The method according to  claim 1 , wherein matting the fiber particles includes a mechanical compressing of the first plurality of fiber particles and second plurality of fiber particles. 
     
     
         13 . The method according to  claim 12 , wherein the mechanical compressing includes using a roller to entangle the first plurality of fiber particles and the second plurality of fiber particles. 
     
     
         14 . A method of making a nonwoven upper, the method comprising:
 preparing a last to receive a plurality of fiber particles;   depositing the plurality of fiber particles onto the last in the shape of an upper, including a throat opening;   applying an adhesive to the plurality of fiber particles;   matting the fiber particles to form a matted layer of the upper;   curing the adhesive; and   removing the resultant upper from the last.   
     
     
         15 . The method according to  claim 14 , wherein the step of preparing the last includes applying to the last a substance designed to capture the plurality of fiber particles. 
     
     
         16 . The method according to  claim 15 , wherein the substance is applied to the last to form an outline of the throat opening of the upper. 
     
     
         17 . The method according to  claim 15 , wherein the substance facilitates removing the upper from the last. 
     
     
         18 . The method according to  claim 17 , wherein the substance is petroleum jelly. 
     
     
         19 . The method according to  claim 17 , wherein the substance is silicone. 
     
     
         20 . The method according to  claim 17 , wherein the step of preparing the last includes applying a release film to the last. 
     
     
         21 . The method according to  claim 14 , wherein the step of preparing the last includes applying a charge to the last. 
     
     
         22 . The method according to  claim 21 , wherein the last has a negative charge when the charge is applied to the last and each fiber in the plurality of fiber particles has a positive charge. 
     
     
         23 . The method according to  claim 14  further comprising removing a completed upper from the last after neutralizing the charge to the last. 
     
     
         24 . The method according to  claim 14  further comprising the step of incorporating the resultant upper into an article of footwear. 
     
     
         25 . The method according to  claim 24  further comprising associating the resultant upper with a sole. 
     
     
         26 . The method according to  claim 24  further comprising finishing the throat opening with at least one of a tongue and a securing system. 
     
     
         27 . A method of making a nonwoven fabric, the method comprising:
 preparing a substantially flat substrate to receive a plurality of fiber particles;   depositing the plurality of fiber particles onto the substantially flat substrate;   applying an adhesive to the plurality of fiber particles;   matting the fiber particles to form a matted layer of the nonwoven fabric;   curing the adhesive; and   removing the resultant nonwoven fabric from the substantially flat substrate.   
     
     
         28 . The method according to  claim 27 , wherein the step of preparing the substantially flat substrate includes applying to the substantially flat substrate a substance designed to capture the plurality of fiber particles. 
     
     
         29 . The method according to  claim 28 , wherein the substance facilitates removing the upper from the substantially flat substrate. 
     
     
         30 . The method according to  claim 28 , wherein the substance is one of petroleum jelly and silicone. 
     
     
         31 . The method according to  claim 28 , wherein the step of preparing the substantially flat substrate includes applying a release film to the substantially flat substrate. 
     
     
         32 . The method according to  claim 27 , wherein the step of preparing the substantially flat substrate includes applying a charge to the substantially flat substrate. 
     
     
         33 . The method according to  claim 32 , wherein the substantially flat substrate has a negative charge when the charge is applied to the substantially flat substrate and each fiber in the plurality of fiber particles has a positive charge. 
     
     
         34 . The method according to  claim 27 , wherein removing the resultant fabric from the substantially flat substrate occurs after neutralizing the charge to the substantially flat substrate. 
     
     
         35 . The method according to  claim 27  further comprising incorporating the nonwoven fabric into an article. 
     
     
         36 . The method according to  claim 35 , wherein incorporating the nonwoven fabric into an article includes cutting the nonwoven fabric into a pattern. 
     
     
         37 . The method according to  claim 35 , wherein the article is an article of apparel. 
     
     
         38 . An article incorporating a nonwoven fabric, the article comprising:
 a first layer incorporating a first plurality of matted fiber particles and an adhesive, wherein each fiber in the first plurality of matted fiber particles is a monofilament, and where all of the fibers in the first plurality of matted fiber particles is the same monofilament; and   a second layer incorporating a second plurality of matted fiber particles 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 to  claim 38 , wherein the fabric has curvature along at least two axes. 
     
     
         40 . The article according to  claim 39 , wherein the article is an upper of an article of footwear. 
     
     
         41 . The article according to  claim 40 , wherein the upper is seamless. 
     
     
         42 . The article according to  claim 41 , wherein the upper is associated with a sole. 
     
     
         43 . The article according to  claim 41 , wherein the upper includes a throat opening. 
     
     
         44 . The article according to  claim 41 , wherein the upper includes a second material. 
     
     
         45 . The article according to  claim 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 to  claim 44 , wherein the second material is a reinforcing layer associated with the throat opening. 
     
     
         47 . The article according to  claim 46 , wherein a first part of a securing system is formed in the reinforcing layer. 
     
     
         48 . The article according to  claim 47 , wherein the first part of the securing system includes eyelets configured to receive a lace. 
     
     
         49 . The article according to  claim 38 , wherein the article is an article of apparel. 
     
     
         50 . The article according to  claim 49 , wherein the nonwoven fabric is associated with a second fabric to form the article of apparel. 
     
     
         51 . The article according to  claim 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 to  claim 50 , wherein the gap is provided to alter at least one performance characteristic of the nonwoven fabric proximate the gap. 
     
     
         53 . The article according to  claim 51 , wherein the at least one performance characteristic includes at least one of breathability, stiffness, flexibility, and permeability.