Patent Description:
The present disclosure generally relates to a wearable article with a nonwoven textile sheet having an integral portion shaped as an integral implement of the wearable article, and a method of manufacturing the wearable article.

Wearable articles such as carry bags, belts, and other apparel should provide sufficient comfort while also being of a durable nature in order to repeatedly and reliably perform functions such as support and closure. Document <CIT> describes a non-woven textile formed from a plurality of polymer filaments that incorporate a thermoplastic polyurethane material, the non-woven textile having a first region and a second region, each of the first region and the second region having a continuous area of at least one square centimeter, and the filaments of the first region being fused to a greater degree than the filaments of the second region.

The present disclosure generally relates to wearable articles and their manufacture. Wearable articles including nonwoven textile sheets with integral portions shaped as integral implements are disclosed. A method of manufacturing the nonwoven textile sheet provides an integral portion of the sheet with a shape and a sufficiently high modulus of elasticity enabling it to serve as an integral implement, while a contiguous portion of the sheet maintains a lower modulus of elasticity for comfort, aesthetic appearance, or both. The wearable articles disclosed herein are reduced in complexity in comparison to wearable articles in which separate (e.g., non-integral) structural components of different materials are secured to a textile sheet to serve the same functions as the integral implements. Additionally, the nonwoven textile sheet may be formed from recycled materials. The invention is defined by a method of manufacturing a wearable article according to independent claim <NUM>. Particular embodiments of the claimed invention are defined by the dependent claims.

In a non-claimed example, a wearable article may comprise a nonwoven textile sheet having a first portion shaped as an integral implement of the wearable article. The nonwoven textile sheet may also have a second portion contiguous with the first portion. The first portion may have a first density and a first modulus of elasticity. The second portion may have a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity. For example, the moduli of elasticity may be tensile moduli (Young's modulus). The first portion is shaped differently than the second portion, and its shape, density, and modulus of elasticity enables it to function as an integral implement of the wearable article.

As used herein, for the purposes of this disclosure, a "wearable article" is an article that is configured to be worn on a human body, and does not include durable goods not intended to be worn on a human body, such as furniture and automotive upholstery. Non-limiting examples of wearable articles include footwear, apparel, carry bags such as backpacks, purses, duffel bags, fanny packs, and other types of portable containment structures intended to be worn on a human body. As used herein, for the purposes of this disclosure, a "carry bag" is a containment device having one or more straps or handles or other features configured for placement on a human body, and includes but is not limited to backpacks, purses, duffle bags, and fanny packs.

As used herein, for the purposes of this disclosure, an "integral implement" is a portion of a nonwoven textile sheet that is of unitary construction with a contiguous portion of the sheet, and that has a function that is at least partly accomplished by its shape, including its contours, and by its sufficient rigidity to accomplish the function, as indicated by its modulus of elasticity. Examples of integral implements as defined herein include closure devices, such as buckles, including male portions of buckles and female portions of buckles, snaps, buttons, and other types of closure devices, and receptacles, such as for power sources or power devices, including batteries, lights, cellular phones, etc. Other examples of integral implements include footwear heel counters.

The first portion and the second portion of the nonwoven textile sheet may originally be of the same density and modulus of elasticity. The first portion may be thermoformed, for example, heating and compressing its fibers together to increase its density and modulus of elasticity so that it can function as an integral implement, whereas the less stiff, less dense second portion does not have the function of the integral implement, but is useful for serving other purposes, such as functions that require more flexibility. The fibers of the different layers may melt together when heated and pressed during thermoforming, as discussed herein, which may make the boundaries of the different layers less distinct. Heating of the first portion of the nonwoven textile sheet may be via heated thermoforming mold tools. Alternatively or in addition, at least the first portion of the nonwoven textile sheet may be heated prior to placing the first portion in the thermoforming mold. In some configurations, the thermoforming mold may be cooled to help maintain the exterior surface of the nonwoven textile sheet below a predetermined temperature in order to prevent some or all of the melt fibers at the exterior surface of the first portion from melting during thermoforming.

The relative thicknesses of the first portion and the second portion may be different in different configurations. For example, a thickness of the first portion may be within a range from about <NUM> percent less than to about <NUM> percent greater than a thickness of the second portion, or within a range from about <NUM> percent less than to about <NUM> percent greater than the thickness of the second portion, or within a range from about <NUM> percent less than to about <NUM> percent greater than the thickness of the second portion. Alternatively, a thickness of the first portion may be more than <NUM> percent greater than a thickness of the second portion, or a thickness of the second portion may be more than <NUM> percent greater than a thickness of the first portion.

In a non-claimed aspect, the first portion may define a through hole extending through the nonwoven textile sheet. For example, one or more laser cut or punched through holes may be made in the first portion. In embodiments in which the wearable article includes a closure device, the through hole may be an opening in a female portion of the closure device at which a male portion of the closure device releasably secures.

In another non-claimed aspect, the wearable article may include a textile component, which may be a textile sheet, and the nonwoven textile sheet may be secured to the textile component. For example, the nonwoven textile sheet may be secured to the textile component such as by sewing or bonding. In other embodiments in which the wearable article includes a textile component, fibers of the second portion of the nonwoven textile sheet may be intertwined with fibers of the textile component to secure the second portion to the textile component, such as by needle punching. In such embodiments, the textile component may underlie both the first portion and the second portion. In one or more implementations, the integral implement of the first portion of the nonwoven textile panel may be one of either a female portion or a male portion of a closure device. For example, the wearable article may be a carry bag or a belt, and the closure device may be a buckle. In implementations where the wearable article is a carry bag, the integral implement may be a male portion of the buckle or a female portion of the buckle. For example, the carry bag may include a flap and a base. The male portion of the buckle may be disposed on a strap extending from the flap to a female portion of the buckle disposed on the base, or on a strap extending from the base to a female portion of the buckle disposed on the flap. The male portion of the buckle may be disposed at the flap or at the strap, such as at an end of the strap.

In a non-claimed example in which the wearable article is a carry bag and the integral implement is a male portion of the buckle, the carry bag may include an additional nonwoven textile sheet with a first portion shaped as an integral implement that may be a female portion of the buckle, and with a second portion contiguous with the first portion. The female portion of the buckle may be an additional integral implement of the carry bag. The first portion of the additional nonwoven textile sheet may have a density greater than a density of the second portion of the additional nonwoven textile sheet and a modulus of elasticity greater than a modulus of elasticity of the second portion of the additional nonwoven textile sheet. The male portion may be shaped and dimensioned to releasably secure to the female portion. In some embodiments, the closure device may be a buckle for sternum straps of a backpack, or a waist belt for a backpack.

In other non-claimed implementations, the wearable article may be footwear, and the integral implement may be a heel counter. The wearable article is not limited to carry bags and articles of footwear, however, and the integral implement is not limited to closure devices and heel counters. For example, the wearable article could be a carry bag, an article of footwear, or an article of apparel, and the integral implement may be a receptacle for a power source or a power device, such as a battery, a light, a cellular phone, etc..

In one or more non-claimed implementations, the first portion may comprise multiple stacked nonwoven textile layers, which may include a first outer layer, a second outer layer and at least one intermediate layer disposed between the first outer layer and the second outer layer. The at least one intermediate layer may extend only in the first portion.

In a non-claimed aspect, an edge of the at least one intermediate layer may be tapered. The edge that is tapered may be adjacent to the second portion.

In a non-claimed example, a carry bag may comprise a nonwoven textile sheet having a first portion shaped as an integral implement that is a portion of a buckle, the nonwoven textile sheet having a second portion contiguous with the first portion. The first portion may have a density greater than a density of the second portion and a modulus of elasticity greater than a modulus of elasticity of the second portion. The first portion of the buckle may be a female portion of a buckle, and the carry bag may further comprise a nonwoven textile strap having a first portion shaped as an integral implement that is as a male portion of the buckle that releasably secures to the female portion. The nonwoven textile strap may have a second portion contiguous with the first portion of the nonwoven textile strap. The first portion of the nonwoven textile strap may have a density greater than a density of the second portion of the nonwoven textile strap and a modulus of elasticity greater than a modulus of elasticity of the second portion of the nonwoven textile strap.

According to the claimed invention, a method of manufacturing a wearable article, such as those disclosed herein, comprises thermoforming a first portion of a nonwoven textile sheet as an integral implement of the wearable article. The nonwoven textile sheet has an unthermoformed second portion contiguous with the thermoformed first portion and shaped differently than the first portion. The first portion has a first density and a first modulus of elasticity after thermoforming. The unthermoformed second portion has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity.

In one or more configurations, the method may include, prior to thermoforming in the thermoforming mold, heating at least the first portion of the nonwoven textile sheet. After heating at least the first portion of the nonwoven textile sheet, the method may include placing the first portion of the nonwoven textile sheet in the thermoforming mold. A temperature of a mold surface of the thermoforming mold may be less than a temperature of the first portion of the nonwoven textile sheet. For example, the mold surface may be at room temperature, or may be actively cooled to a temperature less than or equal to room temperature during the thermoforming process. A temperature differential between the portion of the nonwoven textile sheet being thermoformed and the mold surfaces may help to retain the original texture of the exterior surface of the nonwoven textile sheet, such as a relatively rough (e.g., hairy) texture of felt, even though the sheet is compressed during thermoforming.

According to the claimed invention, the method further comprises, prior to thermoforming the first portion, stacking multiple nonwoven textile layers to define the first portion. The multiple nonwoven textile layers include a first outer layer, a second outer layer, and at least one intermediate layer disposed between the first outer layer and the second outer layer. The at least one intermediate layer extends only in the first portion. The first outer layer and the second outer layer may extend in both the first portion and the second portion. For example, the first outer layer and the second outer layer may be two separate nonwoven textile sheets. In other embodiments, a single nonwoven textile sheet forms the first portion and the second portion, with only the first portion split to create the first outer layer and second outer layer. According to the claimed invention, the method includes, prior to stacking the multiple nonwoven textile layers, splitting the nonwoven textile sheet only at the first portion to define the first outer layer and the second outer layer, the first outer layer and the second outer layer extending only in the first portion. The method may further comprise inserting the at least one intermediate layer in the split between the first outer layer and the second outer layer.

In one or more configurations, the method may further comprise, prior to inserting the at least one intermediate layer between the first outer layer and the second outer layer, tapering an edge of the at least one intermediate layer. Inserting the at least one intermediate layer between the first outer layer and the second outer layer may be with the tapered edge adjacent the second portion. In an aspect, the method may further comprise, after stacking the multiple nonwoven textile layers and before thermoforming the first portion, heat pressing the multiple nonwoven textile layers to one another.

In one or more implementations, the method may further comprise creating at least one through hole in the first portion extending through the nonwoven textile sheet. For example, creating at least one through hole in the first portion may comprise laser cutting the at least one through hole or punching the at least one through hole.

In one or more implementations, the method may further comprise, after thermoforming the first portion, trimming a peripheral edge of the first portion. For example, trimming the peripheral edge of the first portion may be by laser cutting. In embodiments in which the structural component is a male portion of a buckle, trimming the peripheral edge may be to define prongs of the buckle, for example.

In one or more configurations, the wearable article may include a textile component, and the method may further comprise, after thermoforming the first portion, securing the nonwoven textile sheet to the textile component so that the nonwoven textile sheet extends from the textile component. For example, the nonwoven textile sheet may be a flap of a carry bag secured at a peripheral edge to a textile component of the carry bag. In one or more other configurations in which the wearable article includes a textile component, the method may further comprise, after thermoforming the first portion, needle punching the second portion to the textile component. For example, after needle punching the second portion to the textile component, the nonwoven textile sheet may be adjacent to a surface of the textile component with the first portion and the second portion both overlaying the textile component at the surface, and with at least the second portion in contact with the surface. For example, where the integral implement is a female portion of the buckle for a carry bag or is a receptacle for a power source or power device, the first portion and second portion may overlay the textile component. Any through holes in the female portion are then blocked from an interior cavity of the carry bag by the textile component.

Referring to the drawings, <FIG> shows a wearable article <NUM> configured and manufactured according to the teachings herein. In <FIG>, the wearable article <NUM> is a carry bag, such as a purse or a backpack, and may be referred to herein as such. The wearable article <NUM> includes a closure device <NUM>, discussed in further detail herein. The closure device <NUM> is shown as a buckle, and may be referred to as such herein. The closure device may be included in other wearable articles within the scope of the present teachings, such as belts. Shoulder straps of the wearable article <NUM> are not shown, but may be on the back side of the wearable article.

The wearable article <NUM> includes one or more nonwoven textile sheets, such as nonwoven textile sheets <NUM> and <NUM>. The nonwoven textile sheets <NUM>, <NUM> may be a felt material having relatively short and randomly disposed fibers <NUM>. The felt material may include plastic, such as a polyester, including but not limited to a thermoplastic polymer such as polyethylene terephthalate (PET), and may be made from recycled plastic. For example, the fibers <NUM> may be PET. One advantage of felt is that it is suitably soft for use as a wearable article, and is available in sheet form, which can be manufactured according to the method disclosed herein. The random distribution of fibers <NUM> matted together in a nonwoven textile sheet, as opposed to an ordered distribution that occurs in a woven material, enables the sheets <NUM>, <NUM> to be shaped and formed as described herein without the felt providing resistive forces tending to pull the sheet back to its original flat shape, as could occur with a material having woven strands. As described herein, portions of one or both of the nonwoven textile sheets <NUM>, <NUM> may be formed to achieve a nonplanar shape that can function as integral implements of the nonwoven textile sheet, while a contiguous remaining portion of the sheet may remain planar or at least may have a different shape than the first portion.

The nonwoven textile sheet <NUM> is configured as a base of the carry bag <NUM>, and may be referred to as such. The nonwoven textile sheet <NUM> has a first portion <NUM> shaped and dimensioned as an integral implement of the wearable article <NUM>. The first portion <NUM> is a female portion 12A of the closure device <NUM>. The nonwoven textile sheet <NUM> also has a second portion <NUM> contiguous with the first portion <NUM> at an outer boundary <NUM> of the first portion <NUM>. As discussed herein, the first portion <NUM> is molded by thermoforming to achieve the shape different than the second portion <NUM>, whereas the surrounding second portion <NUM> is not thermoformed. The first portion <NUM> of the nonwoven textile sheet <NUM> is that portion inward of the outer boundary <NUM>. Accordingly, prior to thermoforming the first portion <NUM>, the first portion <NUM> and the second portion <NUM> have the same density and modulus of elasticity and the same relatively flat, planar shape. The thermoforming compresses the first portion <NUM> relative to the second portion <NUM>, causing the PET fibers <NUM> of the first portion <NUM> (illustrated in close-up circle A) to establish and maintain a more compacted arrangement relative to the PET fibers <NUM> of the second portion <NUM> (illustrated in close-up circle B). The heat and pressure may melt the fibers, allowing the PET material to flow and form to the shape of the mold. Different percentages of melt fibers versus non-melt fibers will result in different levels of hardness, rigidity, and strength of the thermoformed first portion <NUM>.

For example, the melt fibers included in the PET fibers <NUM> may melt in a temperature range from <NUM> degrees Celsius to <NUM> degrees Celsius, with the molding process lasting between about <NUM> seconds and two minutes. The longer the molding process (e.g., the longer the nonwoven textile sheet <NUM> is held in the thermoforming mold and/or the longer pressure is maintained on the nonwoven textile sheet <NUM> in the mold, the greater percentage of melt fibers that melt, and the greater the resulting compression). The higher the temperature, the greater percentage of the melt fibers that will melt, and the greater the resulting compression. With more melt fibers melting, the exterior surface of the first portion <NUM> may become relatively smooth, losing its original relatively rough (e.g., hairy) texture caused by the randomly distributed fibers <NUM>. If it is desired to maintain more of the original texture at the exterior surface, then, instead of heating the mold tools, the nonwoven textile sheet <NUM> can be pre-heated in an oven to a temperature sufficient to cause melting of the melt fibers, but at the low end of the melt temperature range. The mold tools may then be at room temperature, or even cooled below room temperature. Contact of the mold tools with the nonwoven textile sheet <NUM> will then cool the exterior surface of the nonwoven textile sheet <NUM> relative to its pre-heated temperature, leaving the original texture largely intact. Example pressures that may be used to compress the nonwoven textile sheet <NUM> during thermoforming may be from about <NUM> pounds per square inch (psi) to about <NUM> psi. At higher pressures, the resulting compression will be greater, with a corresponding increase in hardness, rigidity, and strength.

In the finished carry bag <NUM>, the thermoformed first portion <NUM> has a first density and a first modulus of elasticity, while the second portion <NUM> has a second density less than the first density and a second modulus of elasticity less than the first modulus of elasticity, such as a tensile modulus (Young's modulus) that is less than that of the first portion <NUM>. Additionally, the thermoforming imparts a shape to the first portion <NUM> that enables it to function as an integral implement of the nonwoven textile sheet <NUM>.

The nonwoven textile sheet <NUM> also includes a first portion <NUM> shaped and dimensioned as an integral implement that is a male portion 12B of the buckle <NUM> that releasably secures to the female portion 12A. In <FIG>, the first portion <NUM> (male portion 12B) is shown releasably secured to the first portion <NUM> (female portion 12A). The nonwoven textile sheet <NUM> includes a flap <NUM> and a strap <NUM> extending from the flap <NUM>. The strap <NUM> includes the first portion <NUM> and a second portion <NUM> contiguous with the first portion <NUM>. The first portion <NUM> is disposed at an end of the strap <NUM>. The second portion <NUM> is contiguous with the first portion <NUM> at a boundary <NUM> and extends to or includes the flap <NUM>. When the male portion 12B is secured to the female portion 12A, the buckle <NUM> is buckled and the carry bag <NUM> is closed. The flap <NUM> and strap <NUM> are sized to allow the flap <NUM> to overlay the top and part of the front of the carry bag <NUM>, with the strap <NUM> extending downward toward the female portion 12A of the buckle <NUM>. Alternatively, the strap <NUM> with the male portion 12B could extend from the nonwoven textile sheet <NUM> (e.g., from the base of the carry bag <NUM>), and the female portion 12A could be included in the flap <NUM> of the nonwoven textile sheet <NUM>.

The first portion <NUM> is thermoformed in a mold as described herein that compresses the fibers <NUM> of the first portion <NUM> (shown in close-up circle A) in comparison to the fibers <NUM> of the second portion <NUM> (shown in close-up circle B), which is not thermoformed. Prior to thermoforming, the first and second portions <NUM>, <NUM> have the same density and modulus of elasticity. Only the first portion <NUM> is thermoformed, and as a result of the thermoforming, the first portion <NUM> has a density greater than a density of the second portion <NUM> and a modulus of elasticity greater than a modulus of elasticity of the second portion <NUM>.

In <FIG>, the male portion 12B (first portion <NUM>) is shown released from the female portion 12A (first portion <NUM>) so that the buckle <NUM> is unbuckled and the carry bag <NUM> is open at opening <NUM>, allowing access to an interior cavity <NUM> formed at least partially by the base of the carry bag <NUM> (e.g., by the nonwoven textile sheet <NUM>). The first portion <NUM> includes side prongs <NUM> and a center prong <NUM>. The side prongs <NUM> have notches <NUM> at their outer sides that define a first shoulder <NUM> and a second shoulder <NUM> in each of the side prongs <NUM>. The side prongs <NUM> are relatively stiff. When inserted into through hole 50A of the female portion 12A, the side prongs <NUM> will be pressed laterally inward toward the center prong <NUM> and will be biased back outward toward their free orientation shown in <FIG>, to hook to the female portion 12A at through holes 50B, 50C. Accordingly, the shape and dimension of the male portion 12B, including the side prongs <NUM>, enable it to function as an integral implement of the nonwoven textile sheet <NUM> (e.g., as a male portion of the buckle <NUM> that can secure to the female portion 12A).

As best seen in <FIG>, the first portion <NUM> is shaped and dimensioned as an integral implement of the wearable article <NUM>. More specifically, due to the shape of the thermoforming mold discussed herein, the first portion <NUM> is nonplanar with the remainder of the sheet <NUM>, including the second portion <NUM>. The first portion <NUM> extends outward, away from the second portion <NUM>. The first portion <NUM> defines three through holes 50A, 50B, 50C extending through the nonwoven textile sheet <NUM>. For example, the through holes 50A, 50B, 50C may be laser cut or punched in the first portion <NUM>. The through hole 50A generally opens in the same direction as the opening <NUM>. The through holes 50B, 50C are generally orthogonal to the through hole 50A.

The male portion 12B (first portion <NUM>) is shaped and dimensioned to releasably secure to the female portion 12A (first portion <NUM>) by the side prongs <NUM> passing through the through hole 50A and latching to the first portion <NUM> by the second shoulders <NUM> catching on the first portion <NUM> at the through holes 50A, 50B and the first shoulders <NUM> abutting first portion <NUM> outside of the through hole 50A. When the side prongs <NUM> are inserted into the through hole 50A, they are pressed inward toward the center prong <NUM> as they contact and slide against the first portion <NUM> at either side of the through hole 50A. Once they make it past the through hole 50A, they release outward and the shoulders <NUM> are disposed more widely apart from one another than the width of the female portion 12A (first portion <NUM>) so that the shoulders <NUM> catch on the first portion <NUM> at the through holes 50B, 50C. To release the male portion 12B (first portion <NUM>) from the female portion 12A (first potion <NUM>), the side prongs <NUM> are manually pressed laterally inward at the through holes 50B, 50C to allow the male portion 12B (first portion <NUM>) to be withdrawn from the female portion 12A (first portion <NUM>) at the through hole 50A. The denser and stiffer, thermoformed first portions <NUM>, <NUM> allow their respective shapes to be maintained with repeated use to enable long term functioning of the buckle <NUM>.

<FIG> shows two halves of a thermoforming mold <NUM>. A male mold tool <NUM> and a female mold tool <NUM> are shown. The male mold tool <NUM> includes a mold face <NUM> and a protrusion <NUM> extending out of the mold face <NUM>. The female mold tool <NUM> includes a mold face <NUM> that is the same size as the mold face <NUM>. The female mold tool <NUM> includes a recess <NUM> in the mold face <NUM>. The protrusion <NUM> of the male mold tool <NUM> fits within the recess <NUM>. The female portion 12A (first portion <NUM>) of the buckle <NUM> of <FIG> is thermoformed in the mold <NUM> by placing the nonwoven textile sheet <NUM> between the mold faces <NUM>, <NUM> with locators <NUM> on the mold tools <NUM>, <NUM> aligned with one another on pins or the like. The mold tools <NUM>, <NUM> may be heated, such as by resistance heating. Alternatively, instead of heating the mold tools <NUM>, <NUM>, the nonwoven textile sheet <NUM> may be heated in an oven prior to thermoforming, and the mold tools <NUM>, <NUM>, or at least the mold surfaces of the mold tools <NUM>, <NUM>, may be at room temperature or even cooled as discussed above in order to cool the exterior surface of the nonwoven textile sheet <NUM> when it is placed in the mold <NUM> to help maintain the exterior surface texture of the resulting thermoformed first portion <NUM>. The first portion <NUM> of the buckle <NUM> is formed where the nonwoven textile sheet <NUM> is captured between and contacted by the protrusion <NUM> and the recess <NUM>, assuming the shape of the nonplanar first portion <NUM>. The forces exerted on the nonwoven textile sheet <NUM> by the mold <NUM> are not resisted by any woven strands, as the felt material has only short, randomly disposed fibers <NUM>.

<FIG> shows the nonwoven textile sheet <NUM> with the first portion <NUM> and the second portion <NUM> after thermoforming, cooling, and removal from the mold <NUM>. A planar thermoformed portion <NUM> surrounds the first portion <NUM> and is formed where the mold faces <NUM>, <NUM> contact both sides of the nonwoven textile sheet <NUM>. If heated, the mold <NUM> causes the nonwoven textile sheet <NUM> to heat (and/or the nonwoven textile sheet <NUM> is pre-heated as discussed herein), and the fibers <NUM> then compress together and a percentage of the fibers melt (melt fibers) and maintain the new nonplanar shape of the integral implement (female portion 12A) when cooled, with the first portion <NUM> extending outward from the planar thermoformed portion <NUM>. The second portion <NUM> is not in sufficient contact with the mold tools <NUM>, <NUM> and therefore maintains the original density and modulus of elasticity of the nonwoven textile sheet <NUM>, whereas the density and moduli of elasticity of the portions <NUM>, <NUM> increase due to the thermoforming. Stated differently, the mold <NUM> compresses the material of the nonwoven textile sheet <NUM> at the first portion <NUM> and the planar thermoformed portion <NUM>, causing these portions to be thinner and denser than they were prior to thermoforming.

<FIG> shows the nonwoven textile sheet <NUM> with the through holes 50A, 50B, 50C laser cut or punched through the thermoformed portion of the nonwoven textile sheet <NUM>. In the embodiment of <FIG>, the nonwoven textile sheet <NUM> is not backed by any other component at the thermoformed female portion 12A of the closure device <NUM>. The through holes 50A, 50B, 50C therefore extend to the interior cavity <NUM>. In some applications as described herein, it may be desirable to isolate the closure device <NUM> from the interior cavity <NUM> so that there is no access to the interior cavity <NUM> through the through holes 50A, 50B, 50C, thereby better sealing the interior cavity <NUM> from moisture and debris that could otherwise pass through the through holes 50A, 50B, 50C. <FIG> shows the nonwoven textile sheet <NUM> with the female portion 12A of the closure device <NUM> after thermoforming of the first portion <NUM> and with the planar, unthermoformed second portion <NUM>.

<FIG> shows another configuration of a wearable article <NUM> in which the nonwoven textile sheet <NUM> is stacked on a textile component <NUM>, with the textile component <NUM> underlying both the first portion <NUM> and planar thermoformed portion <NUM>. The textile component <NUM> is a planar textile sheet as shown, but may be other configurations in other embodiments. The nonwoven textile sheet <NUM> is secured to the textile component <NUM> with a needle punch <NUM>. The needle punch <NUM> includes a series of needles <NUM> that repeatedly extend into and out of the stacked sheet <NUM> and textile component <NUM> at the unthermoformed second portion <NUM>. Fibers of the second portion <NUM> are intertwined with fibers of the textile component <NUM> to secure the nonwoven textile sheet <NUM> to the textile component <NUM>.

<FIG> schematically shows the areas of the intertwined fibers at <NUM>, making the perimeter of the nonwoven textile sheet <NUM> integrated with and at least somewhat indistinguishable from the textile component <NUM>. The intertwined fibers <NUM> are exaggerated for purposes of illustration on <FIG>, but may be visually indistinguishable from the surrounding fibers. After needle punching the second portion <NUM> to the textile component <NUM>, the nonwoven textile sheet <NUM> is adjacent to a surface <NUM> of the textile component <NUM> with the first portion <NUM>, the thermoformed planar portion <NUM>, and the second portion <NUM> overlaying the textile component <NUM> at the surface <NUM>. The second portion <NUM> is in contact with the surface <NUM> and the first portion <NUM> is disposed above the surface, creating a cavity between the surface <NUM> and the first portion <NUM> in which the first portion <NUM> of the male portion 12B of the closure device <NUM> is received when inserted through the through hole 50A.

<FIG> shows another configuration of a wearable article <NUM> such as a carry bag in which an edge of the nonwoven textile sheet <NUM> is secured to the textile component <NUM> at an edge of the textile component <NUM> rather than over the textile component as in <FIG>. For example, the nonwoven textile sheet <NUM> is secured to the textile component <NUM> such as by sewing or bonding an edge <NUM> of the nonwoven textile sheet <NUM> to an edge <NUM> of the textile component <NUM>. In this configuration the nonwoven textile sheet <NUM> with the thermoformed female portion 12A of the buckle <NUM> is stitched to the textile component <NUM> so that it extends from the textile component <NUM>. In this configuration, the nonwoven textile sheet <NUM> may function as a flap of a carry bag <NUM>. The flap may extend along an exterior of the carry bag when in the closed position, rather than directly over an access opening like opening <NUM> of <FIG>, so that access to the opening through the through holes 50A, 50B, 50C is not possible, and dirt or moisture passing through the through holes does not enter the opening.

Because the thermoforming process tends to compact and melt the nonwoven textile material, the thermoformed portion of a nonwoven textile sheet may be thinner than a contiguous unthermoformed portion of the sheet, and also denser and stiffer, with a greater modulus of elasticity. In some implementations, a difference in thickness may be desirable or aesthetically pleasing. In other implementations, it may be desirable that the thermoformed portion and the contiguous unthermoformed portion appear to be substantially the same thickness. Different desired combinations of thicknesses of the thermoformed portion and the unthermoformed portion are achieved by stacking layers of nonwoven textile sheets, and by inserting intermediate layers of nonwoven textile between a split sheet of a nonwoven textile sheet prior to thermoforming. In the areas that are to be molded/thermoformed, the material thicknesses are originally built up in order to increase wall thickness and rigidity after thermoforming. Otherwise, the thermoforming process may reduce the thickness too much, causing the resulting thermoformed portion to be unstable and fragile. In one example, a sheet or combination of stacked sheets may have an original thickness of about <NUM> millimeters (mm). After thermoforming the resulting thermoformed portion (e.g., first portion <NUM>) will be compressed to a reduced thickness of about <NUM>-<NUM>.

<FIG> shows an example of the nonwoven textile sheet <NUM> prior to thermoforming, having a thickness T1 and a relatively low density as evidenced by the relatively loose and randomly disposed fibers <NUM> in close-up circle C. <FIG> shows the nonwoven textile sheet <NUM> being split inward from a peripheral edge <NUM> only at and through the first portion <NUM> to define a first outer layer 28A and a second outer layer 28B that extend only in the first portion <NUM>, which is not yet thermoformed. <FIG> shows an intermediate layer <NUM> that has an edge <NUM> that has been tapered to create an upper bevel 84A and a lower bevel 84B. The tapered edge <NUM> may also be referred to as a skived edge. The intermediate layer <NUM> has a thickness T2 prior to insertion between the layers 28A, 28B. The intermediate layer <NUM> is a nonwoven textile. In non-claimed examples in which one or more intermediate layers are used that are a different material than the outer layers of the sheet or sheets between which the intermediate layer(s) are inserted, the modulus of elasticity of a thermoformed portion formed from the stacked layers is an effective modulus of elasticity dependent upon moduli of elasticity of the individual layers and their relative thicknesses.

<FIG> shows the intermediate layer <NUM> being inserted between the first outer layer 28A and the second outer layer 28B with the tapered edge <NUM> adjacent the second portion <NUM>. The intermediate layer <NUM> may have a length equal to the length of the split between the outer layers 28A, 28B so that the tapered edge <NUM> abuts the nonwoven textile sheet <NUM> at the end of the split. The positioning of the tapered edge <NUM> of the intermediate layer <NUM> against the nonwoven sheet <NUM> at the end of the split prevents any gap from occurring after thermoforming.

<FIG> shows the stacked outer layers 28A, 28B and intermediate layer <NUM> placed in a heat press <NUM> to provide some securement of the outer layers 28A, 28B to the intermediate layer <NUM> prior to thermoforming. The first outer layer 28A, the intermediate layer <NUM>, and the second outer layer 28B are thus stacked at the first portion <NUM>. <FIG> shows the stacked outer layers 28A, 28B secured to the intermediate layer <NUM> after removal from the heat press <NUM>, prior to thermoforming. At this stage of the manufacturing process, the overall thickness T3 of the stacked layers at the first portion <NUM> is the sum of the thickness T1 of the split first portion <NUM> and the thickness T2 of the intermediate layer <NUM>. As discussed herein, for example, the thickness T1 may be about <NUM> to <NUM>, and the thickness T3 may be about <NUM>. With a given range of pressures, temperatures, and time in the thermoforming mold as discussed herein, the resulting thickness of the thermoformed first portion <NUM> shown in <FIG> may also be the thickness T1.

<FIG> shows an open thermoforming mold <NUM> including mold tools 88A, 88B each having a mold cavity portion 86A, 86B. For example, the mold tools 88A, 88B may be mold halves. The mold tools 88A, 88B are placed with the mold cavity portions 86A, 86B together and with the stacked layers 28A, 28B and intermediate layer <NUM> in the mold cavity portions 86A, 86B, and the stacked layers 28A, 28B and the intermediate layer <NUM> are thermoformed together and cooled, forming the first portion <NUM> having the same thickness T1 as the unthermoformed second portion <NUM>, as shown in <FIG>. Manufacturing the first portion <NUM> and the second portion <NUM> to have the same thickness may be desirable for some applications, for aesthetic reasons or otherwise. Similarly as discussed with respect to <FIG>, the mold tools 88A, 88B may be heated, such as by resistance heating. Alternatively, instead of heating the mold tools 88A, 88B, the stacked layers 28A, 28B and the intermediate layer <NUM> may be heated in an oven prior to thermoforming, and the mold tools 88A, 88B, or at least the mold surfaces of the mold tools 88A, 88B, may be at room temperature or even cooled as discussed above in order to cool the exterior surface of the stacked layers 28A, 28B when placed in the mold <NUM> to help maintain the surface texture of the resulting thermoformed first portion <NUM>.

In <FIG>, the first portion <NUM> is trimmed such as by laser cutting, as shown by laser <NUM> having a laser beam <NUM> directed at the first portion <NUM> to cut the peripheral edge <NUM> of the first portion <NUM> in the shape of the male portion 12B of the buckle <NUM>, providing the lateral side prongs <NUM> and the center prong <NUM>. The male portion 12B of the buckle <NUM> thus has the same thickness at both the thermoformed first portion <NUM> and the unthermoformed second portion <NUM>, thus providing pleasing aesthetic features while still allowing the first portion <NUM> to have a first density greater than a second density of the second portion <NUM>, and a first modulus of elasticity greater than a second modulus of elasticity of the second portion <NUM> so that the first portion <NUM> can serve as an integral implement of the nonwoven textile sheet <NUM>, which in this case is as a male portion of a buckle. As an alternative to laser cutting shown in <FIG>, the peripheral edge <NUM> of the first portion <NUM> could be punched such as with blades <NUM> of a punch <NUM> in the shape of the peripheral edge <NUM> as shown in <FIG>.

<FIG> shows a non-claimed configuration of the male portion 12B in which two nonwoven sheets 16A and 16B are stacked together and thermoformed, without an intermediate layer between the sheets. The sheets 16A, 16B serve as a first outer layer and a second outer layer, respectively, each extending in both the first portion <NUM> and the second portion <NUM>. This configuration is suitable for applications in which a difference in thicknesses of the thermoformed first portion <NUM> and the unthermoformed second portion <NUM> is desired or is at least aesthetically acceptable. The thickness T4 of the unthermoformed second section <NUM> may be twice the thickness T1 of the two stacked sheets 16A, 16B. The thickness of the thermoformed first portion <NUM> is compressed from thickness T4 to a lesser thickness T5 due to the thermoforming, causing the first portion <NUM> to have a first thickness T5 less than the second thickness T4 and a first modulus of elasticity greater than a second modulus of elasticity of the second portion <NUM>.

As illustrated by <FIG> and <FIG>, the relative thicknesses of the first portion <NUM> and the second portion <NUM> may be different in different configurations. For example, a thickness of the first portion <NUM> may be within a range from about <NUM> percent less than to about <NUM> percent greater than a thickness of the second portion <NUM>, or within a range from about <NUM> percent less than to about <NUM> percent greater than the thickness of the second portion, or within a range from about <NUM> percent less than to about <NUM> percent greater than the thickness of the second portion <NUM>. Alternatively, a thickness of the first portion <NUM> may be more than <NUM> percent greater than a thickness of the second portion <NUM>, or the thickness of the second portion <NUM> may be more than <NUM> percent greater than a thickness of the first portion <NUM>.

<FIG> shows an example of a split nonwoven textile sheet <NUM>, similar to that described with respect to <FIG>, except that the thermoforming mold used is configured so that, after thermoforming, the thermoformed first portion <NUM> is more than <NUM> percent thicker than the unthermoformed second portion <NUM>. <FIG> shows a similar configuration except that the thermoforming mold used is configured to result in the thermoformed first portion <NUM> having a thickness equal to or within a range of about one percent less than to one percent greater than the thickness of the unthermoformed second portion <NUM>. Finally, <FIG> shows a configuration in which the thermoforming mold is configured to result in the thermoformed first portion <NUM> having a thickness more than <NUM> percent less than the unthermoformed second portion <NUM>.

<FIG> shows a configuration similar to <FIG>, in which two nonwoven textile sheets 16A, 16B are stacked, with the intermediate layer <NUM> extending only in the first portion <NUM>. In the configuration of <FIG>, the thermoforming mold is configured to result in the thickness of the first portion <NUM>, after thermoforming, being more than <NUM> percent greater than the thickness of the unthermoformed second portion <NUM>. <FIG> shows a similar configuration except that the thermoforming mold used is configured to result in the first portion <NUM> having a thickness after thermoforming equal to or within a range of about one percent less than to one percent greater than the thickness of the unthermoformed second portion <NUM>. Finally, <FIG> shows a configuration in which the thermoforming mold is configured to result in the thickness of the thermoformed first portion <NUM> being more than <NUM> percent less than the thickness of the unthermoformed second portion <NUM>.

<FIG> shows a configuration in which multiple intermediate layers <NUM> are inserted into a split of the nonwoven textile sheet <NUM>, with the split extending only in the first portion <NUM> so that the first portion <NUM> defines a first outer layer 28A and a second outer layer 28B that extend only in the first portion <NUM>. The edges of the intermediate layers <NUM> are tapered so that the intermediate layers <NUM> abut the second portion <NUM> in the split without any gap after thermoforming. The middle intermediate layer <NUM> has both an upper bevel and a lower bevel. The uppermost intermediate layer has only a single bevel, as does the lowermost intermediate layer. The first portion <NUM> is shown after thermoforming, and has a thickness more than <NUM> percent greater than a thickness of the unthermoformed second portion <NUM>.

<FIG> shows a configuration in which multiple intermediate layers <NUM> are inserted between two stacked nonwoven textile sheets 16A, 16B. As in <FIG>, the edges of the intermediate layers <NUM> are tapered so that there is no gap between the sheets 16A, 16B after thermoforming. The first portion <NUM> is shown after thermoforming, and has a thickness more than <NUM> percent greater than a thickness of the unthermoformed second portion <NUM>. The thermoforming molds can be selected so that, even in configurations with multiple intermediate layers <NUM>, the resulting thickness at the thermoformed first portion <NUM> can be less than the thickness of the unthermoformed second portion <NUM>.

<FIG> shows a wearable article that is an article of footwear <NUM>. The article of footwear <NUM> has an upper <NUM> that includes a nonwoven textile sheet <NUM> having a thermoformed first portion <NUM> shaped and dimensioned as an integral implement of the wearable article. More specifically, the first portion <NUM> is thermoformed to form a heel counter. An unthermoformed second portion <NUM> of the nonwoven textile sheet <NUM> is contiguous with the first portion <NUM> at the boundary <NUM>. The first portion <NUM> has a first density and a first modulus of elasticity, and the second portion <NUM> has a second density less than the first density and has a second modulus of elasticity less than the first modulus of elasticity. The denser and stiffer first portion <NUM> enables the first portion <NUM> to function as an integral implement, which in this application is a heel counter. As described herein, only the first portion <NUM> is thermoformed, causing the fibers <NUM> of the nonwoven textile sheet <NUM> to be more densely packed than in the second portion <NUM>, as indicated by the denser fibers <NUM> in the close-up circle D than in the close-up circle E.

<FIG> shows the rear side of a backpack <NUM> that includes two closure devices 412A, 412B within the scope of the present disclosure. For example, the backpack <NUM> has two shoulder straps 411A and 411B. A first closure device 412A is a buckle for a sternum strap 414A, 416A that attaches the shoulder straps 411A, 411B across the front of the body when worn. The first closure device 412A includes integral implements of the sternum strap 414A, 416A. For example, the sternum strap 414A, 416A includes a first nonwoven textile sheet 414A with a first portion <NUM> that is thermoformed as an integral implement that is a female portion of the closure device 412A and is as described with respect to <FIG>. The first portion <NUM> has a first density and a first modulus of elasticity. The first nonwoven textile sheet 414A also includes an unthermoformed second portion <NUM> as described with respect to <FIG>. The second portion <NUM> has a second density less than the first density, and a second modulus of elasticity less than the first modulus of elasticity.

The sternwn strap 414A, 416A also includes a second nonwoven textile sheet 416A with a first portion <NUM> that is thermoformed as an integral implement that is a male portion of the closure device 412A and is as described with respect to <FIG>. The first portion <NUM> has a first density and a first modulus of elasticity. The second nonwoven textile sheet 416A also includes an unthermoformed second portion <NUM> that has a second density less than the first density, and a second modulus of elasticity less than the first modulus of elasticity.

The backpack <NUM> also includes a second closure device 412B that is a buckle on a waist belt 414B, 416B of the backpack <NUM> for securing the lower part of the backpack around the waist when the backpack is worn on the body, and is configured substantially the same as the first closure device 412A. The second closure device 412B includes integral implements of the waist belt 414B, 416B. For example, the waist belt 414B, 416B includes a first nonwoven textile sheet 414B with a first portion <NUM> that is thermoformed as an integral implement that is a female portion of the closure device 412B and is as described with respect to <FIG>. The first portion <NUM> has a first density and a first modulus of elasticity. The first nonwoven textile sheet 414B also includes an unthermoformed second portion <NUM> contiguous with the first portion and as described with respect to <FIG>. The second portion <NUM> has a second density less than the first density, and a second modulus of elasticity less than the first modulus of elasticity. Due to the thermoforming, the density and modulus of elasticity of the first portion <NUM> is greater than those of the second portion <NUM>.

The waist belt 414B, 416B also includes a second nonwoven textile sheet 416B with a first portion <NUM> that is thermoformed as an integral implement that is a male portion of the closure device 412B and is as described with respect to <FIG>. The first portion <NUM> has a first density and a first modulus of elasticity. The second nonwoven textile sheet 416B also includes an unthermoformed second portion <NUM> that is contiguous with the first portion <NUM> and has a second density less than the first density, and a second modulus of elasticity less than the first modulus of elasticity. Due to the thermoforming, the density and modulus of elasticity of the first portion <NUM> is greater than those of the second portion <NUM>.

The stemum strap 414A, 416A and the waist belt 414B, 416B may also include other components and materials, such as cushioning materials, length adjustment slides, etc. Additionally, the numerical values of the densities and moduli of elasticity of the various portions <NUM>, <NUM>, <NUM>, <NUM> of each of the closure devices 412A, 412B may be different for each of the closure devices and may be different than those of other closure devices and integral implements disclosed herein, such as the closure device <NUM> of <FIG>.

<FIG> is a front view of the backpack <NUM> of <FIG>. The backpack includes a nonwoven textile sheet 414C that includes a first thermoformed portion <NUM> that is an integral implement of the sheet 414C. More specifically, the thermoformed first portion <NUM> is a receptacle for a power source or a power device <NUM>, and may be referred to herein as such. In the embodiment shown, the power device <NUM> is a light that provides visibility to the wearer of the backpack <NUM>. Alternatively, a power source such as a solar powered battery could be disposed in the receptacle. The nonwoven textile sheet 414C also has an unthermoformed second portion <NUM> that is contiguous with the first portion <NUM> at a boundary <NUM> as described herein. Due to the thermoforming, the first portion <NUM> has a first density and a first modulus of elasticity, and the second portion <NUM> has a second density less than the first density and has a second modulus of elasticity less than the first modulus of elasticity. The first portion <NUM> is shaped differently than the second portion <NUM> as an integral implement of the wearable article. The first portion <NUM> includes laser cut or punched through holes 50A, 50D. The through hole 50A allows insertion and withdrawal of the device <NUM>. The through hole 50D is a window into the pocket formed by the first portion <NUM>, and provides additional access to the power device, such as by exposing the light emitted from the power device <NUM>. Similar to <FIG>, nonwoven textile sheet 414C may overlay and be needle punched or otherwise secured to a textile sheet so that access to the interior of the bag is not possible through the through holes 50A, 50D, and dirt or moisture passing through the through holes does not enter the backpack <NUM>.

<FIG> is a front perspective view of a wearable article that is a shirt <NUM>. Although depicted as a shirt, the wearable article may instead be a vest, a jacket, a sweater, shorts, pants, or any other wearable garment. The shirt <NUM> includes nonwoven textile sheets 514A, 514B that include thermoformed portions 518A, 518B that are integral implements of the sheets 514A, 514B. More specifically, thermoformed first portions 518A, 518B are receptacles for power sources or power devices, and may be referred to herein as such. In the embodiment shown, the thermoformed first portion 518A is a receptacle that is similar to a pocket, and holds a power device <NUM> that is a light that provides visibility to the wearer of the shirt <NUM>. Alternatively, a different power device could be disposed in the receptacle. The nonwoven textile sheet 514A also has an unthermoformed second portion 520A that is contiguous with the first portion 518A at a boundary <NUM> as described herein. Due to the thermoforming, the first portion 518A has a first density and a first modulus of elasticity, and the second portion 520A has a second density less than the first density and has a second modulus of elasticity less than the first modulus of elasticity. The first portion 518A is shaped differently than the second portion 520A as an integral implement of the wearable article. The first portion 518A includes laser cut or punched through holes 50A, 50D. The through hole 50A allows insertion and withdrawal of the device <NUM>. The through hole 50D is a window into the pocket formed by the first portion 518A, and provides additional access to the power device, such as by exposing the light emitted from the power device <NUM>. Similar to <FIG>, nonwoven textile sheet 514A may overlay and be needle punched or otherwise secured to a textile sheet so that access to the wearer of the shirt is not possible through the through holes 50A, 50D, and dirt or moisture passing through the through holes does not contact the wearer.

In the embodiment shown, the thermoformed first portion 518B is a receptacle that is similar to a pocket, and holds a power device <NUM> that is depicted as a cellular phone. Alternatively, a different power device could be disposed in the receptacle. The nonwoven textile sheet 514B also has an unthermoformed second portion 520B that is contiguous with the first portion 518B at a boundary <NUM> as described herein. Due to the thermoforming, the first portion 518B has a first density and a first modulus of elasticity, and the second portion 520B has a second density less than the first density and has a second modulus of elasticity less than the first modulus of elasticity. The first portion 518B is shaped differently than the second portion 520B as an integral implement of the wearable article. The first portion 518B includes laser cut or punched through holes 50E, 50F, <NUM>, and <NUM>. The through hole 50E allows insertion and withdrawal of the device <NUM>. The through hole 50F is a window into the pocket formed by the first portion 518B, and provides additional access to the power device 592B, such as by exposing a screen of the power device <NUM>. Through holes <NUM> and <NUM> are disposed and sized for access to input features of the power device 592B, such as volume, power, and charging ports. Similar to <FIG>, nonwoven textile sheet 514B may overlay and be needle punched or otherwise secured to a textile sheet so that access to the wearer of the shirt is not possible through the through holes 50E, 50F, <NUM>, and <NUM>, and dirt or moisture passing through the through holes does not contact the wearer.

<FIG> shows a lateral side of a wearable article that is an article of footwear <NUM> with an upper <NUM> that includes a nonwoven textile sheet 616A having a thermoformed first portion 618A shaped and dimensioned as an integral implement of the wearable article. More specifically, the first portion 618A is thermoformed to form a receptacle, such as for a power source or power device <NUM>. Alternatively, a different power device could be disposed in the receptacle. The nonwoven textile sheet 616A also has an unthermoformed second portion 620A that is contiguous with the first portion 618A at a boundary <NUM> as described herein. Due to the thermoforming, the first portion 618A has a first density and a first modulus of elasticity, and the second portion 620A has a second density less than the first density and has a second modulus of elasticity less than the first modulus of elasticity. The first portion 618A is shaped differently than the second portion 620A as an integral implement of the wearable article. The first portion 618A includes a laser cut or punched through holes 50J and <NUM>. Through hole 50J allows insertion and withdrawal of the device <NUM>. The through hole <NUM> is a window into the pocket formed by the first portion 618A, and provides additional access to the power device <NUM>, such as by exposing a light emitted by the power device <NUM>, a screen of the power device <NUM>, or for providing other access to the power device <NUM>. Similar to <FIG>, nonwoven textile sheet 616A may overlay and be needle punched or otherwise secured to a textile sheet so that access to the wearer of the article of footwear is not possible through the through holes 50J and <NUM>, and dirt or moisture passing through the through holes does not contact the wearer.

The article of footwear <NUM> also includes a closure device <NUM> that is a buckle for securing the upper <NUM> to the foot when the article of footwear is worn. The closure device <NUM> includes a first nonwoven textile sheet 614A with a first portion <NUM> that is thermoformed as an integral implement that is a female portion of the closure device <NUM> and is as described with respect to <FIG>. The first portion <NUM> has a first density and a first modulus of elasticity. The first nonwoven textile sheet 614A also includes an unthermoformed second portion <NUM> as described with respect to <FIG>. The second portion <NUM> has a second density less than the first density, and a second modulus of elasticity less than the first modulus of elasticity. The second portion <NUM> may be secured at the lateral side of the article of footwear <NUM>.

The closure device <NUM> also includes a second nonwoven textile sheet 616A with a first portion <NUM> that is thermoformed as an integral implement that is a male portion of the closure device <NUM> and is as described with respect to <FIG>. The first portion <NUM> has a first density and a first modulus of elasticity. The second nonwoven textile sheet 616A also includes an unthermoformed second portion <NUM> that has a second density less than the first density, and a second modulus of elasticity less than the first modulus of elasticity. The second portion <NUM> may be secured at the medial side of the article of footwear <NUM>.

Accordingly, the wearable articles disclosed herein include nonwoven textile sheets with integral implements, providing a reduced complexity, pleasing aesthetics, and the option of using recycled materials to form the sheets. The method of manufacturing the nonwoven textile sheet disclosed herein enables different relative thicknesses of the thermoformed portion of the sheet and the unthermoformed portion to suit various applications. Various shapes of integral implements may be provided with different thermoforming molds. The integral implement of the sheet may be configured with a sufficiently high modulus of elasticity to serve the functions of the implement, while a contiguous portion of the sheet maintains a lower modulus of elasticity for comfort, aesthetic appearance, or both.

As used in the description and the accompanying claims, a value is considered to be "approximately" equal to a stated value if it is neither more than <NUM> percent greater than nor more than <NUM> percent less than the stated value.

The term "longitudinal" refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term "forward" or "anterior" is used to refer to the general direction from a heel region toward a forefoot region, and the term "rearward" or "posterior" is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term "transverse" refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term "vertical" refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term "upward" or "upwards" refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term "downward" or "downwards" refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

The terms "interior", "inner side" and "proximal" with respect to an article refer to relative portions of an article closer to the center of the article than "exterior", "outer side", and "distal" portions of the article when the article is assembled. Thus, the terms interior and exterior may be understood to provide generally opposing terms to describe relative spatial positions, as may inner side and outer side, and proximal and distal.

While various embodiments 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 embodiments, as defined by the appended claims. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims. Also, various modifications and changes may be made within the scope of the attached claims.

Claim 1:
A method of manufacturing a wearable article (<NUM>), the method comprising:
thermoforming a first portion (<NUM>) of a nonwoven textile sheet (<NUM>) as an integral implement of the wearable article (<NUM>), the nonwoven textile sheet (<NUM>) having an unthermoformed second portion (<NUM>) contiguous with the thermoformed first portion (<NUM>) and shaped differently than the first portion (<NUM>);
wherein the first portion (<NUM>) has a first density and a first modulus of elasticity after thermoforming; and
wherein the unthermoformed second portion (<NUM>) has a second density less than the first density and has a second modulus of elasticity less than the first modulus of elasticity;
characterised in that the method further comprises prior to thermoforming the first portion (<NUM>), stacking multiple nonwoven textile layers to define the first portion (<NUM>);
wherein the multiple nonwoven textile layers include a first outer layer (28A), a second outer layer (28B), and at least one intermediate layer (<NUM>) disposed between the first outer layer (28A) and the second outer layer (28B);
and wherein the at least one intermediate layer extends only in the first portion (<NUM>); and
prior to stacking the multiple nonwoven textile layers, splitting the nonwoven textile sheet (<NUM>) only at the first portion (<NUM>) to define the first outer layer (28A) and the second outer layer (28B), the first outer layer (28A) and the second outer layer (28B) extending only in the first portion (<NUM>).