WO2016012796A1

WO2016012796A1 - Method of forming a structural component for a garment or footwear

Info

Publication number: WO2016012796A1
Application number: PCT/GB2015/052130
Authority: WO
Inventors: Miles Stephen Cain
Original assignee: Stretchline Intellectual Properties Ltd Great Britain; STRETCHLINE INTELLECTUAL PROPERTIES Ltd
Current assignee: Stretchline Intellectual Properties Ltd Great Britain; STRETCHLINE INTELLECTUAL PROPERTIES Ltd
Priority date: 2014-07-25
Filing date: 2015-07-23
Publication date: 2016-01-28
Anticipated expiration: 2017-01-25
Also published as: GB201501512D0; GB201413267D0

Abstract

A method of forming a structural component for a wearable item such as a garment or footwear. The method comprises the steps of extruding strands of liquid polymer onto a support such that successive strands are laid over and across previous strands to form an interconnected network of strands and curing or otherwise allowing the liquid polymer to set and solidify so as to form a solidified network of strands having a two-dimensionally or three-dimensionally shaped structure. The liquid polymer is an elastomeric polymer such that the solidified network of strands exhibits stretch in at least one direction.

Description

METHOD OF FORMING A STRUCTURAL COMPONENT

FOR A GARMENT OR FOOTWEAR

The invention relates to a method of forming a structural component for a wearable item, such as a garment or an item of footwear. The invention also relates to a cloth-like sheet and to a garment.

It is known to manufacture a garment or an item of footwear using a textile fabric or other sheet material. Such manufacture may involve cutting of the textile fabric or other sheet material and assembling the resultant piece of fabric or sheet material, either alone or in combination with one or more other pieces of fabric or sheet material, into a desired configuration through the use of sewing and/or gluing.

According to a first aspect of the invention, there is provided a method of forming a structural component for a wearable item, such as a garment or an item of footwear, the method comprising the steps of:

(i) extruding strands of liquid polymer onto a support such that successive strands are laid over and across previous strands to form an interconnected network of strands; and

(ii) curing or otherwise allowing the liquid polymer to set and solidify so as to form a solidified network of strands having a two-dimensionally or three- dimensionally shaped structure,

the liquid polymer being an elastomeric polymer such that the solidified network of strands exhibits stretch in at least one direction.

The use of an elastomeric polymer allows the creation of a structural component that is capable of exhibiting stretch following curing or otherwise setting and solidifying of the liquid polymer. When the structural component is used in the construction of a garment or an item of footwear, the stretchability of the resultant solidified network of strands allows the structural component to stretch about a wearer when the garment or item of footwear is worn. This in turn allows the structural component to modify its shape so as to provide a comfortable fit and to provide structural support to the wearer.

In preferred embodiments of the invention, successive strands may be laid over and across previous strands so as to define a plurality of layers of strands created so as to overlay one another and thereby form a multi-layered structure, the strands in each layer being laid over and across each other to define an open network of interconnected strands, and adjacent layers being created so that openings therein are offset relative to each other to define tortuous paths through the solidified network of strands following curing or setting of the liquid polymer.

Creating a structural component in this manner results in a structure that is open and breathable by virtue of the tortuous paths defined through the structure by the openings defined in the layers of strands. The tortuous paths allow the flow of air through the structure and allow moisture to travel through the structure. Accordingly, when used in the creation of a sole of a training shoe, for example, the tortuous paths provide ventilation to a wearer's foot and allow any moisture from around the wearer's foot to escape.

In addition, the use of an elastomeric polymer means that the resultant open structure is compressible whilst defining an otherwise strong and powerful structure.

It will be appreciated that when used in the creation of a sole for an item of footwear, the multi-layered structure provides far greater comfort than an alternative sole formed from a solid block of polymer, which would be significantly harder. As outlined above, the offset arrangements of the openings in the plurality of layers allows the creation of tortuous paths so as to allow the resultant structural component to breath. This is advantageous when compared with an alternative structure formed from a thicker layer of polymer material having openings formed therein which would inevitably allow the ingress of other articles, such as small stones and grit.

Forming the multi-layered structure by means of extruding strands of liquid polymer material so as to lay and over across previous strands of material allows the openings in the resultant layers of strands to be kept open. In contrast, a method whereby individual layers of strands are laminated requiring the use of glue would inevitably result in at least some of the openings becoming closed by glue. This would affect the breathability of the solidified network of strands following curing or setting of the liquid polymer.

In embodiments where it is desirable to control the movement of liquid material or other fluids through the solidified network of strands, a barrier layer may be introduced between at least two layers of strands during formation of the multi-layered structure. It will be appreciated that in such embodiments the barrier layer is inserted between two layers of strands that would otherwise be considered adjacent layers of the multi-layered structure. This arrangement is particularly advantageous in circumstances where the multi-layered structure is being used to form the sole of an item of footwear, such as a training shoe. The provision of a barrier layer between at two layers of the multi-layered structure effectively divides the structure into two parts - a first part intended to be in contact with a wearer's foot and a second part intended to be used to secure the sole to the body of the shoe. In such use, the provision of the barrier layer prevents the ingress of glue used to secure the sole and body of the item of footwear together from penetrating into the resultant shoe, which would be undesirable and could affect the resultant comfort of the shoe. In addition, the open structure defined by the layers of strands in the second part of the sole, allows the glue to penetrate into the solidified network and form a strong bond between the sole and the body of the shoe.

It is envisaged that the barrier layer could be formed by laying a sheet of fabric or other material between the layers of strands during the step of extruding strands during the step of extruding the strands of liquid polymer.

In such embodiments, a layer of fabric may be chosen on the basis that that it is impenetrable to glue. In other such embodiments however a layer of a plastic material might be inserted between the layers of strands. It will however be appreciated that care must be taken when selecting the material to be used as a barrier layer in that it is essential that the layers of strands located on either side of the barrier layer, following insertion of the barrier layer and continued creation of subsequent layers of strands, must adhere to the barrier layer before or during the step of curing or otherwise allowing the liquid polymer to set and solidify. In order to ensure good adhesion between the layers of strands and the barrier layer, the barrier layer may be produced from the same liquid polymer as the strands themselves. In such embodiments, a plurality of strands may be extruded onto one of the layers of strands such that successive strands are laid over and across previous strands to define a closed network of interconnected strands having no openings therein before extruding the other of the layers of strands over the barrier layer. Proceedings in this manner results in a solid, impervious barrier layer located between the two layers of strands.

As outlined above, the solidified network of strands following curing or setting of the liquid polymer may form a multi-layered sole for an item of footwear.

In other embodiments, where it is desirable to produce a structure that imitates a woven structure, successive strands may again be laid over and across previous strands so as to define a plurality of layers of strands created so as to overlay one another and thereby form a multi-layered structure. The strands in each layer may be laid over and across each other to define a grid structure and adjacent layers may be created so that the grid structures are offset relative to each other and define a woven patter effect following curing or setting of the liquid polymer. It will be appreciated that in such embodiments, the strands of adjacent layers of strands will start to sink into the strands below before the liquid polymer is cured or otherwise allowed to set and solidify. This effect assists in the creation of a woven appearance, particularly in circumstances where the multi-layered structure is limited to two layers of strands.

The use of strands of liquid polymer arranged so as to lay over and across previous strands allows the creation of regions of varying stretch and power. Less material may for example be used in regions where less stretch is required from the resultant structural component by perhaps increasing the distance between adjacent strands or reducing the diameter of the strands themselves during extrusion. In regions where more power is required, more material may be used by perhaps reducing the distance between adjacent strands or increasing the diameter of the strands themselves during extrusion.

In any event, the ability to control the extrusion of the strands results in a structural component that exhibits better stretch and power characteristics than would otherwise be achievable though the use of a solid block of polymer material.

The resultant structural components can be created to exhibit depth, breathability, power, strength, compressibility and an ability to dissipate impact forces.

It is envisaged, for example, that the compressibility and ability to dissipate impact forces could render the structural component suitable for use in the manufacture of protective clothing to protect wearer's against projectiles such as bullets or other debris that a wearer might encounter in a hazardous workplace.

The compressibility of the resultant structural component and the ability of the component to dissipate impact forces allows the structural component to absorb the force of an impact as opposed to transmitting the force to the wearer as would likely occur if the structural component was hard and thus able to directly transmit the force of the impact to the wearer.

A garment component having a two-dimensionally shaped structure may be formed by extruding the strands of liquid polymer onto the support so as to form overlaying layers of liquid polymer to create a planar structure of the interconnected network of strands. A garment component having a three-dimensionally shaped structure may be formed by extruding the strands of liquid polymer onto the support so as to form overlaying layers of liquid polymer to build up a three-dimensional structure of the interconnected network of strands.

The capability to form a solidified network of strands having a two-dimensionally or three- dimensionally shaped structure provides the freedom to form a structural component in accordance with a variety of designs. In addition, the steps of the method according to the invention can be performed quickly, with zero or minimum interruption, thus enabling rapid formation of a structural component, which in turn may be used to create an entire garment or item of footwear.

The freedom to form a solidified network of strands in accordance with a variety of designs, together with the ability subsequently to rapidly form a garment or item of footwear, readily facilitates the creation of bespoke garments or items of footwear. After a wearer's measurements are obtained and a particular garment or footwear design is chosen, the method according to the invention can be used to form the or each structural component required to form the bespoke garment or item of footwear within a matter of minutes or hours. This advantageously obviates the need to stock a high number of garments or items of footwear across a wide range of measurements and designs, which otherwise not only increases the amount of storage space required to store the garments or items of footwear but also could become costly if some of the garments or items of footwear remain unsold. In embodiments of the invention the method may include the use of a support provided in the form of a three-dimensionally shaped form or mould. In such embodiments, the step of extruding strands of liquid polymer to form an interconnected network of strands includes extruding strands of liquid polymer over the form or into the mould so that, following curing or setting of the liquid polymer, the solidified network of strands has a three-dimensional shape defined by the shape of the form or the mould. Forming the solidified network of strands in this manner results in a structural component with a shaped structure that conforms to the shape of the form or the mould. Accordingly the shape of the structural component may be selected through the use of a suitably shaped form. In other embodiments the method may include the use of a substantially flat support, strands of liquid polymer being extruded onto the support so as to form an essentially two- dimensionally shaped network of interconnected strands of liquid polymer, and the step of curing or setting the liquid polymer involves partially curing or setting the liquid polymer before laying the interconnected network of strands over a form or into a mould and then completing the step of curing or setting the liquid polymer so that the solidified network of strands has a three-dimensional shape defined by the shape of the form of the mould.

The step of partially curing or setting the liquid polymer prior to the step of the laying the interconnected network of strands over a form or into a mould is advantageous in that it allows the interconnected network of strands to be shaped so as to readily allow the creation of a solidified network of strands having a three-dimensional shape defined by the form or the mould.

By controlling the extent to which the liquid polymer is partially cured or set prior to the step of the laying the interconnected network of strands over the form or into the mould also allows an element of stretch to be introduced into the interconnected network of strands, which is then retained by completing the step of curing or setting the liquid polymer. This is advantageous in that the introduction of stretch into the solidified network of strands can be used to alter the power and support provided by the structural component when it is incorporated into a garment or an item of footwear.

In further embodiments of the invention the method of forming a structural component may further include the step of moulding or re-moulding the shape of the solidified network of strands following curing or setting of the liquid polymer.

The ability of modify the shape of the solidified network of strands after it is formed obviates the need to maintain a specific shape of the interconnected network of strands in order to obtain a specific shape of the resultant structural component, and thereby allows tailoring of the structural component. It thus simplifies the step of extruding strands of liquid polymer onto the support to form the interconnected network of strands. For example, the solidified network of strands can be formed to initially have a two-dimensionally shaped structure, i.e. to lie flat on a planar surface, before being later moulded to have a three-dimensionally shaped structure.

Preferably the method further includes the step of configuring a controller to control movement of one or more extrusion heads relative to the support so as to extrude strands of liquid polymer onto the support in a predetermined pattern so as to form a solidified network of strands having a predetermined shape and configuration following curing or setting of the liquid polymer.

The use of a controller to control movement of one or more extrusion heads relative to the support minimises the amount of human interaction required during the creation of a structural component for a garment or footwear and readily facilitates the creation of customised designs.

Not only does the use of a controller configured to control movement of an extrusion head relative to the support so as to produce a solidified network of strands having a predetermined outward shape but it also allows the creation of strands arranged relative to each other so as to produce a predetermined surface configuration. The strands of liquid polymer could for example be arranged to lay relative to each other so as to produce a "knitted" appearance following curing or setting of the liquid polymer. By "knitted" appearance we mean that the outward appearance of the resultant solidified network of strands gives the impression of having been knitted from solidified strands of the polymeric material.

In such embodiments, the controller may also be configured to control the rate at which liquid polymer is extruded from the or each extrusion head during movement of the respective extrusion head relative to the support so as to control the cross-sectional size of strands of liquid polymer extruded onto the support during movement of the respective extrusion head. This allows the extent to which the strands of liquid polymer are stretched during extrusion to be controller so as to create regions in the resultant solidified network of strands that exhibit differing degrees of stretch and rigidity and thus exhibit differing degrees of power from a support perspective when the structural component is incorporated into a garment or an item footwear.

In a particularly preferred embodiment, the controller may be configured to control the rate of extrusion of liquid polymer from the or each extrusion head relative to the speed of movement of the extrusion head relative to the support so as to draw out and stretch the strands of liquid polymer and thereby minimise the cross-sectional size of the strands of liquid polymer extruded onto the support. In particularly preferred embodiments, the controller may form part of a computer programmable to control movement of the or each extrusion head and the rate at which liquid polymer is extruded from the or each extrusion head during movement of the respective extrusion head relative to the support so as to produce a solidified network of strands having a predetermined shape and configuration following curing or setting of the liquid polymer. This facilitates the creation of very detailed and complex patterns and create detailed visual effects in the solidified network of strands following curing or setting of the liquid polymer. It could, for example, allow the creation of a solidified network of strands that resembling the appearance of a knitted fabric, a woven fabric, an embroidered fabric or lace.

In the context of this invention, a computer may be considered as any appropriate hardware, including a digital signal processor, a microcontroller, and an implementation in read only memory (ROM), erasable programmable read only memory (EPROM) or electronically erasable programmable read only memory (EEPROM), as examples.

It will be appreciated that controlling the rate of extrusion of liquid polymer from an extrusion head versus the rate of movement of the extrusion head relative to the support allows the creation of relatively fine strands of liquid polymer. This in turn allows the creation of a solidified network of strands having a relatively delicate appearance. Inevitably the minimum cross-sectional size of a strand of liquid polymer extruded from an extrusion head will be determined by the size of nozzle via which the liquid polymer is extruded from the extrusion head together with the strength of the liquid polymer. However through appropriate selection of nozzle size, appropriate selection of liquid polymer and appropriate selections of rate of extrusion and rate of movement, the applicant has discovered that it is possible to create strands of liquid polymer having a cross-sectional size that is comparable with than of conventional yarns. Accordingly the applicant has discovered that it is possible to create a solidified network of strands having a cloth-like sheet, the cloth-like sheet or substrate having handling characteristics that are comparable with a sheet of fabric or cloth.

The creation of a solidified network of strands in the form of a cloth-like sheet or substrate is advantageous in that is provides a material that is suitable for use in the creation of garments or items of footwear in a very similar manner to conventional methods of manufacturing garments and items of footwear using fabric or cloth. The use of an elastomeric polymer in the creation of the cloth-like sheet or substrate however imparts a certain degree of stretch and also results in a material that cannot absorb moisture. Accordingly it renders the material suitable for use in garments or footwear intended to be worn in close contact with a wearer's skin. Such garments or footwear are inevitably unable to absorb moisture from a wearer's skin, which eliminates the associated problems associated with garments or footwear created from fabric or cloth that absorb moisture and retain that moisture against a wearer's skin. Another particular advantage of the resultant cloth-like sheet or substrate is that it cannot crease.

The manner in which the strands of liquid polymer are extruded onto the support in addition results in the creation of a solidified network of strands that inevitably includes openings and is therefore breathable in use in the sense that it allows the through-flow of air.

The elastomeric polymer may be a thermoset material chosen from the group consisting of silicone and acrylic and, in a particularly preferred embodiment, the elastomeric polymer is a two-component liquid silicone rubber consisting of A and B components and produced by MOMENTIVE under reference LSR 2650 and mixed in a ratio of A:B of 40:60.

It will be appreciated that other liquid silicone rubbers could be used in the method of the invention depending on the physical properties required of the structural component. Similarly the ratio A:B of the component parts of MOMENTIVE's LSR 2650 may be varied to produce a solidified network of strands having different physical properties. In the context of this invention, physical properties is intended to refer to the tensile strength, stretch and rigidity of the elastomeric polymer following curing or setting.

In order to create a predetermined finish on the surface of the solidified network of strands, the method may further include the step of spraying the solidified network of strands with a top coat. The provision of a top coat can advantageously be used to provide a matt and non-tacky finish and therefore further improve the handling of the resultant solidified network of strands which could otherwise have a tacky surface as a result of the elastomeric polymer used in the method.

In a particularly preferred embodiment, the top coat may be a two-component liquid silicone rubber consisting of A and B components and produced by MOMENTIVE under the reference LSR top-coat HE and mixed in a ratio A:B of 50:50. The applicant has found this particular top coat to complement the use of MOMENTIVE's LSR 2650 to form the solidified network of strands.

It will again be appreciated that other liquid silicone rubbers could be used as a top coat depending on the physical properties required of the structural component. Similarly the ratio A:B of the component parts of MOMENTIVE's LSR top coat HE may be varied to produce a solidified network of strands having different physical properties.

In other embodiments of the invention the elastomeric polymer may be a thermoplastic material, such as nylon. The use of a thermoplastic material is particularly advantageous in circumstances where it is envisaged that further shaping of the structural component may be required after curing or setting of the liquid polymer. This is because a thermoplastic polymer material becomes pliable or mouldable upon the application of heat, thereby allowing reshaping of the structural component, before cooling to re-solidify the structural component and set the resultant shape. So as to produce decorative or functional effects, one or more additive may be mixed with the liquid polymer prior to the step of extruding the liquid polymer onto the support. The additive could be selected from a non-exhaustive group consisting of a perfume, a scent, a colour, decorative particles and an anti-microbial agent. The term decorative particles is intended to refer to particles that produce a visual effect such as glitter particles, metallic particles, glass particles and coloured particles.

In other embodiments the additive may include a coloured pigment suspended in a silicone oil so as to colour the liquid polymer.

In yet further embodiments the method may further include the step of spraying the solidified network of strands with an anti-microbial agent. In order to assist in the subsequent creation of a garment or item of footwear, the method of forming a structural component may include the step of laying a garment or footwear accessory onto the support before or during the step of extruding strands of liquid polymer onto the support so as to embed the garment or footwear accessory into the solidified network of strands following curing or setting of the liquid polymer.

Examples of garment or footwear accessories that it could be embedded into the solidified network of strands include fastening elements, clasps, hooks, buttons, decorative elements, support elements, shoe lace sockets and shoe lace rings.

In embodiments of the invention the solidified network of strands defines a garment net and the method further includes the step of arranging edges of the garment net relative to each other and gluing together adjacent edges of the garment net with a silicone bead so as to produce a finished garment.

In other embodiments the step of extruding strands of liquid polymer onto the support creates an interconnected network of strands arranged such that the solidified network of strands following curing or setting of the liquid polymer forms an entire garment, particularly in embodiments where one or more garment accessories are embedded in the solidified network of strands.

Particularly preferred examples of garments that could be defined in their totality by the resultant structural component or by means of a garment net include brassieres, basques or other garments including breast cup elements.

It will be appreciated that the garment formed by the method according to the invention are not limited to the specific garment examples set out in this specification. In other embodiments of the invention, the step of extruding strands of liquid polymer onto the support creates a blank for a footwear upper, the blank being shaped either before, during or after curing or setting to produce a three-dimensionally shaped footwear upper.

It is envisaged that in such embodiments the three-dimensionally shaped footwear upper may include a moulded training shoe upper, and the method may further include the step of gluing the moulded training shoe upper onto a rubber sole. Using the method of the invention to create a moulded shoe upper, such as a training shoe upper, is particularly advantageous in that it allows the creation of a three-dimensional matrix of strands defining having a decorative effect that can be used to produce a customised or personalised training shoe.

In still further embodiments of the invention, when the solidified network of strands has a two-dimensional shape, the method of forming a structural component may further include the step of incorporating at least one gap into the solidified network of strands, the or each gap being arranged in the solidified network of strands to permit reconfiguration of the solidified network of strands to have a three-dimensionally shaped structure.

In such embodiments the step of incorporating at least one gap in the solidified network of strands may include extruding strands of liquid polymer onto the support so as to form at least one gap in the interconnected network of strands and/or removing a portion of the solidified network of strands after curing of setting of the liquid polymer.

The or each gap may be in the form of, for example, a slit, a slot or a cut-out.

The incorporation of the or each gap in the solidified network of strands to permit reconfiguration of the structural component to have a three-dimensionally shaped structure simplifies the extrusion of strands of liquid polymer onto the support to form the interconnected network of strands. This is because it becomes possible to create a planar structure of the interconnected network of strands so as to form a solidified network of strands having a two-dimensionally shaped structure, whilst maintaining the ability to create a structural component having a three-dimensionally shaped structure.

The structural component may include the solidified network of strands in combination with a layer of fabric to, for example, modify the functionality and/or aesthetics of the structural component. Such a structural component may be formed in the following ways.

The method of forming a structural component in such embodiments may further include the step of arranging a layer of fabric on the support and extruding strands of liquid polymer onto the layer of fabric so that the strands of liquid polymer form an interconnected network of strands on the layer of fabric and create a fabric component including a solidified network of strands mounted on the layer of fabric following the step of curing or setting the liquid polymer. When the strands of liquid polymer are extruded over a form, the method of forming a structural component may further include the step of arranging a layer of fabric over the form or in the mould prior to the step of extruding the strands of liquid polymer over the form or into the mould so that the strands of liquid polymer are extruded onto the fabric to form an interconnected network of strands on the layer of fabric.

Optionally the method of forming a structural component may further include the step of arranging a layer of fabric over the interconnected network of strands before completion of the curing or setting of the liquid polymer so as to adhere the layer of fabric to the interconnected network of strands so as to adhere the layer of fabric to the interconnected network of strands to create a fabric component including a solidified network of strands mounted on the layer of fabric following completion of the step of curing or setting the liquid polymer, the fabric component having a two -dimensionally or three-dimensionally shaped structure.

When the fabric component has a two-dimensionally shaped structure, the method of forming a structural component may further include the step of reconfiguring the fabric component from having the two-dimensionally shaped structure to having a three- dimensionally shaped structure. In this regard the layer of fabric may be selected to possess stretch properties that readily permits reconfiguration of the fabric component from having the two-dimensionally shaped structure to having the three-dimensionally shaped structure.

Such combination of the layer of fabric and the solidified network of strands, as set out above, may include lamination or encapsulation of the layer of fabric by the solidified network of strands following curing or setting of the liquid polymer.

As mentioned above, to form the structural component, the interconnected network of strands is cured or otherwise allowed to set and solidify so as to form a the solidified network of strands having a two-dimensionally or three-dimensionally shaped structure.

Curing of the interconnected network of strands may be achieved through heating or through exposure to electromagnetic radiation, such as ultraviolet radiation. To cure the interconnected network of strands through heating, the support may be heated and the step of extruding strands of liquid polymer to form an interconnected network of strands may include extruding strands of liquid polymer onto the heated support. The extrusion of strands of liquid polymer onto a heated support not only permits rapid curing of the interconnected network of strands to form the solidified network of strands, but also constrains the flow of the liquid polymer that is extruded onto the heated support so as to maintain a desired shape of the interconnected network of strands during and after the step of curing or otherwise allowing the liquid polymer to set and solidify.

To cure the interconnected network of strands, the method of forming a structural component may, in other embodiments of the invention, include the step of using a radiation source, preferably a laser, to cure the liquid polymer during or subsequent to the step of extruding strands of liquid polymer to form the interconnected network of strands. Such a step permits instantaneous curing of the extruded strands of liquid polymer, thus constraining the flow of the liquid polymer so as to maintain a desired shape of the interconnected network of strands during and after the step of curing or otherwise allowing the liquid polymer to set and solidify.

To cure the interconnected network of strands, the method of forming a structural component may, in yet further embodiments, include the step of extruding a first layer of liquid polymer strands onto the support and curing or setting the first layer of liquid polymer strands followed by the step of simultaneously extruding a second layer of liquid polymer strands onto the solidified network of strands formed by the first layer of liquid polymer strands and curing or setting part or all of the second layer of liquid polymer strands.

Such steps prevent part or all of the solidified network of strands formed by the second layer of liquid polymer strands from adhering to the solidified network formed by the first layer of liquid polymer strands. The lack of adhesion between the solidified networks of strands formed by the first and second layers of liquid polymer strands allows formation of a structural component with a cavity, such as a pocket or the body of a glove. The networked structure of the first and second layers of liquid polymer in addition results in a breathable garment.

The method of forming a structural component may include the step of allowing a plurality of overlaying extruded strands of liquid polymer to merge with each other prior to the step of curing or otherwise allowing the liquid polymer to set and solidify so as to form a garment component having a two-dimensionally or three-dimensionally shaped structure defined by the solidified network of strands. By allowing the plurality of overlaying strands of liquid polymer to merge with each other prior to curing or setting and solidifying, the strength and structural integrity of the resultant structural component is improved.

The method of forming a structural component may include the step of extruding a first layer of liquid polymer strands and curing or setting the first layer of liquid polymer strands, arranging a divider element to cover part of the solidified network of strands formed from the first layer of liquid polymer strands, extruding a second layer of liquid polymer strands onto the divider element and the uncovered part of the solidified network of strands formed from the first layer of liquid polymer strands, and curing or setting the extruded second layer of liquid polymer strands.

The divider element may be made from fabric or paper (e.g. rice or sugar paper). Its during the extrusion and curing of the second layer of liquid polymer strands prevents the second layer of liquid polymer strands from adhering to the covered part of the solidified network of strands from the first layer of the liquid polymer strands, thus enabling formation of a cavity between the solidified networks of strands formed from the first and second layers of liquid polymer strands and thereby allowing formation of a structural component with a cavity. The step of removing the divider element from the structural component after curing or setting the second layer of liquid polymer strands may include dissolving the divider element. Such dissolution of the divided element may be carried out through immersion of the garment in a solvent, such as water, that is capable of dissolving the divider element but not the liquid polymer.

When the method includes the step of retaining the divider element in the structural component after curing the second layer of liquid polymer strands, the second layer of liquid polymer strands may adhere to the divider element. This not only allows the divider element to be retained in place in the structural component, but also enables the divider element to provide the structural component with improved structural integrity.

When the divider element is retained in the structural component, the stretch properties of the divider element may be selected to control the degree of stretch of the solidified network of strands formed from the second layer of liquid polymer strands. The divider element may be made from a range of materials across a range of stretch properties and/or made from an absorbent material, e.g. a sweat-absorbent material. In other embodiments the method of forming a structural component may further include the step of incorporating a or a respective yarn into each extruded strand of liquid polymer prior to the step of curing or otherwise allowing the liquid polymer to set and solidify so as to embed the or each yarn within the solidified network of strands following curing or setting of the liquid polymer. Such incorporation of yarn into each extruded strand of liquid polymer not only improves the structural integrity and strength of the resultant structural component whilst retaining the flexibility of the resultant structural component, but also prevents over-stretch of the solidified network of strands following curing or setting of the liquid polymer so as to prevent it from reaching a degree of extension that would normally cause snapping, tearing or breakage of the solidified network.

The type of yarn used in the method of forming a garment may vary depending on the desired properties of the resultant structural component. For example, the or each yarn may be selected from a group including a crimped-on yarn, a textured yarn, a non-elastic yarn, an elastomeric yarn and a flat yarn.

As outlined above, the elastomeric polymer may be chosen to exhibit selected stretch properties in order to provide the garment with a desired structural strength, e.g. to resist breakage of the solidified network of strands.

The step of extruding strands of liquid polymer onto the support to form an interconnected network of strands may include extruding strands of at least two different elastomeric polymers in liquid form so that, following curing or setting of the different liquid polymers, the different liquid polymers form different regions of the solidified network of strands and the different regions of the solidified network of strands exhibit differing degrees of stretch.

For example, a first liquid polymer, e.g. silicone, may be selected to provide a flexible region that is intended to be comfortable for a wearer when the resultant structural component is incorporated into a garment, and a second liquid polymer, e.g. nylon, may be selected to provide a more rigid region that is intended to provide structural support to a body part of the same wearer.

Forming the solidified network of strands so as to have different regions exhibiting different degrees of stretch therefore permits formation of a structural component having different regions with different stretch properties, e.g. a brassiere with flexible cup elements and a rigid underband to provide structural support, and thereby obviates the need to separately form structural components with different stretch properties and then assemble the separate structural component in order to obtain a similar garment.

The different liquid polymers may include at least one thermoset material and at least one thermoplastic material such that, following curing or setting of the different liquid polymers, regions of thermoset material are interconnected by regions of thermoplastic material.

In embodiments of the invention, the step of extruding strands of liquid polymer onto the support to form the interconnected network of strands may include a sub-step of extruding a first layer of liquid polymer strands onto the support and a sub-step of extruding at least one second layer of liquid polymer strands onto the first layer of liquid polymer strands so that adjacent layers of liquid polymer strands have different orientations. This permits formation of a breathable and padded structural component for use in various wearable items, such as athletic wear.

In further embodiments of the invention, the different orientations of adjacent layers of liquid polymer strands are arranged so that the solidified network of strands created following curing or setting of the liquid polymer exhibits differing degrees of stretch, such as stretch power and recovery, in different stretch directions.

In still further embodiments of the invention, the step of extruding strands of liquid polymer onto the support to form the interconnected network of strands may include varying the distribution of liquid polymer in different regions of the interconnected network of strands and. In such embodiments of the invention, the method of forming a structural component may further include the step of varying the numbers of extruded strands of liquid polymer in the different regions of the interconnected network of strands and/or varying a rate of extrusion of the strands of liquid polymer when varying the distribution of liquid polymer in different regions of the interconnected network of strands. The variable distribution of liquid polymer in the different regions of the interconnected network of strands results in the different regions containing different strand densities, which may be adapted to provide the solidified network of strands created following curing or setting of the liquid polymer with specific stretch properties. In embodiments of the invention the method of forming a structural component may further include the step of flocking extruded strands of liquid polymer. Such flocking of the strands of liquid polymer not only can be used to add surface finish to the solidified network of strands following curing or setting of the liquid polymer, but also prevents debris from adhering to the surface of the interconnected network of strands prior to curing or setting of the liquid polymer, thus protecting the aesthetics of the resultant solidified network of strands.

In such embodiments the method of forming a structural component may further include the step of extruding additional strands of liquid polymer over the flocked strands of liquid polymer so to form an interconnected network of strands with a composite structure defined by flock and liquid polymer.

The inclusion of flock within the structure of the interconnected network of strands in this manner not only permits the flock to acts as a filler to enhance bonding between successive strands of liquid polymer, but also results in a composite structure that enhances the strength of the resultant structural component.

The method of forming a structural component may further include the step of incorporating antimicrobial material, such as silver particles, into the interconnected network of strands

In further embodiments of the invention the step of extruding strands of liquid polymer onto the support to form an interconnected network of strands may include extruding strands of liquid polymer over a fabric to form an interconnected network of strands with an integral fabric. Such a fabric may be in the form of, for example, lace.

In yet further embodiments of the invention the method may include the step of removing at least one selected portion of the solidified network of strands to form a decorative element in the solidified network of strands and/or to finish an edge of the solidified network of strands. Such a step may include using a radiation source, to remove the or each selected portion of the solidified network of strands. For example, removal of at least one selected portion of the solidified network of strands may be carried out through laser etching of the solidified network of strands.

According to a second aspect of the invention, there is provided a cloth-like sheet comprising a plurality of strands of an elastomeric polymer arranged and cured in a solidified network of strands.

As outlined above, the term "cloth-like" is intended to encompass a solidified network of strands having handling characteristics that are comparable with a sheet of fabric or cloth. The nature of the elastomeric polymer means that the cloth-like sheet cannot absorb moisture or crease. These properties are particularly important characteristics that must be borne in mind when a garment or footwear manufacturer is seeking to identify a material from which to create a garment or item of footwear. These properties result in a sheet of material that is breathable, cannot retain moisture and cannot crease.

Preferably the elastomeric polymer is MOMENTIVE's LSR 2650. The cloth-like sheet may further include a top coat applied to the solidified network of strands. In such embodiments, the top coat may comprise MOMENTIVE's LSR top-coat HE.

In addition, or in the alternative, the cloth-like sheet may include an anti-microbial coat applied to the solidified network of strands.

It is envisaged that in other embodiments the cloth-like sheet may further include one or garment or footwear accessories embedded in the solidified network of strands. In such embodiments the or each garment or footwear accessory could include a fastening element, a clasp, a hook, a button, a decorative element, a support element, a shoe lace socket or a shoe lace ring.

In particularly preferred embodiments, the solidified network of strands may be shaped and configured to define a garment blank or to define a garment in its entirety. In such embodiments, the garment or intended garment to be produced through use of the garment blank, could include a brassiere, basque or other garment including breast cup elements. It will be appreciated that this is a not an exhaustive list of the possible garments.

In other particularly preferred embodiments, the solidified network of strands may be shaped and configured to define a shaped footwear upper. In such embodiments the shaped footwear upper may be a moulded training shoe upper.

According to a third aspect of the invention there is provided a computer readable medium comprising computer program code stored thereon, the computer readable medium and computer program code being configured to, when run on at least one processor, perform at least the method of forming a structural component according to the first aspect of the invention. One or more of the computer programs may, when run on a computer, cause the computer to configure any apparatus, including a battery, circuit, controller, or device disclosed herein or perform any method disclosed herein. One or more of the computer programs may be software implementations, and the computer may be considered as any appropriate hardware, including a digital signal processor, a microcontroller, and an implementation in read only memory (ROM), erasable programmable read only memory (EPROM) or electronically erasable programmable read only memory (EEPROM), as examples.

One or more of the computer programs may be provided on a computer readable medium, which may be a physical computer readable medium such as a disc, CD, or a memory device, or may be embodied as a transient signal. Such a transient signal may be a network download, including an internet download.

Preferred embodiments of the invention will now be described, by way of non-limiting examples, with reference to the accompanying drawings in which:

Figure 1a shows a brassiere according to a first embodiment of the invention; Figures 1 b and 1 c illustrate the formation of the brassiere of Figure 1 b;

Figures 1d to 1g respectively show brassieres according to second, third, fourth and fifth embodiments of the invention;

Figures 2a and 2b show brassieres according to sixth and seventh embodiments of the invention;

Figures 3a and 3b show a brassiere according to an eighth embodiment of the invention;

Figure 4 shows a brassiere according to a ninth embodiment of the invention; Figure 5 shows a brassiere according to a tenth embodiment of the invention; Figure 6 shows a brassiere according to an eleventh embodiment of the invention; Figure 7 shows a brassiere according to a twelfth embodiment of the invention;

Figure 8 shows a glove according to a thirteenth embodiment of the invention; Figure 9 shows a garment component according to a fourteenth embodiment of the invention;

Figure 10 illustrates a method of forming a brassiere according to a fifteenth embodiment of the invention;

Figure 11 illustrates a brassiere made in accordance with a further embodiment of the invention; Figure 12 illustrate a training shoe upper made in accordance with a yet further embodiment of the invention;

Figures 13a and 13b illustrate a sole for a training shoe made in accordance with another embodiment of the invention; and

Figures 14a and 14b illustrate the creation of a structural component having a woven appearance in accordance with a yet further embodiment of the invention.

A method of forming a structural component in the form of a brassiere, in accordance with an embodiment of the invention, is carried out as follows.

A printer is provided. The printer includes an extrusion head connected to a supply of a liquid polymer. The liquid polymer is a liquid silicone rubber, an elastomeric material, which is preferably a two-component liquid silicone rubber consisting of A and B components of MOMENTIVE LSR 2650 mixed in a ratio A:B of 40:60.

The printer is connected to a controller, which is configured to control movement of the extrusion head relative to a support. The controller is also configured to control the rate at which the liquid silicone is be dispensed from the extrusion head during movement of the extrusion head relative to the support.

The controller preferably includes a general purpose processor dedicated to executing/processing information received via an input, such as from a user or a CAD/CAM model, in accordance with instructions stored in the form of computer program code on memory. The output signalling generated by such operations from the processor is provided onwards to the printer via an output.

The memory (not necessarily a single memory unit) is a computer readable medium (solid state memory in this example, but may be other types of memory such as a hard drive, ROM, RAM, Flash or the like) that stores computer program code. This computer program code stores instructions that are executable by the processor, when the program code is run on the processor. The internal connections between the memory and the processor can be understood to provide an active coupling between the processor and the memory to allow the processor to access the computer program code stored on the memory. The input, output, processor and memory are all electrically connected to one another internally to allow for electrical communication between the respective components. The components are all located proximate to one another so as to be formed together as an ASIC, in other words, so as to be integrated together as a single chip/circuit that can be installed into an electronic device, such as the printer. Alternatively the processor and memory could be part of a general purpose computer connected to the printer. In order to create the brassiere, the controller controls the extrusion head of the printer so as to extrude strands of liquid silicone onto a relatively flat support in accordance with a pattern input into the controller.

The rate of extrusion of liquid silicone from the extrusion head is controlled relative to the rate of movement of the extrusion head relative to the support so as to control the cross- sectional size of the strands of liquid silicone. Accordingly, by controlling the rate of extrusion of liquid silicone so as to extrude liquid silicone more slowly than the rate of movement of the extrusion head relative to the support, the extrusion head draws out and stretches the strand of liquid silicone as it is extruded onto the support. This results in a relatively fine strand of liquid silicone being extruded onto the support.

The controller controls movement of the extrusion head whilst the extrusion head extrudes strands of liquid silicone onto the support so as to define an interconnected network of strands arranged on the support in accordance with the pattern input into the controller.

During movement of the extrusion head to create the interconnected network of strands, brassiere fastener elements are placed onto the support. The fastener elements are located on the support so at least an edge of the fastener overlays at least one layer of liquid silicone strands already extruded onto the support and so that a second layer of liquid silicone strands are laid over the edge of the fastener thereafter.

Curing of the strands of liquid silicone starts as soon as components A and B of the liquid silicone composition are mixed and extruded onto the support. The curing processing may however be accelerated by heating the support, exposing the interconnected network of strands of liquid silicone to heat via a heat lamp, or by exposing the interconnected network of strands of liquid to a source of radiation, preferably a laser.

Once the strands of liquid silicone are cured so as to form a solidified network of strands, the brassiere fastener elements are embedded in the solidified network of strands and the brassiere may be removed from the support. The use of an elastomeric polymer means that the solidified network of strands exhibit stretch, which allows the brassisere to mould to the shape of a wearer's body when the brassiere is worn. Preferably the brassiere is formed so as to pass over a wearer's head, a front section being located over a wearer's front and a rear section being located over a wearer's back, the fastener's being embedded in the solidified network of strands so as to allow the front and back sections of the brassiere to be fastened together. A schematic illustration of a brassiere 500 according to one such embodiment of the invention is shown in Figure 1 1.

The brassiere 500 includes a front section 80 formed integrally with a back section 512, the front and back sections 80,512 being joined by shoulder strap portions 514. The shoulder strap portions 514 define an opening 516 to receive a wearer's head and allow the brassiere 500 to be placed over the wearer's head.

Fasteners in the form of hooks 518 and loops 520 are embedded in the solidified network of strands so as to allow the front and back sections 80,512 to be secured together about a wearer's body.

The elastomeric nature of the silicone rubber allows cup elements 522 provided in the front section 80 of the brassiere 500 to mould to the shape of the wearer's breasts whilst providing support.

The pattern of strands of silicone rubber laid down in order to create the interconnected network of strands of silicone rubber is preferably denser in the cup elements 522 so as to increase the amount of support provided by the cup elements 522 and so as to increase the supportive strength of the brassiere in the regions of the cup elements 522.

The use of a liquid silicone rubber produces a solidified network of strands having a relatively tacky surface. So as to produce a matt surface, a top coat may be applied to the solidified network of strands. The top coat used is preferably a two-component liquid silicone rubber consisting of A and B components and produced by MOMENTIVE under the reference LSR top-coat HE and mixed in a ratio of A:B of 50:50. The top coat is preferably sprayed over the solidified network of strands so as to cover all exposed surfaces.

In embodiments of the invention, an anti-microbial agent may also be sprayed over the solidified network of strands.

The nature of the solidified network of strands means that the resultant brassiere is breathable and allows heat to escape from a wearer's body. The solidified network of strands cannot absorb moisture and hence the brassiere cannot retain moisture. This in turn means that the brassiere is easy to wash and dry, and cannot retain moisture against the wearer's body that might otherwise make the wearer feel cold.

Another advantage of the use of a silicone rubber is that it means the resultant brassiere cannot crease and is hence very easy to care for.

In the method outlined above, the brassiere is created on a substantially flat support. In other embodiments, the step of curing the liquid silicone may be performed in two steps in order to allow moulding of the cup elements 522 into a three-dimensional shape. In such an embodiment, the interconnected network of strands of liquid silicone are part cured before being placed over a form so as to shape the cup portions of the brassiere into a three-dimensional shape. The curing process is then completed so as to set the cup portions in the three-dimensional shape created by the form. A benefit of part curing the interconnected network of strands of liquid silicone before placing the part cured network of strands over the form is that it creates a degree of stretch in the cup portions of the brassiere when they are placed over the form. This stretch is then locked into the brassiere by completing the curing process and increases the support, strength and power of the cup portions defined in the solidified network of strands.

In other embodiments of the invention, strands of liquid silicone may be extruded onto the support in order to define structural components of other wearable items.

Strands of liquid silicone may for example be extruded onto the support so as to form a training shoe upper, such as that shown schematically in Figure 12. The shoe upper 600 shown in Figure 12 includes opposing side portions 90, which are intended to be shaped to reach around a wearer's foot, and include lace hole apertures 612. The shoe upper 600 also includes heal sections 614 that are intended to be connected together so as to reach around a wearer's heal and a tongue section 616 that is intended to extend over the top of a wearer's foot, between the interlaced side portions 90.

In such an embodiment of the invention, strands of liquid silicone may be extruded onto the support so as to define decoratively patterned areas of the shoe upper 600 interconnected by other functional and supportive areas of the shoe upper 600.

The resultant interconnected network of strands of liquid silicone is then part cured before being placed over a form to mould the shoe upper 600 into the required shape before completing the curing process so as to produce a solidified network of strands.

The moulded shoe upper may then be glued onto a rubber sole element in order to complete the manufacture of the training shoe. Preferably, during extrusion of the strands of liquid silicone, footwear accessories are laid onto the support so as to become embedded into the silicone on curing. These may include shoe lace sockets and/or shoe lace rings so as to allow shoe laces to be threaded into the training shoe upper following moulding.

An example of a possible sole element 700 is illustrated in Figures 13a and 13b.

The sole element 700 is shaped to include a foot portion 712 and a heal portion 714, as is the case in a conventional sole for an item of footwear.

The sole element 700 is created by extruding strands of liquid silicone onto the support, successive strands being laid over and across previous strands so as to define a plurality of layers of strands created so as to overlay one another and thereby form a multi-layered structure.

So as to create a breathable structure, the strands in each layer are laid over and across each other to define an open network of interconnected strands, and adjacent layers are created so that openings in each of the layers are offset relative to each other. This results in the creation of tortuous paths through the solidified network of strands following curing or setting of the liquid polymer.

During creation of the subsequent layers of strands, a barrier layer 718 is created between at least two layers of strands.

It is envisaged that the barrier layer 718 may be created between the at least two layers of strands by arranging a layer of material onto a lower layer of strands before continuing extrusion of the next layer of strands of liquid silicone directly onto the barrier layer 718 so as to encase the barrier 718 between the layers of strands.

In other embodiments it is envisaged that the barrier layer 718 may instead be created by extruding strands of liquid silicone directly onto a lower layer of strands so as to form a closed network of interconnected strands having no openings there between before continuing extrusion of the next layer of strands of liquid silicone directly onto the barrier layer 718 so as to encase the barrier 718 between the layers of strands that define open networks of strands.

The inclusion of a barrier layer 718 facilitates the sole element 700 to be glued to a shoe upper, such as the shoe upper 600 shown in Figure 12. This is because the barrier layer 718 divides the sole element 700 into two sections - a first section 716 to define the inner sole of the resultant show and intended to be in contact with a wearer's foot and a second section 720 to define an attachment portion for securing the sole element 700 to the shoe upper 600.

In such embodiments it is envisaged that the sole element would be secured to the shoe upper 600 by laying the sole element 700 onto the shoe upper 600, between the side portions 90, and securing the sole element 700 in position by means of glue. The creation of an open structure in the second section 720 of the sole element 700 allows the glue to penetrate into the structure and thereby form a strong bond between the sole element 700 and the shoe upper 600, whilst the provision of the barrier layer 718 prevents the spread of the glue further into the sole element 700. The barrier layer 718 prevents the spread of the glue into the resultant shoe itself.

In particularly preferred embodiments, the multi-layered structure of the sole element 700 may be created so as to include 24 layers in the first portion 716 intended to define the inner sole of the shoe and 12 layers in the second portion 720 intended to attach the sole to the shoe upper 600.

It will be appreciated that in other embodiments, the first and second portions 716,720 may be reversed depending on the structure of the item of footwear. For example, in circumstances where the upper section of the footwear is intended to be glued to an upper surface of the sole element, the barrier layer may prevent the spread of glue downwards into the portion of the sole element intended to contact the ground. This helps to ensure that the glue does not affect the compressibility and comfort created by the use of the open and multi-layered structure.

It is envisaged that in each of the embodiments described above, one or more additives may be mixed with the liquid silicone prior to the step of extruding the liquid silicone onto the support.

The additive may include a perfume, a scent, a colour, decorative particles (such as glitter particles, metallic particles, glass particles and coloured particles) or an anti-microbial agent. In embodiments wherein the additive is a colour, the colour may be provided in the form of pigment suspended in a silicone oil. One example of a suitable material is produced by MOMENTIVE under the reference LSR farb paste.

As outlined above, controlling the rate of extrusion of liquid polymer from an extrusion head versus the rate of movement of the extrusion head relative to the support allows the creation of relatively fine strands of liquid polymer.

This in turn allows the creation of a solidified network of strands having a relatively delicate appearance.

Inevitably the minimum cross-sectional size of a strand of liquid polymer extruded from an extrusion head will be determined by the size of nozzle via which the liquid polymer is extruded from the extrusion head together with the strength of the liquid polymer. However through appropriate selection of nozzle size, appropriate selection of liquid polymer and appropriate selections of rate of extrusion and rate of movement, the applicant has discovered that it is possible to create strands of liquid polymer having a cross-sectional size that is comparable with than of conventional yarns.

Accordingly it is possible to create a structural component for a garment or footwear in the form of a cloth-like sheet, the cloth-like sheet or substrate having handling characteristics that are comparable with a sheet of fabric or cloth.

The creation of a solidified network of strands in the form of a cloth-like sheet or substrate is advantageous in that is provides a material that is suitable for use in the creation of garments or items of footwear in a very similar manner to conventional methods of manufacturing garments and items of footwear using fabric or cloth. It will be appreciated that in such methods, sewing would be replaced by gluing - a bead of silicone being suitable for adhereing pieces of the cloth-like sheet or substrate together in the creation of a garment or item of footwear.

The use of an elastomeric polymer in the creation of the cloth-like sheet or substrate however imparts a certain degree of stretch and also results in a material that cannot absorb moisture. Accordingly it renders the material suitable for use in garments or footwear intended to be worn in close contact with a wearer's skin. Such garments or footwear are inevitably unable to absorb moisture from a wearer's skin, which eliminates the associated problems associated with garments or footwear created from fabric or cloth that absorb moisture and retain that moisture against a wearer's skin. Another particular advantage of the resultant cloth-like sheet or substrate is that it cannot crease.

A structural component in the form of a cloth-like sheet or substrate is manufactured in accordance with the method outlined above in connection with the brassiere and the shoe upper and hence will not be described again in detail. The use of a top coat to create a matt finish over the solidified network of strands is however particularly advantageous in the formation of the cloth-like sheet or substrate in that it eliminates the risk of sections of the cloth-like sheet or substrate adhering to each other as a result of any tackiness arising through the use of a silicone rubber to form the solidified network of strands.

It will also be appreciated that the pattern in which the strands are laid over and across each other as they are extruded onto the support will have an effect on the resultant appearance of the structural component.

For example, in order to produce a woven-effect pattern, a first layer of strands of liquid silicone may be extruded onto the support so as to form a first grid pattern 810 of strands, such as that illustrated in Figure 14a.

A second layer of strands of liquid silicone may then be extruded onto the support and over the first layer of strands of liquid silicone so as to form a second grid pattern 812 of strands. As shown in Figure 14b, it is possible to produce a woven-effect pattern by offsetting the second grid pattern 812 relative to the first grid pattern 810.

As will be appreciated, the nature of the strands of liquid silicone means that the strands of the second grid pattern 812 will inevitably sink into and around the strands of the first grid pattern 810, which on curing or otherwise allowing to set and solidify, results in a woven-pattern effect.

Each of the embodiments outlined above has been described with reference to the use of a silicone rubber. It is envisaged that in other embodiments different elastomeric polymers may be used. Another thermoset material, such as acrylic, could for example be used. In other embodiments a thermoplastic material, such as nylon, could for example be used. The method steps outlined above would apply equally well to the use of such different elastomeric polymers.

Moving now to the garments and method illustrated in the accompanying figures, Figure 1a shows a brassiere 10 according to a first embodiment of the invention. The brassiere 10 comprises a pair of cup elements 12 and an underband 14.

A method of forming the brassiere 10 is carried out as follows. A form is provided. The form is a plate 16 with two hemispherical projections 18 mounted thereon. The hemispherical projections 18 are positioned on the plate 16 to match the relative positions of the cup elements 12 on the brassiere 10. A printer (not shown) is provided. The printer includes a silicone dispensing unit with an extruder head to produce extruded strands 20 of silicone, which typically have sub- millimetre widths. In use, the printer includes a controller to control movement and positioning of the extruder head relative to the form, as well as rate of extrusion of silicone from the extrude head, so as to control extrusion of strands 20 of silicone over the form.

The controller provided to control movement and positioning of the extruder head of the printer as well as the rate of extrusion of silicone from the extruder head is preferably includes a general purpose processor dedicated to executing/processing information received via an input, such as from a user or a CAD/CAM model, in accordance with instructions stored in the form of computer program code on memory. The output signalling generated by such operations from the processor is provided onwards to the printer via an output.

The memory (not necessarily a single memory unit) is a computer readable medium (solid state memory in this example, but may be other types of memory such as a hard drive, ROM, RAM, Flash or the like) that stores computer program code. This computer program code stores instructions that are executable by the processor, when the program code is run on the processor. The internal connections between the memory and the processor can be understood to provide an active coupling between the processor and the memory to allow the processor to access the computer program code stored on the memory.

The input, output, processor and memory are all electrically connected to one another internally to allow for electrical communication between the respective components. The components are all located proximate to one another so as to be formed together as an ASIC, in other words, so as to be integrated together as a single chip/circuit that can be installed into an electronic device, such as the printer. Alternatively the processor and memory could be part of a general purpose computer connected to the printer.

The printer is initially operated to extrude strands 20 of silicone over the form to form a first layer of silicone strands. Thereafter, as shown in Figure 1 b, the printer is operated to extrude strands 20 of silicone over the form such that successive strands 20 are laid over and across previous strands 20 to form a matrix 22 of strands 20. More particularly, the strands 20 of silicone are extruded to form overlaying layers of silicone strands over the hemispherical projections 18 so as to form three-dimensionally shaped structures 24 that are intended to form the cup elements 12 of the brassiere 10, and to form overlaying layers of silicone strands on the plate 16 around the hemispherical projections so as to form a planar structure 26 that is intended to form the underband 14 of the brassiere 10.

The extrusion of successive strands 20 over and across previous strands 20 is repeated until a desired thickness of the matrix 22 of strands 20 is achieved. The thickness of the matrix 22 of strands 20 may vary depending on the required properties, such as flexibility and strength, of the resultant brassiere 10.

During the extrusion of strands 20 of silicone over the form to form the matrix 22 of strands 20, the form is heated at a temperature (e.g. 180-200 °C) that is sufficiently high to cure the matrix 22 of strands 20 formed from silicone. The extrusion of strands 20 of silicone onto the heated form not only permits rapid curing of the matrix 22 of strands 20 over the form to form the brassiere 10, but also constrains the flow of the silicone that is extruded on the form so as to maintain a desired shape of the matrix 22 of strands 20. Curing of the matrix 22 of strands 20 forms a solidified matrix 22 of strands 20 that defines the structure of the brassiere 10, thus forming the brassiere 10 as shown in Figure 1 c.

Alternatively the form can be initially unheated during the extrusion of strands 20 of silicone over the form to form the matrix 22 of strands 20, and is only heated to cure the completed matrix 22 of strands 20. It is envisaged that, in other embodiments of the invention, curing of the matrix of strands may be achieved through exposure to electromagnetic radiation, such as ultraviolet radiation. It is also envisaged that, in other embodiments of the invention, the liquid polymer may be selected such that the resultant matrix of strands is capable of setting and solidifying so as to form the brassiere defined by the solidified matrix of strands.

Further alternatively, to cure the matrix 22 of strands 20, a laser may be used to cure the silicone during or subsequent to the step of extruding strands 20 of silicone to form the matrix 22 of strands 20. Such a step permits instantaneous curing of the extruded strands 20 of silicone, thus constraining the flow of the silicone so as to maintain a desired shape of the matrix 22 of strands 20.

It is envisaged that, in other embodiments of the invention, the form may be replaced by a mould. In this regard the printer would be initially operated to extrude strands 20 of silicone into the mould to form the matrix 22 of strands 20 in order to form the three-dimensionally shaped structures 24 that are intended to form the cup elements 12 of the brassiere 10. It is also envisaged that, in other embodiments of the invention, the method of forming the brassiere may further include the step of removing at least one portion of the brassiere to form a decorative element in the brassiere. The design of the decorative element may vary depending on the preferences of the wearer. For example, as shown in Figure 1d, portions of the brassiere 40 may be removed to form a lace pattern in the brassiere 40.

It is further envisaged that, in other embodiments of the invention, the method of forming the brassiere may further include the step of removing at least one portion of the brassiere to finish an edge of the brassiere. This may be carried out by removing away excess, unwanted material from an edge of the brassiere to produce a finished edge.

Removal of at least one portion of the brassiere may be carried out through, for example, laser etching, which is quick and precise. Optionally the method of forming the brassiere 50 may further include the step of flocking the matrix 22 of strands 20 with nylon flock 28. The nylon flock 28 partially sinks into the matrix 22 of strands 20 to add surface finish to the resultant brassiere 50, as shown in Figure 1e. The presence of the nylon flock 28 on the surface of the brassiere 50 also prevents debris from adhering to the surface of the brassiere 50, thus protecting the aesthetics of the brassiere 50.

Further optionally the method of forming the brassiere 60 may further include the step of extruding additional strands 20 of silicone over flocked strands 20 of silicone so to form a matrix 22 of strands 20 with a composite structure defined by nylon flock 28 and silicone, thus enabling formation of a brassiere 60 with a composite structure defined by nylon flock 28 and solidified silicone as shown in Figure 1f.

The inclusion of nylon flock 28 within the structure of the matrix 22 of strands 20 in this manner not only permits the nylon flock 28 to acts as a filler to enhance bonding between successive strands 20 of silicone, but also results in a composite structure that enhances the strength of the resultant brassiere 60.

It is envisaged that, in other embodiments of the invention, the method of forming the brassiere 70 may further include extruding strands 20 of silicone over fasteners 30, such as a clasp and a hook, to form a matrix 22 of strands 20 with integral fasteners 30, as shown in Figure 1g. This in turn provides the resultant brassiere 70 with integral fasteners 30 in its underband 14. In addition, it is envisaged that, in still other embodiments of the invention, the method of forming the brassiere 70 may further include extruding strands 20 of silicone over a fabric, such as lace, to form a matrix 22 of strands 20 with integral fabric. This in turn provides the resultant brassiere 70 with integral fabric, which could be designed to improve the aesthetics of the brassiere 70.

The brassiere 80,90 may include the solidified matrix 22 of strands 20 in combination with a layer of fabric 32 to, for example, modify the functionality and/or aesthetics of the brassiere 80,90. Such a brassiere 80, as shown in Figure 2a, may be formed by arranging a layer of fabric 32 over the form prior to the extrusion of strands 20 of silicone over the form so that the strands 20 of silicone are extruded onto the fabric 32 to form the matrix 22 of strands 20 on the layer of fabric 32. Alternatively such a brassiere 90, as shown in Figure 2b, may be formed by arranging a layer of fabric 32 over the matrix 22 of strands 20 before completion of the curing of the silicone so as to adhere the layer of fabric 32 to the matrix 22 of strands 20.

The brassiere 100 may be formed to have flexible cup elements 12 that is intended to be comfortable for a wearer of the brassiere 100, and a rigid underhand 14 that is intended to provide structural support.

To form such a brassiere 100, the printer may be configured to be capable of extruding strands 20 of two different liquid polymers so that, following curing or setting of the different liquid polymers, the different liquid polymers form different regions 34,36 of the solidified matrix 22 of strands 20, as shown in Figure 3a and the different regions 34,36 of the solidified matrix 22 of strands 20 exhibit differing degrees of stretch. More particularly, the printer may include a first dispensing unit with an extruder head to produce strands 20 of a first liquid polymer, and a second dispensing unit with an extruder head to produce strands 20 of a second liquid polymer that is different from the first liquid polymer.

Silicone may be selected as the first liquid polymer to form the flexible cup elements 12, while nylon may be selected as the second liquid polymer to form the rigid underband 14.

Following curing or setting of the different liquid polymers, the flexible cup elements 12 formed of silicone are interconnected by the underband 14 formed of nylon, thus forming the brassiere 100 with flexible cup elements 12 and a rigid underband 14. Forming the solidified matrix 22 of strands 20 to have different regions exhibiting different degrees of stretch therefore permits formation of a brassiere 100 having different regions 34,36 with different stretch properties, as shown in Figure 3b, and thereby obviates the need to separately form the cup elements and underband and then assemble the separate cup elements and underband in order to obtain a similar brassiere.

A brassiere 110 according to a ninth embodiment of the invention is shown in Figure 4. The brassiere 110 of Figure 4 is similar to the brassiere 10 of Figure 1 and like features share the same reference numerals.

The method of forming the brassiere 110 of Figure 4 is similar to the method of forming the brasserie 10 of Figure 1 , except that, in the method of forming the brassiere 110 of Figure 4, the form omits the hemispherical projections 18, and the strands 20 of silicone are extruded to form overlaying layers of silicone on the plate 16 so as to form a planar structure 26 that is intended to form the cup elements 12 and underband 14 of the brassiere 110.

Following curing of the matrix 22 of strands 20 to form a solidified matrix 22 of strands 20 that defines the structure of the brassiere 110, the shape of the brasserie is moulded using a suitably shaped form (not shown) to form the desired hemispherical shape of the cup elements 12 whilst maintaining the planar shape of the underband 14.

It is envisaged that, in other embodiments of the invention, one or more gaps may be incorporated in the planar structure 26, whereby the or each gap is arranged in the planar structure 26 to permit reconfiguration of the planar structure 26 to form the cup elements 12 of the brassiere 110. Such incorporation of one or more gaps in the planar structure 26 may be carried out by extruding strands 20 of silicone to form at least one gap in the matrix 22 of strands 20 and/or removing a portion of the planar structure 26 subsequent to the formation of the planar structure 26 to so as to form at least one gap in the planar structure 26. The or each gap may be in the form of, for example, a slit, a slot or a cutout.

A brassiere 120 according to a tenth embodiment of the invention is shown in Figure 5. The brassiere 120 of Figure 5 is similar to the brassiere 10 of Figure 1 and like features share the same reference numerals. The method of forming the brassiere 120 of Figure 5 is similar to the method of forming the brasserie 10 of Figure 1 , except that, in the method of forming the brassiere 120 of Figure 5, the cup elements 12 and underband 14 are formed separately. More particularly, the strands 20 of silicone are extruded to form overlaying layers of silicone on the plate 16 so as to form a planar structure 26 that is intended to form the underband 14 of the brassiere 110, and the cup elements 12 are formed through conventional techniques, such as using laminated fabric to form the cup elements 12.

Following curing of the matrix 22 of strands 20 to form a solidified matrix 22 of strands 20 that defines the structure of the underband 14, the cup elements 12 are attached 38 to the solidified matrix 22 of strands 20 to form the brasserie 120.

A brassiere 130 according to an eleventh embodiment of the invention is shown in Figure 6. The brassiere 130 of Figure 6 is similar to the brassiere 10 of Figure 1 and like features share the same reference numerals.

The method of forming the brassiere 130 of Figure 6 is similar to the method of forming the brasserie 10 of Figure 1 , except that, in the method of forming the brassiere 130 of Figure 6, the strands 20 of silicone are extruded to form overlaying layers of silicone over the hemispherical projections 18 so as to form three-dimensionally shaped structures 24 that are intended to form the cup elements 12 of the brassiere 10, and the underband 14 is formed through conventional techniques, such as using laminated fabric to form the underband 14. Following curing of the matrix 22 of strands 20 to form a solidified matrix 22 of strands 20 that defines the structure of the cup elements 12, the underband 14 is attached 38 to the solidified matrix 22 of strands 20 to form the brasserie 120.

A brassiere 140 according to a twelfth embodiment of the invention is shown in Figure 7. The brassiere 140 of Figure 7 is similar to the brassiere 110 of Figure 4 and like features share the same reference numerals.

The method of forming the brassiere 140 of Figure 7 is similar to the method of forming the brasserie 810 of Figure 4, except that, in the method of forming the brassiere 140 of Figure 7, the strands 20 of silicone are combined with a layer of fabric 32 so as to form a fabric component including the layer of fabric 32 and matrix 22 of strands 20, whereby the fabric component has a two-dimensionally shaped structure. Methods of combining the strands 20 of silicone with a layer of fabric 32 are described elsewhere in this specification.

Following curing of the matrix 22 of strands 20 on the layer of fabric 32 to form a fabric component that defines the structure of the brassiere 140, the shape of the brasserie 140 is moulded using a suitably shaped form (not shown) to form the desired hemispherical shape of the cup elements 12 whilst maintaining the planar shape of the underband 14, i.e. the fabric component is reconfigured from having a two-dimensionally shaped structure to having a three-dimensionally shaped structure.

It is envisaged that, in other embodiments of the invention, the fabric component with the two-dimensionally shaped structure may be used to form other types of garments that require the fabric component to retain its two-dimensionally shaped structure. A glove 1210 according to a thirteenth embodiment of the invention is shown in Figure 8. The glove comprises first and second glove faces 1220,1240, each of which is in the shape of a hand. The first and second glove faces 1220,1240 are similar in cross-section and are attached to each other along the edges of their respective cross-sections, whereby the edges correspond to a perimeter of a hand. The glove further includes a cavity formed between the first and second glove faces 1220,1240.

A method of forming the glove 1210 is carried out as follows.

The printer is initially operated to extrude strands 20 of silicone to form a first layer of silicone. Thereafter, as shown in Figure 9, the printer is operated to extrude strands 20 of silicone such that successive strands 20 are laid over and across previous strands 20 to form a matrix 22 of strands 20. More particularly, the strands 20 of silicone are extruded to form overlaying layers of silicone so as to form the first glove face 1220. The matrix 22 of strands 20 defining the first glove face 1220 are then cured. Such curing can be carried out using various curing steps, such as the curing steps described elsewhere in this specification.

A divider element 100 is arranged to cover part of the cured first glove face 1220. The divider element 100 is similar in shape as the first glove face 1220 but has a smaller cross- section so that the edges 1260 of the first glove face 1220, which correspond to a perimeter of a hand, remains exposed when the divider element 100 is arranged to cover part of the cured first glove face 1220. Thereafter, the printer is operated to extrude a second matrix 22 of strands 20 onto the divider element 100 and the uncovered part of the first glove face 1220 so as to form the second glove face 1240, which is subsequently cured. After the second glove face 1240 is cured, the divider element 100 is then removed 102 from between the first and second glove faces 1220,1240. In the embodiment shown in Figure 8, the divider element 100 is pulled from between the first and second glove faces 1220,1240.

Whilst the second glove face 1240 is permitted to adhere to the uncovered part of the first glove face 1220, the presence of the divider element 100 during the extrusion and curing of the second glove face 1240 prevents the second glove face 1240 from adhering to the covered part of the first glove face 1220, thus enabling formation of a cavity between the first and second glove faces 1220,1240 and thereby allowing formation of the glove 1210. The networked structure of the first and second glove faces 1220,1240 results in a breathable glove 1210.

Optionally, instead of pulling the divider element 100 from between the first and second glove faces 1220,1240, the divider element 100 may be removed from between the first and second glove faces 1220,1240 by dissolving the divider element 100 in a suitable solvent that is capable of dissolving the divider element 100 but not the silicone. For example, the divider element 100 may be made from paper, such as rice or sugar paper, and the divider element 100 may be dissolved through immersion of the glove 1210 in water. Alternatively, instead of being removed from between the first and second glove faces 1220,1240, the divider element 100 may be retained in the glove after curing the second glove face 1240. In such embodiments, the second glove face 120 preferably adheres to the divider element 100. This not only allows the divider element 100 to be retained as an inner lining inside the glove 1210, e.g. as a palm layer inside the glove 1210, but also enables the divider element 100 to provide the glove 1210 with enhanced structural integrity.

When the divider element 100 is retained in the glove, the stretch properties of the divider element 100 may be selected to control the degree of stretch of the second glove face 1240, e.g. to prevent over-stretch of the second glove face 1240. The divider element 100 may be made from a range of materials across a range of stretch properties and/or made from an absorbent material, e.g. a sweat-absorbent material. The divider element 100 may be made from fabric.

This method is applicable to formation of any other type of garment with a cavity, such as a pocket.

It is envisaged that, in embodiments of the invention, the method of forming a garment may include the step of allowing a plurality of overlaying extruded strands of silicone to merge with each other prior to the step of curing or otherwise allowing the silicone to set and solidify so as to form the garment component having a two-dimensionally or three- dimensionally shaped structure defined by the solidified matrix of strands. This may be achieved by adapting the speed of extruding successive, overlaying strands of silicone and/or the speed at which the silicone is cured or allowed to set and solidify. By allowing the plurality of overlaying extruded strands of silicone to merge with each other prior to curing or setting and solidifying, the strength and structural integrity of the resultant garment component is improved.

It is envisaged that, in other embodiments of the invention, a garment with a cavity may be formed by extruding a first layer of silicone and curing the first layer of silicone following by the step of simultaneously extruding the second layer of silicone onto the cured first layer of silicone and curing part or all of the extruded second layer of silicone. Such steps prevents part or all of the extruded second layer of silicone from adhering to the extruded first layer of silicone. The lack of adhesion between the first and second layers of silicone allows formation of a garment component with a cavity.

Optionally, in each of the aforementioned embodiments, the step of extruding strands 20 of silicone to form the matrix 22 of strands 20 may include extruding a first layer 300 of silicone and extruding at least one second layer of silicone 302 onto the first layer 300 of silicone so that the orientation 304 of the extruded first layer 300 of silicone is different from the orientation 306 of the or each extruded second layer 302 of silicone, an example of which is shown in Figure 9. This permits formation of a breathable and padded garment component. The different orientations 304,306 of the extruded first layer 300 of silicone and the or each extruded second layer 302 of silicone are arranged to allow the resultant garment component to exhibit differing degrees of stretch, such as stretch power and recovery, in different stretch directions. Further optionally, in each of the aforementioned embodiments, the step of extruding strands 20 of silicone to form the matrix 22 of strands 20 may include varying the distribution of silicone in different regions of the matrix 22 of strands by, for example, varying the numbers of extruded strands 20 of silicone in the different regions of the matrix 22 of strands 20 and/or operating the printer to vary a rate of extrusion of the strands 20 of silicone when varying the distribution of silicone in different regions of the matrix 22 of strands 20.

The variable distribution of silicone in the different regions of the matrix 22 of strands 20 results in the different regions containing different strand densities, which may be adapted to provide the resultant garment component with specific stretch properties. For example, the strand density at the underband of the brassiere may be increased to increase the rigidity of the underband, and/or the strand density at the cup elements of the brassiere may be decreased to increase the flexibility of the cup elements.

A method of forming a brassiere according to a fifteenth embodiment of the invention is illustrated in Figure 10.

The method of forming the brassiere of Figure 10 is similar to the method of forming the brasserie 10 of Figure 1 , except that, in the method of forming the brassiere of Figure 10, a respective yarn 400 is incorporated into each extruded strand 20 of silicone prior to the step of curing the silicone so as to form the brassiere.

To incorporate the respective yarn 400 into each extruded strand 20 of silicone, a yarn source 402 is positioned by the extruder head 404 to allow a yarn 400 to be laid into each strand 20 of silicone undergoing extrusion. Each yarn 400 then sinks into the corresponding strand 20 of silicone so as to become embedded. The extrusion of successive strands 20 over and across previous strands 20 causes each embedded yarn 400 to be further embedded into the resultant matrix 22 of strands 20. Subsequent curing of the silicone, for example using a laser, secures each yarn 400 embedded in the resultant matrix 22 of strands 20.

Such incorporation of yarn 400 into each extruded strand of silicone 22 not only improves the structural integrity and strength of the resultant brassiere whilst retaining the flexibility of the resultant brassiere, but also prevents over-stretch of the extruded silicone so as to prevent it from reaching a degree of extension that would normally cause snapping or breakage. The type of yarn 400 used in the method of forming a brassiere of Figure 10 may vary depending on the desired properties of the resultant brassiere. For example, each yarn 400 may be selected from a group including a crimped-on yarn, a textured yarn, a non- elastic yarn, an elastomeric yarn and a flat yarn.

It will be appreciated that the method of forming a brassiere of Figure 10 may be combined with each of the other embodiments described hereinabove. It is envisaged that, in other embodiments, another type of apparatus, other than a printer, may be used to extrude strands of liquid polymer to form the matrix of strands.

It is envisaged that, in other embodiments of the invention, other types of liquid polymers may be used to form the matrix of strands. It is further envisaged that, in other embodiments of the invention, a coloured liquid polymer may be used to form the matrix of strands, thus adding colour to the resultant brassiere.

It is also envisaged that, in other embodiments of the invention, antimicrobial material may be incorporated into the matrix 22 of strands 20.

It will be appreciated that the brassieres and glove in each of the aforementioned embodiments were merely chosen to help illustrate the working of the invention, and that the method according to the invention may be used to form other types of garments.

Claims

1. A method of forming a structural component for a wearable item such as a garment or footwear, the method comprising the steps of:

2. A method of forming a structural component according to Claim 1 wherein successive strands are laid over and across previous strands so as to define a plurality of layers of strands created so as to overlay one another and thereby form a multi-layered structure, the strands in each layer being laid over and across each other to define an open network of interconnected strands, and adjacent layers being created so that openings therein are offset relative to each other to define tortuous paths through the solidified network of strands following curing or setting of the liquid polymer.

3. A method of forming a structural component according to Claim 2 further including the step of introducing a barrier layer between at least two layers of strands during formation of the multi-layered structure.

4. A method of forming a structural component according to Claim 3 wherein the step of introducing a barrier layer between at least two layers of strands during formation of the multi-layered structure involves laying a sheet of fabric or other material between the layers of strands during the step of extruding the strands of liquid polymer.

5. A method of forming a structural component according to Claim 3 wherein the step of introducing a barrier layer between at least two layers of strands during formation of the multi-layered structure involves extruding a plurality of strands of liquid polymer onto one of the layers of strands such that successive strands are laid over and across previous strands to define a closed network of interconnected strands having no openings therein before extruding the other of the layers of strands over the barrier layer.

6. A method of forming a structural component according to any one of Claims 2 to 5 wherein the solidified network of strands following curing or setting of the liquid polymer forms a multi-layered sole for an item of footwear.

5 7. A method of forming a structural component according to any one of the preceding claims wherein successive strands are laid over and across previous strands so as to define a plurality of layers of strands created so as to overlay one another and thereby form a multi-layered structure, the strands in each layer being laid over and across each otherto define a grid structure, and adjacent layers being created so that the grid structures o are offset relative to each other and define a woven pattern effect following curing or setting of the liquid polymer.

8. A method of forming a structural component according to any one of the preceding claims wherein the support includes a three-dimensionally shaped form or mould and the5 step of extruding strands of liquid polymer to form an interconnected network of strands includes extruding strands of liquid polymer over the form or into the mould so that, following curing or setting of the liquid polymer, the solidified network of strands has a three-dimensional shape defined by the shape of the form or the mould. 0

9. A method of forming a structural component according to any one of Claims 1 to 7 wherein the support is substantially flat and the step of curing or setting the liquid polymer involves partially curing or setting the liquid polymer before laying the interconnected network of strands over a form or into a mould and then completing the step of curing or setting the interconnected network of strands so that the solidified network of strands has5 a three-dimensional shape defined by the shape of the form or the mould.

10. A method of forming a structural component according to any one of the preceding claims further including the step of moulding or re-moulding the shape of the solidified network of strands following curing or setting of the liquid polymer.

0

11. A method of forming a structural component according to any one of the preceding claims further including the step of configuring a controller to control movement of one or more extrusion heads relative to the support so as to extrude strands of liquid polymer onto the support in a predetermined pattern so as to form a solidified network of strands5 having a predetermined shape and configuration following curing or setting of the liquid polymer.

12. A method of forming a structural component according to Claim 11 wherein the controller is further configured to control the rate at which liquid polymer is extruded from the or each extrusion head during movement of the respective extrusion head relative to the support so as to control the cross-sectional size of the strands of liquid polymer extruded onto the support during movement of the respective extrusion head.

13. A method of forming a structural component according to Claim 12 wherein the controller is configured to control the rate of extrusion of liquid polymer from the or each extrusion head is controlled relative to the speed of movement of the extrusion head relative to the support so as to draw out and stretch the strands of liquid polymer and thereby minimise the cross-sectional size of the strands of liquid polymer extruded onto the support.

14. A method of forming a structural component according to any one of the preceding claims wherein the elastomeric polymer is a thermoset material chosen from the group consisting of silicone and acrylic.

15. A method of forming a structural component according to Claim 14 wherein the elastomeric polymer is a two-component liquid silicone rubber consisting of A and B components of MOMENTIVE LSR 2650 mixed in a ratio A:B of 40:60.

16. A method of forming a structural component according to Claim 14 or Claim 15 further including the step of spraying the solidified network of strands with a top coat so as to produce a predetermined finish on the surface of the solidified network of strands.

17. A method of forming a structural component according to Claim 16 wherein the top coat is a two-component liquid silicone rubber consisting of A and B components of MOMENTIVE LSR top-coat HE mixed in a ratio A:B of 50:50.

18. A method of forming a structural component according to any one of Claims 1 to 13 wherein the liquid polymer is a thermoplastic material, preferably nylon.

19. A method of forming a structural component according to any one of the preceding claims wherein an additive is mixed with the liquid polymer prior to the step of extruding strands of liquid polymer onto the support.

20. A method of forming a structural component according to Claim 19 wherein the additive includes one or more chosen from the group consisting of a perfume, a scent, a colour, decorative particles and an anti-microbial agent.

21. A method of forming a structural component according to Claim 19 wherein the additive includes a coloured pigment suspended in a silicone oil.

22. A method of forming a structural component according to any one of Claims 1 to 19 further including the step of spraying the solidified network of strands with an anti- microbial agent.

23. A method of forming a structural component according to any one of the preceding claims further including the step of laying a garment or footwear accessory onto the support before or during the step of extruding strands of liquid polymer onto the support so as to embed the garment or footwear accessory into the solidified network of strands following curing or setting of the liquid polymer.

24. A method of forming a structural component according to Claim 17 wherein the garment or footwear accessory is chosen from the group consisting of fastening elements, clasps, hooks, buttons, decorative elements, support elements, shoe lace sockets and shoe lace rings.

25. A method of forming a structural component according to any one of the preceding claims wherein the solidified network of strands defines a garment net and the method further includes the step of arranging edges of the garment net relative to each other and gluing together adjacent edges of the garment net with a silicone bead so as to produce a finished garment.

26. A method of forming a structural component according to any one of Claims 1 to 5 and 7 to 24 wherein the step of extruding strands of liquid polymer onto the support creates an interconnected network of strands arranged such that the solidified network of strands following curing or setting of the liquid polymer forms an entire garment.

27. A method of forming a structural component according to Claim 25 or Claim 26 wherein the garment is a brassiere, basque or other garment including breast cup elements.

28. A method of forming a structural component according to any one of Claims 1 to 24 wherein the step of extruding strands of liquid polymer onto the support creates a blank for a footwear upper, the blank being shaped either before, during or after curing or setting to produce a three-dimensionally shaped footwear upper.

29. A method of forming a structural component according to Claim 28 wherein the footwear upper is a moulded training shoe upper.

30. A method of forming a structural component according to Claim 29 further including the step of gluing the moulded training shoe upper onto a rubber sole.

31. A method of forming a structural component according to any one of the preceding claims wherein the solidified network of strands has a two-dimensional shape and the method further includes the step of introducing at least one gap into the solidified network of strands, the or each gap being arranged in the solidified network of strands to permit reconfiguration of the solidified network of strands to have a three-dimensionally shaped structure.

32. A method of forming a structure component according to Claim 31 wherein the step of introducing at least one gap into the solidified network of strands includes extruding strands of liquid polymer onto the support so as to form at least one gap in the solidified network of strands following curing or setting of the liquid polymer and/or removing a portion of the solidified network of strands after curing or setting of the liquid polymer.

33. A method of forming a structural component according to any one of the preceding claims further including the step of arranging a layer of fabric on the support and extruding strands of liquid polymer onto the layer of fabric so that the strands of liquid polymer form an interconnected network of strands on the layer of fabric and create a fabric component including a solidified network of strands mounted on the layer of fabric following the step of curing or setting the liquid polymer.

34. A method of forming a structural component according to Claim 33 when dependent from Claim 8, the method further including the step of arranging a layer of fabric over the form or in the mould prior to the step of extruding strands of liquid polymer over the form or into the mould.

35. A method of forming a structural component according to any one of the preceding claims further including the step of arranging a layer of fabric over the interconnected network of strands before completion of the curing or setting of the liquid polymer so as to adhere the layer of fabric to the interconnected network of strands to create a fabric component including a solidified network of strands mounted on the layer of fabric following completion of the step of curing or setting the liquid polymer, the fabric component having a two-dimensionally or three-dimensionally shaped structure.

36. A method of forming a structural component according to any of Claims 33 to 35 further including the step of moulding or re-moulding the shape of the fabric component following curing or setting of the liquid polymer.

37. A method of forming a structural component according to any one of the preceding claims wherein the support is heated and the strands of liquid polymer are extruded onto the heated support.

38. A method of forming a structural component according to any one of the preceding claims wherein the step of curing the liquid polymer involves exposing the strands of liquid polymer to a source of radiation, preferably a laser, during or subsequent to the step of extruding the strands of liquid polymer onto the support to form the interconnected network of strands.

39. A method of forming a structural component according to any one of the preceding claims including the step of extruding a first layer of liquid polymer strands onto the support and curing or setting the first layer of liquid polymer strands, followed by the step of simultaneously extruding a second layer of liquid polymer strands onto the solidified network of strands formed by the first layer of liquid polymer strands and curing or setting part or all of the second layer of liquid polymer strands.

40. A method of forming a structural component according to any one of the preceding claims including the step of allowing overlaying extruded strands of liquid polymer to merge with each other prior to the step of curing or setting the liquid polymer so as to form the solidified network of strands having a two-dimensionally or three-dimensionally shaped structure.

41. A method of forming a structural component according to any one of the preceding claims including the steps of extruding a first layer of liquid polymer strands and curing or setting the first layer of liquid polymer strands, arranging a divider element to cover part of the solidified network of strands formed from the first layer of liquid polymer strands, extruding a second layer of liquid polymer strands onto the divider element and the uncovered part of the solidified network of strands formed from the first layer of liquid polymer strands, and curing or setting the extruded second layer of liquid polymer strands.

42. A method of forming a structural component according to Claim 41 wherein the solidified network of strands formed from the second layer of liquid polymer strands adhere to the divider element.

43. A method of forming a structural component according to Claim 42 further including the step of dissolving the divider element after curing or setting of the second layer of liquid polymer strands.

44. A method of forming a structural component according to any one of the preceding claims further including the step of incorporating a or a respective yarn into each extruded strand of liquid polymer prior to the step of curing or setting the liquid polymer so as to embed the or each yarn within the solidified network of strands following curing or setting of the liquid polymer.

45. A method of forming a structural component according to Claim 44 wherein the or each yarn is selected from a group consisting of a crimped-on yarn, a textured yarn, a non-elastic yarn, an elastomeric yarn and a flat yarn.

46. A method of forming a structural component according to any one of the preceding claims wherein the step of extruding strands of liquid polymer onto the support to form an interconnected network of strands includes extruding strands of at least two different elastomeric polymers in liquid form so that, following curing or setting of the different liquid polymers, the different liquid polymers form different regions of the solidified network of strands and the different regions of the solidified network of strands exhibit differing degrees of stretch.

47. A method of forming a structural component according to Claim 46 wherein the different liquid polymers include at least one thermoset material and at least one thermoplastic material such that, following curing or setting of the different liquid polymers, regions of thermoset material are interconnected by regions of thermoplastic material.

48. A method of forming a structural component according to any one of the preceding claims wherein the step of extruding strands of liquid polymer onto the support to form the interconnected network of strands includes a sub-step of extruding a first layer of liquid polymer strands onto the support and a sub-step of extruding at least one second layer of liquid polymer strands onto the first layer of liquid polymer strands so that adjacent layers of liquid polymer strands have different orientations.

49. A method of forming a structural component according to Claim 48 wherein the different orientations of the adjacent layers of liquid polymer strands are arranged so that the solidified network of strands created following curing or setting of the liquid polymer exhibits differing degrees of stretch in different stretch directions.

50. A method of forming a structural component according to any one of the preceding claims wherein the step of extruding strands of liquid polymer onto the support to form the interconnected network of strands includes varying the distribution of liquid polymer in different regions of the interconnected network of strands.

51. A method of forming a structural component according to Claim 50 further including the step of varying the numbers of extruded strands of liquid polymer in the different regions of the interconnected network of strands and/or varying a rate of extrusion of the strands of liquid polymer when varying the distribution of liquid polymer in different regions of the interconnected network of strands.

52. A method of forming a structural component according to any one of the preceding claims further including the step of flocking extruded strands of liquid polymer.

53. A method of forming a structural component according to Claim 52 further including the step of extruding additional strands of liquid polymer over the flocked strands of liquid polymer so to form an interconnected network of strands with a composite structure defined by flock and liquid polymer.

54. A method of forming a structural component according to any one of the preceding claims further including the step of removing at least one selected portion of the solidified network of strands to form a decorative element in or on the solidified network of strands and/or to finish an edge of the solidified network of strands.

55. A method according to Claim 54 wherein the step of removing at least one selected portion of the solidified network of strands includes using a radiation source, preferably a laser, to remove the or each selected portion.

56. A cloth-like sheet comprising a plurality of strands of an elastomeric polymer arranged and cured to define a solidified network of strands.

57. A cloth-like sheet according to Claim 56 wherein the elastomeric polymer is MOMENTIVE LSR 2650.

58. A cloth-like sheet according to Claim 56 or Claim 57 further including a top coat applied to the solidified network of strands.

59. A cloth-like sheet according to Claim 58 wherein the coating is MOMENTIVE LSR top-coat HE.

60. A cloth-like sheet according to any one of Claims 56 to 59 further including an anti-microbial coating applied to the solidified network of strands.

61. A cloth-like sheet according to any one of Claims 56 to 60 further including a garment or footwear accessory embedded in the solidified network of strands.

62. A cloth-like sheet according to Claim 61 wherein the garment or footwear accessory is chosen from the group consisting of fastening elements, clasps, hooks, buttons, decorative elements, support elements, shoe lace sockets and shoe lace rings.

63. A cloth-like sheet according to any one of Claims 56 to 62 wherein the solidified network of strands is shaped and configured to define a garment blank.

64. A cloth-like sheet according to any one of Claims 56 to 62 wherein the solidified network of strands is shaped and configured to define a garment.

65. A cloth-like sheet according to Claim 64 wherein the garment is a brassiere, basque or other garment including breast cup elements.

66. A cloth-like sheet according to any one of Claims 56 to 62 wherein the solidified network of strands is shaped and configured to define a shaped footwear upper

67. A cloth-like sheet according to Claim 66 wherein the shaped footwear upper is a moulded training shoe upper.

68. A computer readable medium comprising computer program code stored thereon, the computer readable medium and computer program code being configured to, when run on at least one processor, perform at least the method of forming a structural component according to any one of Claims 1 to 55.