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WO2024226812A2 - Article de marchandise souple de forme unitaire possédant des caractéristiques physiques variables entre différentes régions - Google Patents

Article de marchandise souple de forme unitaire possédant des caractéristiques physiques variables entre différentes régions Download PDF

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Publication number
WO2024226812A2
WO2024226812A2 PCT/US2024/026290 US2024026290W WO2024226812A2 WO 2024226812 A2 WO2024226812 A2 WO 2024226812A2 US 2024026290 W US2024026290 W US 2024026290W WO 2024226812 A2 WO2024226812 A2 WO 2024226812A2
Authority
WO
WIPO (PCT)
Prior art keywords
formula
region
soft goods
goods article
synthetic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/026290
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English (en)
Other versions
WO2024226812A3 (fr
Inventor
Maria INTSCHER-OWRANG
Philip Cohen
Joseph Miller
Juliana JARDIM
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SimplifyFiber Inc
Original Assignee
SimplifyFiber Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SimplifyFiber Inc filed Critical SimplifyFiber Inc
Publication of WO2024226812A2 publication Critical patent/WO2024226812A2/fr
Publication of WO2024226812A3 publication Critical patent/WO2024226812A3/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/08—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns
    • D04H5/10—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns otherwise than in a plane, e.g. in a tubular way
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/03—Shape features
    • D10B2403/033—Three dimensional fabric, e.g. forming or comprising cavities in or protrusions from the basic planar configuration, or deviations from the cylindrical shape as generally imposed by the fabric forming process

Definitions

  • the field of the invention is apparatus and method for molding a three- dimensional unitary soft goods article and, more specifically, for molding a three-dimensional unitary soft goods article from at least two different aqueous slurries that each contain a plurality of fibers.
  • a shaped soft goods article is a unitary non-woven material having at least one three-dimensional shape.
  • the article includes at least a first region substantially comprised of a first formula and a second region substantially comprised of a second formula.
  • An intermingling region that includes at least some of the first formula and the second formula is formed where the first region and second region generally meet and the first and second formulas intermingle.
  • the first and second formulas are both comprised of at least one type of natural or synthetic fibers and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex. The first and second are different from each other in at least one characteristic.
  • the first formula and the second formula differ in any manner, including visually (e g., colorant) and/or structurally (e.g., the first formula may include a high percentage of fibers).
  • the article may include a third (or more) region comprised of a third formula.
  • the third formula is different from at least one of the first and second formula.
  • One advantage of the present invention is the ability to design a unitary fibrous molded part that can vary in characteristics from region to region throughout without the requirement of secondary operations.
  • Another advantage of the present invention is the ability to design a unitary fibrous molded part that can visually vary from region to region throughout without the requirement of secondary operations.
  • a further advantage of the present invention is the ability to design a unitary fibrous molded part that can vary structurally from region to region throughout without the requirement of secondary operations.
  • FIG. 1 shows a diagrammatic set up for adding at least some of the desired ingredients of the slurry into a mixer
  • FIG. 2 shows a diagrammatic set up for mixing the slurry, providing an amount of a single formula of the slurry into a molding form, and removing the solid fibrous molded part from the molding form;
  • FIG. 3 shows a form into which a first formula and a second formula are being poured
  • FIG. 3 A shows a robotic arm agitating the first and second formulas in the form
  • FIG. 4 shows a solid fibrous molded part comprising a region created from a first formula and a second region created from a second formula being placed into a press;
  • FIG. 5 shows a shoe upper attached to a shoe sole wherein the shoe upper was at least partially formed in the press shown in FIG. 4;
  • FIG. 6 shows a form having at least two dividers wherein a first formula is poured into a first region, a second formula is poured into a second region, and a third formula is poured into a third region;
  • FIG. 7 shows a shoe upper attached to a shoe sole wherein the shoe upper was at least partially formed in the press shown in FIG. 4;
  • FIG. 8 shows a handbag having at least one region comprised of a first formula and a second region comprised of a second formula.
  • the present invention is an article 10 that includes at least a first region 11 comprised of a first formula 15 and second region 13 comprised of a second formula 17 wherein the first formula 15 differs from the second formula 17 in at least one physical characteristic (described infra.).
  • additional regions in the article can also be included wherein the additional regions (e.g., a third region 27) can be comprised of additional formulas (e.g., a third formulal9) wherein the third formula 19 (optionally) differs from the first and/or second formulas Associated apparatus and methods for making the article are also described herein.
  • Common articles formed using the methods and apparatus disclosed herein include, but are not limited to, footwear, clothing and various other apparel, -bags and various other accessories, automotive interior upholstery and parts, consumer goods, furniture upholstery, and soft medical products.
  • footwear include, but are not limited to, shoe uppers.
  • clothing articles include, but are not limited to, shirts, shorts, gowns and other medical clothing, dresses, skirts, pants, socks, vests, sweaters, scarves, hats, gloves, mittens, and undergarments.
  • Examples of bags include, but are not limited to, handbags, purses, backpacks, bookbags, satchels, clutches, travel cases, luggage and toiletry cases.
  • Examples of automotive interior parts include, but are not limited to, interior panels, interior trim, seat covers, floor mats, dashboard covers and steering wheel covers.
  • Examples of consumer goods include, but are not limited to, laptop/computer housings, soft circuit board coverings, phone cases, soft cleaning products and feminine hygiene products.
  • Examples of furniture upholstery include, but are not limited to, chair and couch coverings, and wall coverings or panels.
  • Examples of soft medical products include, but are not limited to, bandages and various other coverings, slings, and various other stabilization elements, to include soft goods for internal body use.
  • FIG. 8 shows the creation of a handbag having a first region 11 and a second region 13.
  • the present invention includes a solid molded fibrous part 14 that is formed from having at least a first region formed substantially from a first formula and a second region substantially formed from a second formula.
  • the first and second formulas are both aqueous slurry that includes a plurality of fibers 16
  • the first formula 15 is created by mixing a slurry 20 that can include natural fibers, semi-synthetic fibers, synthetic fibers or a combination thereof.
  • Natural fibers include wood fibers, plant fibers, fungus (e.g., mycelium), and animal fibers.
  • Wood fibers include, but are not limited to, hardwood and/or softwood fibers, bleached and/or unbleached, virgin and/or recycled.
  • Plant-based fibers can include, but are not limited to, cotton, flax, hemp, jute, ramie, bamboo, sisal, abaca, kapok, coir, and general agricultural waste.
  • Animal fibers can include, but are not limited to, wool, silk, cashmere, alpaca, llama, mohair, yak, camel hair, qiviut, vicuna, angora, and horsehair.
  • the semi-synthetic fibers can include, but are not limited to, cellulose- based fibers such as rayon, viscose, modal, Tencel, Lyocell, and acetate.
  • Synthetic fibers can include, but are not limited to, polyester, nylon, olefin, spandex/elastane, acrylic, PVC, aramid, microfiber. Additionally, sustainable synthetic fibers such as polylactic acid (PLA) fibers and polyhydroxyalkanoates (PHA) fibers can be used.
  • PVA polylactic acid
  • PHA polyhydroxyalkanoates
  • One or more fiber types are added and any other ingredient, such as, but not limited to, biobased and/or synthetic molecules/polymers, and additives can be added to the material to be used, either before formation (while in a fluid state), after the material is dried or after the item (or part of the item) is formed.
  • Biobased molecules/polymers can be added as binding agents and/or retention agents in order to enhance the wet and dry strength of the solid fibrous molded part 14.
  • biobased molecules/polymers include, but are not limited to, chitosan, starches, ionic starches, cellulosic materials such as, but not limited to, carboxymethylcellulose, nanofibrillated cellulose, nanocellulose, natural rubber latex, collagen, gelatine, alginate, polylactic acid, polyglycolic acid, and polyhydroxyalkanoates.
  • synthetic molecules/polymers and synthetic molecules/polymers with a certain amount of biobased carbon can be used in the materials, such as, but not limited to, polyurethane emulsions, thermoplastic materials, and resins, such as polyaminoamide-epichlorohydrin (PAE) in order to improve mechanical strength.
  • PAE polyaminoamide-epichlorohydrin
  • FIG. 1 shows an exemplary set up where a series of ingredient sources 30 are in communication with the mixer that enable an amount of various ingredients to be provided (e.g., pumped or gravity fed) into the mixer 28, as desired.
  • a water source 32 and a source for fibers 16 are also provided for adding desired amounts of fiber 16 into the mixer 28.
  • the ingredients are mixed, generally until all ingredients are fully mixed and/or dispersed, and the slurry takes on the form of a mixture, foam, or a homogeneous fiber dispersion.
  • An example of the aforementioned slurry may contain, but is not limited to, the following content: water (20-99.99%), fibers (0.0075-60%), other additives (0.0025-20%).
  • FIGS. 2 and 4 once the desired ingredients are combined and mixed in the mixer 28, and the mixed slurry 20 can then be poured, pumped or gravity fed into a molding form 34.
  • FIG. 2 is provided as an exemplary figure depicting this process with a single formula.
  • the molding form 34 includes a first mold portion 36 and a second mold portion 38.
  • the first mold portion 36 includes a screen 40 with openings 42 that generally allow water to drain therethrough but retains the solid fibers.
  • the second mold portion 38 includes a desired two- or three-dimensional shape that is at least partially imparted onto the solid fibrous molded part 14.
  • FIG. 4 shows that a three-dimensional shape may be of particular utility in various applications.
  • the solid fibrous molded part 14 that exits the form 34 has one or more regions of increased thickness and, conversely, regions of reduced thickness in order to provide the desired physical characteristics (e.g., strength, toughness, flexibility, etc.) desired of the final product after pressing.
  • the screen 40 in the first mold portion may also have a two- or three- dimensional shape that is at least partially imparted onto the solid fibrous molded part 14.
  • heat and/or pressure may be applied to achieve fiber to fiber bonding, polymer to polymer bonding, and polymer to fiber bonding, as well as chemical cross-linking.
  • some or substantially all of the water is removed from the slurry 20.
  • the solid fibrous molded part 14 can be removed from the mold form 34 and, optionally, further dried.
  • the second formula 17 can be created using substantially the same process described above in connection with the first formula 15, provided that the second formula 17 includes at least one difference in visual, physical or chemical characteristics relative to the first formula 15.
  • the second formula 17 may have an increased (or decreased) strength/structural characteristic, different finish, different color, different environmental response reaction, texture and/or surface features, or different hardness/softness characteristics.
  • the second formula may include, e.g., a higher (or lower) fiber count, different fiber types, different reactive ingredients, different process additives and/or colorants.
  • FIGS. 3 and 6 depict a process wherein a form is provided, and more than one formula 15, 17 are provided into the form 34.
  • a first formula 15 and a second formula 17 are provided into the form 34 at generally opposed ends such that a first region 11 is substantially filled with the first formula 15 and a second regional 13 is substantially filled with the second formula 17.
  • the first region 11 and the second region 13 generally meet at an intermingling region 21 where the first formula 15 and the second formula 17 meet and intermingle.
  • the degree of intermingling can be, optionally, controlled. For example, and now referring to FIG.
  • a robotic arm 23 is shown agitating the first and second formulas 15, 17 together at or near the intermingling region 21.
  • the degree of intermingling between various slurry 20 formulas 15, 17 can also be at least be partially chemically by, for example, adjusting the viscosity, fiber composition, and/or pH to achieve the desired effect and final product.
  • the dispensing of the slurries 20 can also be automated through the use of, e.g., the robotic arm 23, as well.
  • the rate at which the various slurries 20 are provided in mold form 34 can also affect the intermingling of formulas 15,17. For example, increasing the rate of dispensing the slurries 20 into the mold form will generally increase the intermingling between the regions 11, 13, 27 and slower dispensing of the slurries 20 will generally decrease the intermingling between the regions 11, 13, 27.
  • FIG. 5 shows a form 34 having a series of dividers 25 that generally separate a series of regions 11, 13, 27.
  • Three formulas 15, 17, 19 are shown being provided to some or all of the regions 1 1, 13, 27 defined by the form 34 and the dividers 25.
  • the first, second and third formulas 15, 17, 19 are provided into the form 34 and, initially, the regions 11, 13, 27 are separated by dividers 25.
  • the dividers 25 Prior to fully the slurries 20 of the various formulas 15, 17, 19 setting (as described supra. ), the dividers 25 are removed.
  • the dividers 25 may be removed all at together or separately, quickly or slowly, depending on the physical characteristics of the various formulas and the designer’s desired effect of the final article 10.
  • the components to a slurry 20 for a first formula 15, including at least water 26, a single type of fiber or a plurality of fiber types 16, and additives are provided to a mixer 28.
  • the components are mixed until the slurry 20 is a mixture, foam, or a homogeneous suspension.
  • the components to a slurry 20 for a second formula 17, including at least water 26, a single type of fiber or a plurality of fiber types 16, and additives are provided to a mixer 28.
  • the second formula 17 differs from the first formula 15 in at least one characteristic.
  • the components are mixed until the slurry 20 is a mixture, foam, or a homogeneous suspension.
  • the components to a slurry 20 for a third formula 19 (or more), including at least water 26, a single type of fiber or a plurality of fiber types 16, and additives are provided to a mixer 28.
  • the third formula 17 optionally differs from the first formula 15 and/or second formula 17 in at least one characteristic.
  • the components are mixed until the slurry 20 is a mixture, foam, or a homogeneous suspension.
  • the slurries 20 of the first formula 15 the second formula 17 (and optional additional formulas) are then added to the molding form 34.
  • the molding form 34 may include dividers 25 separating the various regions 11, 13, 27 within the molding form 34. In embodiments lacking dividers, the slurries 20 will meet at intermingling region(s) 21. None, some, most, or all of the water (depending on final product material) from the slurries 20 is removed by, e.g., draining and/or drying, effectively dehydrating the substance during the process of converting the slurry 20 to a solid fibrous molded part 14.
  • heat and/or pressure can be applied to the mold form to further eliminate water from the slurry 20 and achieve, e g., fiber to fiber bonding, polymer to polymer bonding, and polymer to fiber bonding, as well as chemical cross-linking.
  • the dividers 25 are removed prior to completion of the bonding and formation of the solid fibrous molded part 14.
  • the solid fibrous molded part 14 After removal from the molding form 34, the solid fibrous molded part 14 that includes regions having different characteristics due to the differences in the formulas of the slurries utilized is, in some instances, permitted to continue to dry and/or subjected to an additional forming operation. Referring to FIG. 4 in particular, the solid fibrous molded part 14 may include regions of varied thickness.
  • the solid fibrous molded part 14 is then pressed (see e.g., FIG. 4) into the final desired shape of the article 10 (see e.g., FIGS. 5, 7 and 8) or affixed to additional items (e.g., shoe sole or handbag handle).
  • additional items e.g., shoe sole or handbag handle.
  • first region, second region, third region, etc. and first formula, second formula, third formula are intended to refer to corresponding elements during and after any forming processes.
  • the first formula is intended to the slurry comprised of the first formula as well as the portion of the article that is substantially formed from the first formula.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un article de marchandise souple façonné qui est un matériau non tissé unitaire possédant au moins une forme tridimensionnelle. L'article comprend une première région sensiblement formée d'une première formule et une seconde région sensiblement formée d'une seconde formule. Entre les première et seconde régions se trouve une région d'entremêlement qui comprend au moins une partie de la première formule et de la seconde formule. Les première et seconde formules sont toutes deux constituées d'au moins un type de fibres naturelles ou synthétiques et d'au moins l'un parmi des agents de réticulation, des adhésifs naturels et/ou synthétiques, des thermoplastiques biosourcés et/ou synthétiques, comprenant de la nanocellulose, et/ou du latex ; cependant, les première et seconde formules diffèrent dans au moins une caractéristique. Une région d'entremêlement existe où la première région (et la première formule) s'entremêlent avec la seconde région (et la seconde formule) et se rencontrent.
PCT/US2024/026290 2023-04-25 2024-04-25 Article de marchandise souple de forme unitaire possédant des caractéristiques physiques variables entre différentes régions Pending WO2024226812A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363461780P 2023-04-25 2023-04-25
US63/461,780 2023-04-25

Publications (2)

Publication Number Publication Date
WO2024226812A2 true WO2024226812A2 (fr) 2024-10-31
WO2024226812A3 WO2024226812A3 (fr) 2025-03-13

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PCT/US2024/026290 Pending WO2024226812A2 (fr) 2023-04-25 2024-04-25 Article de marchandise souple de forme unitaire possédant des caractéristiques physiques variables entre différentes régions

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WO (1) WO2024226812A2 (fr)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060061000A1 (en) * 2004-09-22 2006-03-23 Shih-Chien Chun Method for manufacturing a two-color and two-hardness EVA foamed sole
CA2800346A1 (fr) * 2010-05-18 2011-11-24 Montrail Corporation Chaussure a proprietes de reponse multiples
CN114073355B (zh) * 2017-06-01 2024-10-11 耐克创新有限合伙公司 利用泡沫颗粒制造物品的方法
US20190126580A1 (en) * 2017-10-31 2019-05-02 Saucony, Inc. Method and apparatus for manufacturing footwear soles
MX2024002601A (es) * 2021-09-01 2024-03-22 Braskem Sa Composiciones polimericas reticulables dinamicamente, articulos y sus procedimientos.

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US20240360605A1 (en) 2024-10-31

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