The present invention is directed to a shaped soft goods article that is unitary non-woven material having at least one three-dimensional shape. The article includes a first region substantially formed of a first formula and a second region substantially formed of a second formula. Between the first and second regions, there is an intermingling region that includes at least some of the first formula and the second formula. 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; however, the first and second formulas differ in at least one characteristic. An intermingling region exists where the first region (and first formula) intermingle with the second region (and second formula) meet.
D04H 5/10 - Non-tissés formés de mélanges de fibres relativement courtes et de fils ou de matériaux filamenteux similaires de bonne longueur caractérisés par la méthode de formation des voiles ou couches, p. ex. par réorientation des fibres ou fils autrement que dans un plan, p. ex. de manière tubulaire
2.
SOFT GOODS FROM A SYSTEM OF MOLDING AND PRESSING USING A SLURRY CONTAINING FIBERS WITH A SECOND ELEMENT AT LEAST PARTIALLY EMBEDDED THEREIN
The present invention discloses a shaped soft goods article that includes a first material, and second element at least partially embedded therein. The first material is a unitary non-woven material having at least one three-dimensional feature that is made from a slurry containing 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 second element can be functional or decorative.
B29C 70/68 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts en incorporant ou en surmoulant des parties préformées, p. ex. des inserts ou des couches
B29C 70/42 - Façonnage ou imprégnation par compression pour la fabrication d'objets de longueur définie, c.-à-d. d'objets distincts
B29K 105/08 - Présentation, forme ou état de la matière moulée contenant des agents de renforcement, charges ou inserts de grande longueur, p. ex. ficelles, mèches, mats, tissus ou fils
The present invention discloses a shaped soft goods article that includes a first material, and second element at least partially embedded therein. The first material is a unitary non-woven material having at least one three-dimensional feature that is made from a slurry containing 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 second element can be functional or decorative.
B29C 70/24 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts comprenant uniquement des renforcements, p. ex. matières plastiques auto-renforçantes des renforcements fibreux uniquement caractérisées par la structure des renforcements fibreux utilisant des fibres de grande longueur, ou des fibres continues orientées dans au moins trois directions formant une structure tridimensionnelle
D04H 3/12 - Non-tissés formés uniquement ou principalement de fils ou de matériaux filamenteux similaires de bonne longueur caractérisés par la méthode de renforcement ou de consolidation avec filaments ou fils retenus ensemble par des agents de liage chimiques ou thermo-activables, p. ex. adhésifs, appliqués ou incorporés sous une forme liquide ou solide
B29C 43/36 - Moules pour la fabrication d'objets de longueur définie, c.-à-d. d'objets séparés
B29C 43/00 - Moulage par pressage, c.-à-d. en appliquant une pression externe pour faire couler la matière à moulerAppareils à cet effet
D21J 3/00 - Fabrication d'articles par pressage d'une pâte fibreuse humide ou de papier mâché, entre des moules
4.
A UNITARY SHAPED SOFT GOODS ARTICLE HAVING VARIABLE PHYSICAL CHARACTERISTICS BETWEEN DIFFERENT REGIONS
The present invention is directed to a shaped soft goods article that is unitary non-woven material having at least one three-dimensional shape. The article includes a first region substantially formed of a first formula and a second region substantially formed of a second formula. Between the first and second regions, there is an intermingling region that includes at least some of the first formula and the second formula. 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; however, the first and second formulas differ in at least one characteristic. An intermingling region exists where the first region (and first formula) intermingle with the second region (and second formula) meet.
The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.
B29C 70/24 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts comprenant uniquement des renforcements, p. ex. matières plastiques auto-renforçantes des renforcements fibreux uniquement caractérisées par la structure des renforcements fibreux utilisant des fibres de grande longueur, ou des fibres continues orientées dans au moins trois directions formant une structure tridimensionnelle
B29C 41/10 - Revêtement d'une forme, d'un noyau ou d'un autre support par pulvérisation ou fluidisation, p. ex. pulvérisation de poudre par fluidisation
B29C 70/68 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts en incorporant ou en surmoulant des parties préformées, p. ex. des inserts ou des couches
B32B 3/26 - Produits stratifiés comprenant une couche ayant des discontinuités ou des rugosités externes ou internes, ou une couche de forme non planeProduits stratifiés comprenant une couche ayant des particularités au niveau de sa forme caractérisés par une couche continue dont le périmètre de la section droite a une allure particulièreProduits stratifiés comprenant une couche ayant des discontinuités ou des rugosités externes ou internes, ou une couche de forme non planeProduits stratifiés comprenant une couche ayant des particularités au niveau de sa forme caractérisés par une couche comportant des cavités ou des vides internes
D04H 3/12 - Non-tissés formés uniquement ou principalement de fils ou de matériaux filamenteux similaires de bonne longueur caractérisés par la méthode de renforcement ou de consolidation avec filaments ou fils retenus ensemble par des agents de liage chimiques ou thermo-activables, p. ex. adhésifs, appliqués ou incorporés sous une forme liquide ou solide
D06M 15/263 - Composés macromoléculaires obtenus par des réactions faisant intervenir uniquement des liaisons non saturées carbone-carbone d'acides carboxyliques non saturésLeurs sels ou esters
The present invention is a method for forming a fibrous molded article that includes providing a aqueous slurry containing a plurality of fibers, providing the slurry into a dehydration chamber to remove at least some of the amount of water from the slurry to achieve an intermediate form, removing the fibrous intermediate form from the dehydration chamber and placing the fibrous intermediate form in a press having a first mold portion and a second mold portion wherein at least one of the first or second mold portions includes a contour, applying at least one of heat and pressure to the press such that at least fiber to fiber bonding or chemical cross-linking of fibers occurs, and removing the three-dimensional solid fibrous molded part from the press.
The present invention discloses a method and apparatus for molding a fibrous molded article. An aqueous slurry that contains an amount of water and a plurality of fibers is added to the molding apparatus. First and second molding screens are positioned on a first pressing unit and a second pressing unit, respectively, and include a plurality of openings. The first and second molding screens can include secondary relief features. A pressing chamber sleeve slidably engages with the first pressing unit and the second pressing unit to ensure proper alignment during molding operation. The first and second molding screens at least partially form a void that is intended to receive an amount of the aqueous slurry. The apparatus includes a heat and pressure source that removes at least some of the water from the aqueous slurry and bonds the fibers to one another resulting in the fibrous molded article.
D21J 3/00 - Fabrication d'articles par pressage d'une pâte fibreuse humide ou de papier mâché, entre des moules
B29C 70/24 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts comprenant uniquement des renforcements, p. ex. matières plastiques auto-renforçantes des renforcements fibreux uniquement caractérisées par la structure des renforcements fibreux utilisant des fibres de grande longueur, ou des fibres continues orientées dans au moins trois directions formant une structure tridimensionnelle
D04H 3/12 - Non-tissés formés uniquement ou principalement de fils ou de matériaux filamenteux similaires de bonne longueur caractérisés par la méthode de renforcement ou de consolidation avec filaments ou fils retenus ensemble par des agents de liage chimiques ou thermo-activables, p. ex. adhésifs, appliqués ou incorporés sous une forme liquide ou solide
10.
SOFT GOODS FORMED FROM A FIBER LIQUID SLURRY HAVING SURFACE FEATURES, AND METHODS FOR MAKING THE SAME
The present invention discloses a molded article having a surface feature created by a light reactive agent interacting with light from a light source, and a method for making the same. The article is molded from a slurry comprised of an aqueous solution that includes a plurality of fibers and a light reactive agent. The slurry is molded into a three-dimensional solid fibrous molded part. The solid fibrous molded part is exposed to a light source such that the light reacts with the light reactive agent to create at least one surface feature. The surface feature can be, for example, a texture or a color change.
D21J 3/00 - Fabrication d'articles par pressage d'une pâte fibreuse humide ou de papier mâché, entre des moules
B29C 70/24 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts comprenant uniquement des renforcements, p. ex. matières plastiques auto-renforçantes des renforcements fibreux uniquement caractérisées par la structure des renforcements fibreux utilisant des fibres de grande longueur, ou des fibres continues orientées dans au moins trois directions formant une structure tridimensionnelle
D04H 3/12 - Non-tissés formés uniquement ou principalement de fils ou de matériaux filamenteux similaires de bonne longueur caractérisés par la méthode de renforcement ou de consolidation avec filaments ou fils retenus ensemble par des agents de liage chimiques ou thermo-activables, p. ex. adhésifs, appliqués ou incorporés sous une forme liquide ou solide
11.
FORMING A CONTOURED FINISHED SOFT GOOD FROM A FLATTER FIBROUS INTERMEDIATE PART
The present invention is a method for forming a fibrous molded article that includes providing a aqueous slurry containing a plurality of fibers, providing the slurry into a dehydration chamber to remove at least some of the amount of water from the slurry to achieve an intermediate form, removing the fibrous intermediate form from the dehydration chamber and placing the fibrous intermediate form in a press having a first mold portion and a second mold portion wherein at least one of the first or second mold portions includes a contour, applying at least one of heat and pressure to the press such that at least fiber to fiber bonding or chemical cross-linking of fibers occurs, and removing the three-dimensional solid fibrous molded part from the press.
The present invention discloses a molded article having a surface feature created by a light reactive agent interacting with light from a light source, and a method for making the same. The article is molded from a slurry comprised of an aqueous solution that includes a plurality of fibers and a light reactive agent. The slurry is molded into a three-dimensional solid fibrous molded part. The solid fibrous molded part is exposed to a light source such that the light reacts with the light reactive agent to create at least one surface feature. The surface feature can be, for example, a texture or a color change.
C08J 3/24 - Réticulation, p. ex. vulcanisation, de macromolécules
B29C 41/16 - Coulée de suspensions, c.-à-d. application d'une suspension ou d'un coulis sur une surface perforée, poreuse ou absorbante avec élimination du liquide par drainage
B29C 41/42 - Démoulage des objets formés, des moules, des noyaux ou d'autres supports
The present invention discloses a method and apparatus for molding a fibrous molded article. An aqueous slurry that contains an amount of water and a plurality of fibers is added to the molding apparatus. First and second molding screens are positioned on a first pressing unit and a second pressing unit, respectively, and include a plurality of openings. The first and second molding screens can include secondary relief features. A pressing chamber sleeve slidably engages with the first pressing unit and the second pressing unit to ensure proper alignment during molding operation. The first and second molding screens at least partially form a void that is intended to receive an amount of the aqueous slurry. The apparatus includes a heat and pressure source that removes at least some of the water from the aqueous slurry and bonds the fibers to one another resulting in the fibrous molded article.
The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.
The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.
The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.
B29C 41/10 - Revêtement d'une forme, d'un noyau ou d'un autre support par pulvérisation ou fluidisation, p. ex. pulvérisation de poudre par fluidisation
B29C 70/24 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts comprenant uniquement des renforcements, p. ex. matières plastiques auto-renforçantes des renforcements fibreux uniquement caractérisées par la structure des renforcements fibreux utilisant des fibres de grande longueur, ou des fibres continues orientées dans au moins trois directions formant une structure tridimensionnelle
B29C 70/68 - Façonnage de matières composites, c.-à-d. de matières plastiques comprenant des renforcements, des matières de remplissage ou des parties préformées, p. ex. des inserts en incorporant ou en surmoulant des parties préformées, p. ex. des inserts ou des couches
B32B 3/26 - Produits stratifiés comprenant une couche ayant des discontinuités ou des rugosités externes ou internes, ou une couche de forme non planeProduits stratifiés comprenant une couche ayant des particularités au niveau de sa forme caractérisés par une couche continue dont le périmètre de la section droite a une allure particulièreProduits stratifiés comprenant une couche ayant des discontinuités ou des rugosités externes ou internes, ou une couche de forme non planeProduits stratifiés comprenant une couche ayant des particularités au niveau de sa forme caractérisés par une couche comportant des cavités ou des vides internes
D04H 1/732 - Non-tissés formés uniquement ou principalement de fibres coupées ou autres fibres similaires relativement courtes caractérisés par la méthode de formation des voiles ou couches, p. ex. par la réorientation des fibres les fibres étant disposées au hasard par courant de fluide, p. ex. flux d'air
D04H 3/12 - Non-tissés formés uniquement ou principalement de fils ou de matériaux filamenteux similaires de bonne longueur caractérisés par la méthode de renforcement ou de consolidation avec filaments ou fils retenus ensemble par des agents de liage chimiques ou thermo-activables, p. ex. adhésifs, appliqués ou incorporés sous une forme liquide ou solide
D06M 15/263 - Composés macromoléculaires obtenus par des réactions faisant intervenir uniquement des liaisons non saturées carbone-carbone d'acides carboxyliques non saturésLeurs sels ou esters
