Formation of contoured finished soft articles from flatter fibrous intermediate members

Abstract

The present invention is a method for forming a fibrous molded article, the method comprising: providing an aqueous slurry comprising a plurality of fibers; providing the slurry into a dewatering chamber to remove at least some of an amount of water from the slurry to obtain an intermediate form; removing the fibrous intermediate form from the dewatering chamber and placing the fibrous intermediate form in a press having a first mold portion and a second mold portion, where at least one of the first mold portion or the second mold portion includes a profile; applying at least one of heat and pressure to the press such that at least fiber-to-fiber binding or fiber chemical crosslinking occurs; and removing the three-dimensional solid fibrous molded part from the press.

Description

[0001] Priority Declaration

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 425,768, filed on November 16, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The field of the present invention is an apparatus and method for molding three-dimensional objects, and more particularly for molding solid fiber three-dimensional articles from an aqueous slurry containing a plurality of fibers and a substantially flat or slightly contoured intermediate component, and then changing the shape of the molded fiber intermediate component to a second shape in a post-forming operation. Background Art

[0004] Current processes for forming soft goods, such as clothing, footwear (e.g., uppers), luggage, furniture, medical supplies, cleaning tools and consumables, toys, automotive interior components, housings and casings for consumer electronics, and other soft goods, are often wasteful and involve numerous steps. Within each manufacturing step is a separate, inefficient, and labor-intensive process, with materials often having to be transported between steps. Waste material (e.g., cut but unused cloth) is often simply discarded, adding to the waste in the process. Additionally, molds for making contoured objects are often expensive and require complex equipment that requires, for example, equipment with numerous moving parts. It has also been found that certain soft goods, especially those that are highly contoured, are assembled from numerous parts. It has also been found that contoured soft goods are often difficult to stack and expensive to ship. The present invention addresses these and other shortcomings in the prior art, as disclosed herein. Summary of the Invention

[0005] According to one aspect of the present invention, a method for forming a fiber molded product includes: providing an aqueous slurry containing a plurality of fibers; providing the slurry to a dewatering chamber to remove at least some of a certain amount of water from the slurry to obtain an intermediate form; removing the fiber intermediate form from the dewatering chamber and placing the fiber intermediate form in a press having a first mold part and a second mold part, wherein at least one of the first mold part or the second mold part includes a contour; applying at least one of heat and pressure to the press so that at least fiber-to-fiber bonding or chemical cross-linking of the fibers occurs; and removing the three-dimensional solid fiber molded part from the press.

[0006] According to another aspect of the present invention, the slurry is in the form of a mixture, a foam or a homogenized suspension after mixing.

[0007] According to a further aspect of the present invention, the pulp comprises at least one type of fiber selected from the group consisting of natural fibers, semi-synthetic fibers and synthetic fibers.

[0008] According to a still further aspect of the present invention, the pulp comprises at least one type of fiber selected from the group consisting of natural fibers, semi-synthetic fibers and synthetic fibers.

[0009] According to a still further aspect of the present invention, the pulp comprises more than one type of fibers selected from the group consisting of natural fibers, synthetic fibers, semi-synthetic fibers and synthetic fibers.

[0010] According to a further aspect of the invention, the slurry comprises bio-based molecules or polymers including, for example, chitosan, starch, ionic starch, cellulosic materials such as, but not limited to, carboxymethyl cellulose, nanofibrillated cellulose, nanocellulose; natural rubber latex, collagen, gelatin, alginate, polylactic acid, polyglycolic acid and / or polyhydroxyalkanoates.

[0011] According to a further aspect of the present invention, at least one of the first mould part and the second mould part comprises at least one of a contour, a texture, a pattern imparted onto the three-dimensional solid fibre moulding component.

[0012] One advantage of the present invention includes reducing the cost of the mold by making the mold flatter and requiring less material.

[0013] Another advantage of the present invention includes reducing the complexity of the mold assembly by reducing the need for detachable or flexible components, or reducing the number of parts in the mold.

[0014] Further advantages of the present invention include the ability to better stack partially manufactured articles together so that they can be shipped or stored prior to use.

[0015] These and other advantages will be apparent to those skilled in the art in view of this disclosure and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features of the present disclosure will be more readily understood from the following detailed description of various aspects of the present disclosure, taken in conjunction with the accompanying drawings which depict various embodiments of the present disclosure, in which:

[0017] Figure 1 shows a schematic arrangement for adding at least some of the desired ingredients of a slurry to a mixer;

[0018] Figure 2A One embodiment of a generally rectangular dewatering chamber intended to produce a substantially flat dewatered fibrous sheet is shown;

[0019] Figure 2B Another embodiment of a generally rectangular dewatering chamber intended to produce a contoured dewatered fibrous sheet is shown;

[0020] Figure 3 An image of a dehydrated flat sheet is shown;

[0021] Figure 4 shows a diagrammatic exploded view of one embodiment of a press chamber intended to press dewatered flat sheets into butterfly-shaped shoe uppers;

[0022] Figure 5 A diagrammatic view showing the steps of removing the butterfly-shaped upper from the press chamber and performing secondary operations;

[0023] Figure 6 is a photographic image of one example of an intermediate form of a shoe upper; and

[0024] Figure 7 is a photographic image of one example of an intermediate form being transformed into its final shape and attached to additional components to form a finished shoe. DETAILED DESCRIPTION

[0025] Now refer to Figures 1 to 7 The present invention is an article 10 comprising a three-dimensional solid fiber molded part 12 having at least one contour, and a method for making the same. The three-dimensional solid fiber molded part 12 is first formed into an intermediate shape 14 and then converted to its final shape in a secondary operation and optionally attached or otherwise connected to additional components. Common articles formed using the methods and apparatus disclosed herein include, but are not limited to, footwear, clothing and various other apparel, luggage and various other accessories, automotive interior trim and components, consumer goods, home furnishings, and soft medical products. Examples of footwear include, but are not limited to, shoe uppers. Examples of articles of clothing include, but are not limited to, shirts, shorts, gowns and other medical garments, dresses, skirts, pants, socks, vests, sweaters, scarves, hats, gloves, mittens, and underwear. Luggage includes, but is not limited to, handbags, wallets, backpacks, satchels, shoulder bags, and clutches. 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 products include, but are not limited to, laptop / computer cases, soft circuit board covers, phone cases, soft cleaning products, and feminine hygiene products. Examples of home furnishings include, but are not limited to, chair and sofa covers, and wall coverings or panels. Examples of soft medical products include, but are not limited to, bandages and various other covers, slings, and various other stabilizing elements, including soft items for internal use.

[0026] The present disclosure relates to forming a shoe upper according to the present invention; however, it will be understood by those skilled in the art that any of the above-described articles (or similar articles) may be made using the teachings herein without departing from the spirit or scope of the present invention. The above listing of articles is intended to be exemplary and not limiting.

[0027] The present invention includes a solid molded fiber component 12 formed from an aqueous slurry (hereinafter referred to as "slurry 20") comprising a plurality of fibers 16. The slurry 20 may comprise natural fibers, semi-synthetic fibers, synthetic fibers, or combinations thereof. Natural fibers include wood fibers, plant fibers, 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 may include, but are not limited to, cotton, flax, hemp, jute, ramie, bamboo, sisal, abaca, kapok, coconut fiber, and general agricultural waste. Animal fibers may include, but are not limited to, wool, silk, cashmere, alpaca, camel, mohair, yak, camel, musk ox, vicuña, angora, and horsehair. Semi-synthetic fibers may include, but are not limited to, cellulose-based fibers such as rayon, viscose, modal, tencel, lyocell, and acetate. Synthetic fibers may include, but are not limited to, polyester fibers, nylon, olefin fibers, spandex / elastane, acrylic fibers, PVC, aramid, microfibers. Additionally, sustainable synthetic fibers such as polylactic acid (PLA) fibers and polyhydroxyalkanoate (PHA) fibers may be used. One or more fiber types may be added, and any other ingredients, such as, but not limited to, bio-based and / or synthetic molecules / polymers, and additives, may be added to the material to be used before formation (while in a fluid state), after the material is dried, or after the object (or portion of the object) is formed. Bio-based molecules / polymers may be added as binders and / or retainers to enhance the wet and dry strength of the solid fiber molded part 12. These bio-based molecules / polymers include, but are not limited to, chitosan, starch, ionic starch, cellulosic materials (such as, but not limited to, carboxymethyl cellulose, nanofibrillated cellulose, nanocellulose, natural rubber latex, collagen, gelatin, alginate, polylactic acid, polyglycolic acid, and polyhydroxyalkanoate). Additionally, synthetic molecules / polymers and synthetic molecules / polymers with specific amounts of bio-based carbon, such as, but not limited to, polyurethane emulsions, thermoplastic materials, and resins such as polyaminoamide-epichlorohydrin (PAE), may be used in the material to improve mechanical strength. A suitable slurry is disclosed in U.S. Patent Application Serial No. 17 / 466,792, the disclosure of which is hereby incorporated by reference.

[0028] refer to Figure 1 A slurry 20 may be formed by combining fibers 16 , water 26 , and any other desired ingredients into a mixer 28 . Figure 1An exemplary arrangement is shown in which a series of ingredient sources 30 are in communication with a mixer 28, enabling quantities of various ingredients to be provided (e.g., pumped or gravity-fed) to the mixer 28 as desired. In the example shown, up to six ingredient sources 30 are provided. In addition, a water source 32 and a fiber source 16 are provided for adding desired quantities of fiber 16 to the mixer 28. Once in the mixer 28, the ingredients are mixed, typically until all ingredients are thoroughly mixed and / or dispersed and the slurry is in the form of a mixture, foam, or homogenized fiber dispersion. Examples of such slurries may contain, but are not limited to, the following: water (20%-99.99%), fiber (0.0075%-60%), and other additives (0.0025%-20%).

[0029] Now refer to Figure 2A and Figure 2B Once mixed to the desired consistency, the slurry can be poured, pumped, gravity fed or provided by any other known means into the dewatering chamber 18. The screen can be flat (see Figure 2A ), or include at least one contour ( Figure 2B Dewatering chamber 18 consists of walls 22, a screen 23 at the bottom, and a container for collecting effluent. The screen has openings 25 that generally prevent at least fibers 16 from the slurry 20 from exiting dewatering chamber 18, but allow at least some of the water 26 from the slurry to drain, thereby effectively achieving dewatering. After the slurry has been dewatered to the desired degree, a substantially flat or contoured fibrous material 24 is obtained and removed from dewatering chamber 18. Dewatering chamber 18 can be 3D printed or manufactured from PVC, nylon, and wood materials. Figure 3 An example of fibrous cuboid material being removed from a dewatering chamber is shown in FIG.

[0030] After removal from the dewatering chamber 18, the fibrous material may be a substantially flat or contoured material, which may optionally be further dried. To obtain the desired intermediate form 14, the substantially flat or contoured fibrous material 24 is then formed in a pressing operation.

[0031] Now refer to Figure 4The substantially flat or contoured fibrous material 24 can be placed in a press 34 comprising a first mold portion 36 and a second mold portion 38. For example, one of the mold portions may typically be a male mold and the other a female mold. However, the present invention is not limited thereto, and for example, the mold portion may be partially female and partially male. When the substantially flat or contoured fibrous material 24 is pressed between the first and second mold portions, the substantially flat or contoured fibrous material 24 undergoes a shape change. Furthermore, due to the pressure and, optionally, the addition of heat, fiber-to-fiber, polymer-to-polymer, and / or polymer-to-fiber bonding and chemical crosslinking occur, thereby forming a material having the desired structural stability. The first and second mold portions 26, 28 may be 3D printed or manufactured from metal. The first and second mold portions 26, 28 may also include additional contours, textures, and / or patterns that impart a desired surface effect on the final object, the three-dimensional solid fiber molded part 12.

[0032] In an alternative embodiment, although not shown, the substantially flat or contoured fibrous material 24 can be a bladder against a single 3D printed or metal mold portion. In further embodiments, it may be desirable to achieve the substantially flat or contoured fibrous material 24 by molding the slurry 20 into the intermediate form 14 rather than first dewatering the slurry 20 and then pressing it.

[0033] Once the intermediate form 14 is obtained, further drying and / or cutting away of portions may be necessary. Figure 5 As shown, a substantially flat or contoured fibrous material 24 is pressed into a sheet having two distinct portions formed in a single sheet. Figure 5 An intermediate form 14 having two parts is shown, but the intermediate form 14 may have only a single final part, or three or more final parts without departing from the scope of the invention. Preferably, the intermediate part 14 comprises a flatter or less contoured version of the final part in a shape that is, for example, stackable. For example, in Figure 5 In this shape, one component is the "butterfly" upper and the second component is the heel. In this shape, the product is not as good as its final form as a finished shoe (such as Figure 5 The components are then cut from the excess material. In embodiments where there are multiple components in the intermediate member 14 or where there is a single component with excess material, the components can be trimmed by any known means, including cutting, punching, or trimming. Finally, further processing (by gluing, sewing, bundling, taping, welding to another object) can be performed to achieve the desired final shape and / or product. For example, in Figure 5In the example shown, two molded parts cut from the intermediate member 14 (i.e., the upper and the heel) are attached to each other, holes are cut in the material and laces are threaded through, and the sole is attached. The final product includes a highly contoured piece and can include surface effects while using fewer parts and reducing manufacturing steps compared to traditional methods.

[0034] In operation, and with reference to Figure 1 The components of the slurry 20, including at least water 26, a single type of fiber or multiple fiber types 16, and optionally additives, are provided to a mixer 28. The components are mixed until the slurry 20 is a mixture, foam, or homogenized suspension.

[0035] refer to Figure 2A and Figure 2B The slurry 20 is then added to a dewatering chamber 18 where some, most, or all of the water (depending on the final product material) in the slurry 20 is drained away, effectively dewatering the material during the process of converting the slurry 20 into the intermediate formed part 14.

[0036] refer to Figure 3 , the intermediate formed piece 14 is removed from the dewatering chamber 18 and optionally further dried. Then, referring now to Figure 4 The intermediate form 14 is placed in a press 34 between a first mold section 36 and a second mold section 38. Pressure and / or heat are applied to the intermediate form 14, thereby inducing fiber-to-fiber, polymer-to-polymer, and / or polymer-to-fiber bonding and chemical crosslinking to form a material having the desired structural stability. The result is a three-dimensional solid fiber molded part 12.

[0037] See also Figure 5 One or more parts can be trimmed from the three-dimensional solid fiber molded part 12 and then subjected to secondary operations to obtain the final product. The secondary operations can be performed at the same location as the other processes, or at a different, more convenient location after the three-dimensional solid fiber molded part 12 is shipped.

[0038] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements specifically claimed. The description of the present disclosure is for illustration and description purposes only and is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the present disclosure. The embodiments are chosen and described in order to best explain the principles of the invention and practical application, and to enable others of ordinary skill in the art to understand the disclosure of various embodiments with various modifications suitable for the specific use contemplated.

Claims

1. A method for forming a fiber molded article, the method comprising: providing a slurry comprising at least a certain amount of water and a plurality of fibers; providing the slurry to a dewatering chamber having a screen capable of allowing water to flow therethrough but substantially preventing the passage of the fibers from the slurry; dewatering the slurry by allowing at least some of the quantity of water to flow through the screen until a substantially flat or contoured fibrous material is obtained; removing the fiber intermediate forming member from the dewatering chamber; placing the fiber intermediate form in a press having a first mold portion and a second mold portion, wherein at least one of the first mold portion or the second mold portion includes a profile; applying at least one of heat and pressure to the press such that at least fiber-to-fiber bonding or chemical cross-linking of the fibers occurs; as well as An intermediate component consisting of a three-dimensional solid fiber material is removed from the press.

2. The method according to claim 1, wherein the slurry is in the form of a mixture, a foam or a homogenized suspension after mixing.

3. The method according to claim 1, wherein the slurry comprises at least one type of fiber selected from the group consisting of natural fibers, semi-synthetic fibers, and synthetic fibers.

4. The method according to claim 3, wherein the slurry comprises at least two types of fibers selected from the group consisting of natural fibers, synthetic fibers, semi-synthetic fibers, and synthetic fibers.

5. The method of claim 1, wherein the slurry comprises bio-based molecules or polymers.

6. The method of claim 5, wherein the bio-based molecule or polymer is one of: chitosan, starch, ionic starch, a cellulosic material such as but not limited to carboxymethyl cellulose, nanofibrillated cellulose, nanocellulose; natural rubber latex, collagen, gelatin, alginate, polylactic acid, polyglycolic acid and / or polyhydroxyalkanoate.

7. The method of claim 1, wherein at least one of the first mold portion and the second mold portion comprises at least one of a contour, a texture, a pattern imparted to a three-dimensional solid fiber molded part.

8. The method of claim 1, wherein heat and pressure are applied to the press.

9. The method of claim 1, wherein the three-dimensional solid fiber molded part comprises one or more final parts and excess material.

10. The method of claim 9, wherein the excess material is removed from the one or more final components.

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