System and method for manufacturing fiber-based articles with steam molding

Abstract

In an example method, an NWM molding blank comprising a nonwoven material held compressed by an adhesive is placed in a separable mold and heated to a melting temperature of the adhesive. The molding blank expands, shaping into an NWM molded object having a 3D geometry as an intermediate NWM object. The intermediate NWM object is cooled through a temperature band having an upper boundary and a lower boundary, and further cooled to a solidification temperature of the adhesive. The upper boundary is above the solidification temperature and the lower boundary is below the adhesive melting temperature. While in the temperature band, the mold is separated so that exposed surfaces of the intermediate NWM object are accessible. The object is then transported to a contoured forming surface of a forming bed by an actuatable arm having an end effector that grips the exposed surfaces via vacuum suction, the object is lifted from the mold and placed on the contoured forming surface. Optionally, the end effector contacting surfaces include final forming features. The actuatable arm compresses the intermediate NWM object against the contoured forming surface and, optionally, the end effector final forming features, and continues compression until cooled to the solidification temperature.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application 63 / 123,567, filed December 10, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention generally relates to molding three-dimensional objects or portions thereof, and more specifically to molding objects or portions thereof using blanks of compressed, thermally expanding nonwoven materials. Background Technology

[0004] U.S. Patent Publication PCT / US2020 / 022893, whose full disclosure is included in U.S. Provisional Application 63 / 123,567, describes techniques for molding thermally expanding blanks (e.g., sheets) containing certain nonwoven materials held under compression by certain cured adhesives into objects of various three-dimensional (3D) shapes. As described in PCT / US2020 / 022893, the cured adhesive stores a significant amount of kinetic energy while holding the nonwoven material in a compressed state. As also described, the melting temperature of the adhesive is lower than the melting temperature of the nonwoven material. Therefore, heating the blank to a temperature between these two melting points releases the nonwoven material to expand toward its pre-compressed state.

[0005] As described in PCT / US2020 / 022893, the molding of thermally expandable nonwoven material molding blanks (hereinafter also referred to as "HE NWM blanks") can be performed using a two-part separable mold, for example comprising an upper portion and a lower portion, which, upon assembly, form a mold interior with an uneven surface matching a desired 3D shape. During molding, the mold portions are separated (e.g., by raising the upper portion from the lower portion) so that the uneven surface in the lower portion becomes accessible. One or more HE NWM blanks are placed on the accessible uneven mold surface of the lower portion, and the mold is reassembled (e.g., by lowering the upper portion onto the lower portion), surrounding the mold interior with one or more mold blanks, and heat is applied, for example, by introducing steam into the mold interior via a steam channel. When the temperature of the HE NWM blank reaches the binder melting temperature, the binder becomes liquid, releasing the nonwoven material from its compressed state. Using the force of the kinetic energy stored during compression, the nonwoven material expands outward toward the pre-compressed dimensions of the HE NWM blank until it reaches the uneven surface inside the mold. Then, through operations such as terminating heat and introducing airflow, over time, the temperature of the expanded NWM and adhesive decreases below the adhesive's melting temperature and eventually to its curing temperature. The molded NWM 3D object can then be removed from the mold.

[0006] In some applications, a drawback of the above techniques is that the shape of the molded NWM 3D object may change after it is removed from the mold. Summary of the Invention

[0007] The embodiments provide a high-volume first-stage molding process and a second-stage multi-configuration feature enhancement and finishing. Benefits and advantages provided by the two-stage HE-NWM molding process according to different embodiments include, for example, but not limited to, the removability of 3D objects molded from HE-NWM mold blanks and their molding dies before they have fully cooled to the binder curing temperature. Secondary benefits may include, but are not limited to, the higher throughput of the first-stage HE-NWM molding process, which eliminates the need to wait for the product to fully cool before removal.

[0008] Features and advantages provided by the operable arm also include the concave-convex contact surface end effector and the final molding surface according to various embodiments, which maintain the inherent optimal distribution of molding stabilizing forces on the final molded NWM 3D object until the object has completely cooled to the state of curing of the adhesive material, and do so without consuming heated molding resources.

[0009] Other features and advantages include the use of gap angle mold sidewalls (i.e., angled backwards with respect to the vertical direction of the final product) for thermal expansion molding of vertical sidewall NWM 3D objects. This avoids the difficulties of lifting the upper part of the mold and removing the molded NWM object from the lower part after molding.

[0010] Examples of the disclosed methods according to various embodiments include a method for molding an object, which may include: thermally expanding a compressed nonwoven material (NWM) molding preform within a separable mold to form an intermediate NWM-molded three-dimensional (3D) object; cooling the intermediate NWM-molded 3D object through a temperature band having an upper and lower boundary, and further cooling it to the curing temperature of an adhesive, the lower boundary being above the curing temperature of the adhesive and the upper boundary being below the melting temperature of the adhesive. The example method further includes, while in the temperature band: separating the separable mold to make access to the exposed surface of the intermediate NWM-molded 3D object; clamping the intermediate NWM-molded 3D object by vacuum suction from an end effector of an actuated arm; transporting the clamped intermediate NWM-molded 3D object to the molding surface of a molding base by transport movement of the actuated arm; and

[0011] Compressing at least a portion of the intermediate NWM molded 3D object against a molding surface, and further comprising finishing the intermediate NWM molded 3D object by continuing to compress at least a portion of the intermediate NWM molded 3D object against the molding surface until it cools to a curing temperature.

[0012] Examples of systems disclosed according to various embodiments include: an end effector device for retrieving an expandable object from a mold; wherein the mold has a top inner surface and a bottom inner surface, and each surface faces the expandable object; the end effector device includes: an expandable object contact surface, at least one robotic arm connected to the expandable object contact surface, and at least one vacuum suction system; the expandable object contact surface is similar to at least a portion of the top inner surface of the mold; the robotic arm is configured to move the expandable object contact surface to contact the top portion of the expandable object; the at least one vacuum suction system is connected to the expandable object contact surface, wherein the at least one vacuum suction system is configured to extract heat and moisture while providing a sufficient vacuum to keep the expandable object against the expandable object contact surface.

[0013] Examples of disclosed systems according to various embodiments include a separable mold comprising a lower part and an upper part that, when assembled, form a molding chamber, and the system examples include a steam passage for receiving supplied steam and conveying at least a portion of the steam to the molding chamber. The mold is configured to enclose one or more HE-NWM preforms within the molding chamber during assembly, the one or more HE-NWM preforms comprising compressed NWM within a cured adhesive material. The mold is configured to at least partially respond to the supplied steam to thermally mold the HE-NWM preforms, filling the molding chamber to form an intermediate-molded 3D NWM object. The example system may include a mold separation device configured to separate the upper part from the lower part, leaving an intermediate-molded 3D NWM object supported by the lower part and having an exposed top surface. The exemplary system also includes an end effector connected to an actuable arm and characterized by a contact surface conforming to the uneven shape of the exposed top surface. The actuating arm is configured to, for example, in response to a control signal from a controller, perform the transport of an intermediate-molded 3D NWM object, positioning a contact surface against an exposed top surface, establishing vacuum clamping via a vacuum channel opened at the contact surface, lifting the intermediate-molded 3D NWM object from the lower part of the mold, and transporting the intermediate-molded 3D NWM object to the concave-convex lower final forming surface of a molding base adjacent to a separable mold. The actuating arm, end effector, end effector contact surface, and concave-convex lower support surface are also configured to apply specific pressure to the intermediate-molded 3D NWM object for feature enhancement and finishing, and to maintain stable pressure on the final-molded 3D NWM object until the adhesive material is fully cured.

[0014] Another example of the method disclosed according to various embodiments includes a method of molding an object, the method comprising: providing a mold including a top portion and a bottom portion, wherein the mold is configured to deliver heat from steam to the top and bottom portions of the mold, wherein the mold is configured to remove moisture from inside the mold by vacuum suction; placing an expandable object in the mold to form a structure using heat from steam while the top portion is placed on the bottom portion of the mold and an expandable object is positioned between the top and bottom portions of the mold. The exemplary method further includes: removing heat and moisture from the mold by applying vacuum suction to the mold during and / or after molding; and opening the mold such that the top and bottom portions of the mold separate to expose at least some portions of the expandable object while the expandable object remains on the bottom portion of the mold. The exemplary method further includes: placing an expandable object contact surface of an end effector device onto an exposed portion of an expandable object while applying a vacuum sufficient to cool the expandable object and hold it against the expandable object contact surface of the end effector device, wherein the expandable object contact surface of the end effector device sets the configuration to a first configuration by cooling and holding; and retrieving the first configuration expandable object from the bottom portion of the mold.

[0015] The synopsis identifies exemplary features and aspects, rather than an exclusive or exhaustive description of the disclosed subject matter. Whether a feature or aspect is included in or omitted from the synopsis is not intended to indicate the relative importance of such features or aspects. Additional features, explicitly and implicitly described, will be understood by those skilled in the art upon reading the following detailed description and reviewing the accompanying drawings, which form a part of it. Attached Figure Description

[0016] Figure 1 This is a functional block diagram of an exemplary implementation of a system supporting a two-stage HE-NWM molding process according to one or more exemplary embodiments.

[0017] Figure 2A A top view of an exemplary assembled separable mold 200 for a molding process, according to one or more embodiments, is shown. Figure 2B yes Figure 2A The front view of the transverse projection 2B-2B.

[0018] Figure 3 It is an example of a separable mold. Figure 2A Enlarged front cross-sectional view of cross-sectional projection 2B-2B, in which an exemplary compressed HE-NWM molded preform is inside the mold.

[0019] Figure 4This illustrates an intermediate NWM 3D object produced by the first stage of HE-NWM molding process using compressed HE-NWM molding preforms. Figure 3 The front cross-section view of the cross-projection.

[0020] Figure 5 It shows Figure 3 and Figure 4 The front cross-sectional view on the cross-sectional projection shows the exposed upper surface of the molded object in the middle of the NWM 3D after the removal of the parts on the mold.

[0021] Figure 6 A front cross-sectional view of an exemplary actuator according to an exemplary embodiment is shown. The actuator provides a contact surface configured for the top surface of a first-stage NWM 3D object, the contact surface being... Figure 1 The operable boom is positioned above the central NWM 3D modeled object.

[0022] Figure 7 Illustrations are shown according to one or more embodiments Figure 6 A front cross-section view of an exemplary end effector, wherein the contact surface abuts against the upper surface of the intermediate NWM 3D molded object and initiates vacuum suction for further transport to a second stage of enhancement and finishing.

[0023] Figure 8 This shows the process of lifting the first-stage NWM 3D molded object from the lower part of the separable mold. Figure 7 A front cross-section view of the end effector, wherein the contact surface abuts against the upper surface of the intermediate NWM 3D molded object.

[0024] Figure 9 Illustrations are shown according to one or more embodiments Figure 7 The front cross-section view of the end effector that has transported the first-stage NWM 3D molded object and positioned it above an exemplary finishing molding surface of an exemplary second-stage molding base, the exemplary finishing molding surface having exemplary finishing feature convex and concave shapes for second-stage shape enhancement and finishing.

[0025] Figure 10 Illustrations are shown according to one or more embodiments Figure 8 A front cross-sectional view of the end effector, which is used to mold the object in the first stage of NWM 3D modeling. Figure 9 After aligning the second-stage molding base, the central NWM 3D molded object is pushed onto the finishing molding surface and its exemplary finishing feature molding convex and concave shapes for second-stage molding enhancement and finishing.

[0026] Figure 11 It shows in Figure 10 The second-stage enhancement and finishing demonstrated involves cooling the completed NWM 3D molded object to below the adhesive curing temperature, fixing the shape and size of the 3D molded object, and providing an exemplary front cross-section view of the completed NWM 3D molded object after the end effector has been removed from the actuator arm.

[0027] Figure 12A and Figure 12B A first and a second rotated view of a completed NWM 3D molded object produced by the described exemplary two-stage HE-NWM molding process according to one or more embodiments are shown.

[0028] Figure 13 The diagram shows an exemplary end effector connected to an actuable arm for the first-stage NWM object removal, transport, and second-stage molding enhancement and finishing operations in an exemplary two-stage NWM 3D molding process, according to different embodiments.

[0029] Figure 14 Different embodiments are shown. Figure 13 Another isometric view of the exemplary concave-convex contact surface of the end effector.

[0030] Figure 15 yes Figure 14 A plan view of an exemplary concave-convex contact surface of an end effector.

[0031] Figure 16 An isometric view is shown of the finishing features of another exemplary molded concave-convex shape of another exemplary second-stage molding base for additional second-stage molding enhancement and finishing in a two-stage NWM 3D molding process, according to different embodiments.

[0032] Figure 17 A first projection image of another exemplary completed NWM 3D modeled object is shown. The NWM 3D modeled object can be used according to various embodiments through... Figures 13-15 The exemplary end effector shown and Figure 16 The two-stage HE-NWM molding process shown is used to produce the finely shaped concave and convex form.

[0033] Figure 18 yes Figure 17 The image shown is an isometric view of the completed NWM 3D molded object from the rear viewpoint.

[0034] Figure 19 A flowchart illustrating operations in an exemplary process of a two-stage HE-NWM molding process according to different embodiments is shown. Detailed Implementation

[0035] Figure 1 This is a functional block diagram of an exemplary embodiment of a system 100 that supports a two-stage HE-NWM molding process according to one or more exemplary embodiments. System 100 includes a separable mold 102, which may include an upper component 106 and a lower component 104. See also... Figure 2A and Figure 2B In more detail, the upper component 106 and the lower component 104 may be configured to accommodate one or more HE-NWM molding blanks on a generally upward-facing lower molding surface disposed on the lower component, and the upper component 106 may be configured with a generally downward-facing upper molding surface that complements the molding surface of the lower component 104 to form a molding chamber when the mold 102 components are assembled, thereby enclosing one or more molding blanks. As described in more detail in later sections, the lower component 104 and the upper component 106 may include steam passages for the molding process to distribute supplied steam within the separable mold 102 components and thereby heat the separable mold components, and to transport the supplied steam into the molding chamber for direct heating of the HE-NWM molding blanks.

[0036] According to various embodiments, system 100 also includes an actuable robotic arm 108, which, for the sake of brevity, may alternatively be referred to herein as an "actuable arm" 108, and an end effector 110 is connected to the distal end of the actuable arm 108. Figure 1 With the operable boom 108 facing downwards and positioned, a contact surface is arranged on a portion of the end effector 110, an example of which is shown in [reference]. Figure 6-10 , Figure 14-15 And as described in more detail elsewhere in this document. Generally, the contact surface may be irregular to conform to the upper surface of the 3D object, which will be molded in a separable mold 102 using one or more HE NWM material blanks. The end effector 110 also includes a vacuum suction channel forming system that extends from the connection of the vacuum suction tube 112 to an inflation chamber or equivalent (such as represented by a housing composed of straight lines shown on top of the upper housing of the end effector 110), and extends from the internal volume of the inflation chamber or equivalent via a tube or channel within the end effector 110 to a vacuum channel opening on the contact surface.

[0037] According to various embodiments, the functions of the actuated arm 108 and the end effector 110 include: after HE-NWM steam heating molding, transporting the NWM-molded 3D object from the lower part 104 to an adjacent final-molded lower structure or base 114, and then placing the NWM-molded 3D object onto the lower final-molded surface 116 of the structure 114. For example, the movement of the exemplary actuated arm 108 for such transport and placement can be performed under the control of a control processor, either within the actuated arm 108 or connected to the actuated arm 108 via a network. Operation may include positioning the contact surface of the end effector 110 on the upper exposed surface of the NWM molded 3D object by moving the actuated arm 108, for example by initiating suction clamping of the contact surface onto the upper surface by controlling a vacuum flow valve, then lifting the clamped NWM molded 3D object and manipulating the arm 108 to position the object above and on the lower final molded surface 116.

[0038] It will be understood that a substantial feature of the two-stage HE-NWM molding process according to different embodiments is to trigger a second-stage process, for example, after the NWM-molded 3D object has cooled to below the upper boundary of the temperature zone, the NWM-molded 3D object is transported to the lower final molding surface 116, which is referred to herein as the “secondary molding temperature zone” for convenience and consistency purposes.

[0039] The upper boundary is below the melting temperature of the adhesive material, but above the curing temperature of the adhesive material.

[0040] Among other features, the methods according to different embodiments provide for the development of certain processability of NWM-molded 3D objects within the secondary molding temperature range.

[0041] Features and advantages provided by the actuable arm 108 and end effector 110, in combination with the lower final forming surface 116, also include: maintaining optimally distributed forming stabilizing forces on the final formed NWM 3D object until the object has completely cooled to the state of the adhesive material curing.

[0042] The functions of the actuating boom 108 and end effector 110 also include what may be alternatively referred to herein as “enhancing and completing the forming process” for descriptive purposes.

[0043] According to one or more embodiments, the system 100 providing such functionality is characterized by the irregular shape of the contact surface of the end effector and the irregular shape of the lower final forming surface 116. According to various embodiments, other features may include the arrangement of attachments, trims, and other articles and devices on the lower final forming surface 116, as well as the end effector 110, for compressing and embedding it into the NWM-molded 3D object before cooling it below the temperature band.

[0044] Another feature of the two-stage HE-NWM molding process according to different embodiments is that the reinforcement and final molding process is completed, or at least substantially completed except for secondary molding, before the NWM-molded 3D object cools below the lower boundary of the strip, or at least before further molding becomes unacceptably costly after cooling. Exemplary costs may include an unacceptable risk of causing structural defects in the final molded NWM 3D object. Costs may also include, for example, reduced tool life or the life of the actuator arm 108 due to wear and breakage caused by the greater forces required for molding at lower temperatures.

[0045] Figure 2A It shows Figure 1 A top view of an exemplary assembly embodiment of the two separable mold parts 100. Figure 2B yes Figure 2A The front cross-sectional view of Figure 2 is a cross-sectional projection 2B-2B. The embodiment of Figure 2 includes an exemplary embodiment of a lower component 104 and an overlapping upper component 106. The complementary inner surfaces of the assembled lower component 104 and the overlapping upper component 106 surround a mold interior 202. The molding surface of the mold interior 202 includes a convex bottom molding surface 204 formed by features in the upper portion of the lower component 104, which is complementary to a convex top molding surface 206 formed by features in the lower portion of the upper component 106. For descriptive purposes, the convex bottom molding surface 204 and the convex top molding surface 206 will also be collectively referred to as “convex inner molding surfaces 204 / 206”.

[0046] What will be understood is that these uneven internal molding surfaces are 204 / 206. Figure 2A and 2B The illustrations can be general representations of complex geometric shapes and forms in different applications and implementations.

[0047] For illustrative purposes, the uneven top molded surface 206 includes any configuration of molding features, including a first top surface molding feature 206a, a second top surface molding feature 206b, and optional other features 206n, wherein only the nth top surface molding feature 206n is visible.

[0048] Figure 3 yes Figure 2A-2B An exemplary two-part separable mold 102 Figure 2A Front view of transverse projection 2B-2B, in which an illustrative compressible, heat-expandable non-woven material (HE-NWM) mold blank 302 is placed inside the mold.

[0049] Example processes in the methods according to the different embodiments disclosed will be described in the following paragraphs, including those using... Figure 3 The initial example shows an HE-NWM mold blank 302 in an exemplary two-part separable mold 102.

[0050] Before proceeding to a further description of the example features and processes of the systems and methods according to different embodiments, reference will be made to... Figures 3 to 1 Section 2b describes certain characteristics, selections, and options of examples of compressed HE-NWM die blanks that may be used in the practice of such systems and methods. Further descriptions, for example, can be found in the publication cited in PCT / US2020 / 022893 for academic purposes.

[0051] In general, the formation of exemplary embodiments of the HE-NWM die blank 302 can begin with a nonwoven material. The nonwoven material can be made from a large quantity of fibers including adhesive fibers and one or more other fibers. The adhesive fibers can be, for example, polyester, such as... The exemplary adhesive fibers, including EMF-type high-elasticity LMF, were commercially available from Teijin Co., Ltd., Toray Chemical Korea Co., Ltd., and Huvis Co., Ltd., respectively. These fibers have a melting temperature of, for example, 80-150°C, which is lower than the melting or decomposition temperature of one or more other fibers. When the adhesive fibers melt, they adhere to the outer sides of one or more other fibers and, upon hardening, form a nonwoven structure as a mass of one or more other fibers, wherein adjacent fibers are held together at various locations by the adhesive material, causing the adhesive fibers to melt and re-harden. Therefore, these nonwovens are also referred to as "thermally bonded nonwovens."

[0052] The molding HE-NWM die blank 302 may include compressing the nonwoven material while heating it to the melting temperature of the binder material, and the molding HE-NWM die blank 302 may further include maintaining the compression until cooling and re-curing the binder. The compressed state of the NWM fibers maintained by the cured binder effectively stores kinetic energy because the compressed fiber orientation is not the natural orientation of the fibers. Therefore, it should be understood that for a blank to store compressive kinetic energy, its dimensions (i.e., the compressed dimensions maintained by the cured binder) must be smaller than the original dimensions (height, width, or length) of the nonwoven fabric.

[0053] Vertical overlap (“V-lap”) nonwoven materials are preferred for applications such as seating or bedding components. “Vertical” refers to the direction opposite to the weight of a person’s back or hips, as it has greater stiffness and elasticity in the vertical direction. Blanks formed from V-lap nonwovens can be compressed by 50%, 60%, 70%, 80%, or 90% of their original height and can expand to or beyond their original height upon subsequent heating.

[0054] Preferably, the thermally bonded nonwoven fabric used in practice according to the disclosed embodiments has at least 5% by weight of adhesive material and up to 95% by weight of one or more other fibers. The percentages may depend on the requirements of a particular application. Furthermore, for some applications, the thermally bonded nonwoven fabric may include other materials such as flame-retardant (“FR”) compounds, fragrance compounds, antimicrobial compounds or materials, polymer coatings, and metal or ceramic particles.

[0055] In practice according to the disclosed embodiments, the exemplary ratio of the adhesive material to one or more other fibers in the nonwoven fabric may be in the range of 5:95 to 95:5.

[0056] Examples of thermally bonded nonwovens that can be used in practice according to the disclosed embodiments may include, but are not limited to, any thermal adhesive made with any exemplary combination of the materials listed in Table 1 and their corresponding percentages.

[0057]

[0058]

[0059] Examples of thermally bonded nonwovens that can be used in practice according to the disclosed embodiments may also include, but are not limited to, any thermal adhesive made of any hollow core fiber (e.g., hollow polyethylene terephthalate (PET)).

[0060] Examples of thermally bonded nonwovens that can be used in practice according to the disclosed embodiments may also include, but are not limited to, any thermally bonded nonwoven made of composite fibers (sometimes referred to as sheath-core fibers).

[0061] The adhesive fibers used to produce nonwovens that can be used in practice according to the disclosed embodiments may also include sheath-core fibers, wherein the sheath is polyester or some other low melt temperature material.

[0062] Examples of nonwoven fabrics that are not preferred for practicing the present invention include: any thermally bonded nonwoven fabric made of fibers melted at a temperature equal to or below the melting temperature of the adhesive fibers; and any thermally bonded nonwoven fabric made solely of adhesive.

[0063] Optionally, in practice according to one or more of the disclosed embodiments, the blanks may be laminated to form a sheet. The lamination may be blank-to-blank or may be a lamination of a blank with a non-expandable material, such as foam, fabric (e.g., woven material), rubber, metal, metal alloy, polymer, ceramic, and paper material. For example, the sheet may also be cut to the desired size and shape using a suitable computer-controlled or manual cutting machine.

[0064] "Nonwoven fabric" refers to sheets, webs, or waddings made by bonding natural and / or man-made fibers or filaments together using any of several methods. The manufacture of nonwoven products is well described in the following literature: "Nonwoven Textile Fabrics," Kirk-Othmer Encyclopedia of Chemical Technology, 3rd ed., Vol. 16, July 1984, John Wiley and Sons, pp. 72-124; and "Nonwoven Textiles," November 1988, Carolina Academic Press. Nonwoven fabrics are commercially available from many manufacturers.

[0065] For some applications, sheets / blanks made from NWM constructed with vertical overlaps (“V-laps”) can offer advantages in terms of support or comfort, where “vertical” means in the direction opposite to the weight of, for example, a person’s back or hips. V-lapped nonwoven blanks or sheets can be compressed by 50%, 60%, 70%, 80%, 90%, etc., from their original height dimension and can expand to, or exceed, their original height dimension upon subsequent heating. Vertical overlaps can be made using methods as set forth in US2008 / 0155787 and US 7,591,049, which are incorporated herein by reference. Vertically overlapped nonwovens are commercially available from a variety of commercial suppliers.

[0066] In practice according to the disclosed embodiments, the nonwoven fabric can be made from a large number of fibers, which may include adhesive fibers and one or more other fibers. The adhesive fibers have a melt temperature lower than the melt temperature or decomposition temperature of the one or more other fibers; for example, adhesive fibers typically have a melt temperature of 80-150°C. (Polyester is a typical example of an adhesive fiber used to produce nonwoven fabrics. Examples of elastic polyester adhesive fibers include...) (And EMF-type high-elasticity LMF, which are commercially available from Teijin Co., Ltd., Toray Chemical Korea Co., Ltd., and Huiweishi Co., Ltd., respectively). Once the binder fibers melt, they will typically adhere along the outer side of one or more other fibers. Upon cooling, they will harden to produce a nonwoven fabric, which is essentially a large amount of one or more other fibers, with adjacent fibers held together by the binder material at different locations throughout the nonwoven fabric, produced by the melting and re-hardening of the binder fibers. These nonwoven fabrics are commonly referred to as thermally bonded nonwoven fabrics. In the practice of this invention, the thermally bonded nonwoven fabric will have at least 5% binder material by weight and up to 95% one or more other fibers by weight. Depending on the needs of the article manufacturer, the binder material may constitute 5-50% by weight of the nonwoven fabric, with the remainder being one or more other fibers, or one or more other fibers plus additional materials. Additional materials may include, but are not limited to, flame retardant compounds, fragrance compounds, antimicrobial compounds or materials (e.g., silver particles or fibers), polymer coatings, metal or ceramic particles; etc. Examples of FR chemicals / compounds include, but are not limited to, phosphoric acid and its derivatives, phosphonic acid and its derivatives, sulfuric acid and its derivatives, aminosulfonic acid and its derivatives, boric acid, ammonium phosphate, ammonium polyphosphate, ammonium sulfate, ammonium aminosulfonate, ammonium chloride, and ammonium bromide.

[0067] Depending on the application, for practice according to the disclosed embodiments, the ratio of adhesive material to one or more other fibers in the nonwoven fabric can range from 5:95 to 95:5.

[0068] Hollow core fibers, such as hollow polyethylene terephthalate (PET), can be used in the practice according to the disclosed embodiments. Furthermore, nonwovens usable in the practice according to the disclosed embodiments can be formed using composite fibers, which may be referred to as sheath-core fibers. Adhesive fibers used to prepare nonwovens usable in the practice according to the various embodiments may include sheath-core fibers, wherein the sheath is polyester or some other low-melting-temperature material.

[0069] As mentioned above, Figure 3 An exemplary separable mold 102 is shown. Figure 2A A front cross-sectional view of cross-sectional projection 2B-2B, wherein, as described above, an exemplary compressed HE-NWM molded blank 302 is formed inside a mold.

[0070] Figure 4 The image shows an intermediate NWM molded 3D object 402 produced by the first stage of HE-NWM molding process using a compressed HE-NWM molding preform 302. Figure 3 The front cross-section view of the cross-projection.

[0071] Figure 5 It shows Figure 3 and Figure 4 A front cross-sectional view on a transverse projection, showing the exposed upper surface 502 of the intermediate NWM 3D molded object after the removal of part 106 from the mold. The upper surface 502 is shown having a corresponding... Figure 2A and Figure 2B Example of an uneven top molded surface 206, the first top surface molding feature 206a of an intermediate object, the first top surface uneven shape 502a, and respectively corresponding to Figure 2A-2B The intermediate object of the second top surface molding feature 206b and the nth top surface molding feature 206n has a second top surface convex shape 502b and an nth top surface convex shape 502n.

[0072] Figure 6 A front cross-sectional view of an exemplary embodiment of the end effector 110 according to an exemplary embodiment is shown. Figure 6 The end effector provides a contact surface 602, which is configured for the top surface or upper surface 502 of the intermediate NWM-molded 3D object 402, through Figure 1 The actuation positioning of the actuator arm 108 is located above the centrally NWM 3D molded object. According to different embodiments, the contact surface 602 can be configured with different uneven shapes, such as... Figure 6Examples are shown (see but not individually labeled) corresponding to the first top surface irregularity 502a, the second top surface irregularity 502b, and the nth top surface irregularity 502n of the intermediate object, respectively. Therefore, the contact surface 602 is also referred to herein as the "irregular contact surface" 602.

[0073] In one respect, the uneven shape features of the contact surface 602 may be the same as the top molding surface features of the upper part 106 of the separable mold 102. Figure 6 An example of this configuration is that the first top surface convex shape 502a, the second top surface convex shape 502b, and the nth top surface convex shape 502n of the intermediate object are respectively... Figure 2A-2B The first top surface molding feature 206a, the second top surface molding feature 206b, and the nth top surface molding feature 206n of the uneven top molding surface 206 are identical. As described below, while performing a second molding enhancement and finishing operation on the bottom surface of the intermediate NWM molded 3D object 402, this configuration can provide finishing and fixation of the upper uneven shape of the final NWM product to match the original uneven top molding surface 206. The benefits and advantages of this configuration may include, but are not limited to, solving the problem of undesirable post-molding expansion that may occur when the molded NWM 3D object is removed from its thermal expansion mold before it has fully cooled to the NWM adhesive curing temperature.

[0074] On the other hand, the contact surface 602 may have contact unevenness features, or some of these features, attached to... Figure 2A-2B The uneven top molding surface 206, or may be increased Figure 2A-2B The uneven top molded surface 206 or otherwise with Figure 2A-2B The uneven top molded surface 206 is different.

[0075] refer to Figure 6 The exemplary end effector 110 includes a plurality of vacuum channels 604, each channel establishing a fluid connection from an opening at a contact surface 602 and a vacuum filling chamber 606. It should be understood that the vacuum channels 604 are merely examples of distribution conduits for vacuum. Alternative embodiments include, but are not limited to, tubular structures. For illustrative purposes, Figure 6 The vacuum being started is indicated by a representative flow arrow.

[0076] Figure 7 Illustrations are shown according to one or more embodiments Figure 6 A front cross-section view of an exemplary end effector 110, wherein the contact surface 602 abuts against the upper surface 502 of the intermediate NWM 3D molded object 402 and initiates vacuum suction for further transport to a second stage of enhancement and finishing.

[0077] Figure 8 This illustrates the process after the intermediate NWM 3D molded object 402 is lifted from the lower part 104 of the separable mold 102, in conjunction with... Figure 7 The end effector 110 is viewed on the same front cross-sectional projection, with the contact surface 602 abutting against the upper surface 502 of the object 402. Figure 8 The visible position is, according to one or more embodiments, for example, under the control of a controller as described above, transporting the intermediate NWM 3D molded object 402 from the lower part 104 of the now separated mold 102 to... Figure 1 The second-stage forming base 114 is used for snapshots in the movement sequence or trajectory performed by the actuable arm 108 during the second-stage enhancement and finishing.

[0078] Figure 9 It shows Figure 7 A front cross-sectional view of the end effector 110, which has transported the first-stage NWM 3D molded object and positioned it. Figure 1 Above an example of the finished forming surface 116 and the finished uneven shape feature 116A of the second-stage forming base 114. To illustrate the various features of the second-stage reinforcement and finishing according to various embodiments, Figure 9 The visible angle projection of the second-stage molding base 114, its finished molding surface 116, and the finished concave-convex shape feature 116A are Figure 1 The cross-sectional projection 9-9. Operations during the second-stage enhancement and finishing process according to the disclosed embodiments may include: the actuating arm 108 lowering the end effector 110 to compress the lower surface of the clamped intermediate NWM 3D molded object 402 onto the finishing forming surface 116 and its exemplary finishing concave-convex shape feature 116A. Although not explicitly visible and depending in part on the specific construction of the concave-convex contact surface 602, the compression may also complement or enhance the features of the upper surface 502 of the intermediate NWM 3D molded object 402, as described above.

[0079] Figure 10 In Figure 8 An end effector 110 according to one or more embodiments is shown on the same front cross-sectional projection, the end effector 110 being used to model the first-stage NWM 3D molded object 402. Figure 9 After aligning above the second-stage molding base 114, the intermediate NWM 3D molded object is pushed onto the finishing molding surface 116 and its exemplary finishing feature molding concave-convex shape 116A for second-stage molding enhancement and finishing.

[0080] Figure 11It shows in Figure 10 The second-stage enhancement and finishing shown cools the completed NWM 3D molded object below the adhesive curing temperature, fixes the shape and size of the 3D molded object, and is an exemplary front cross-section view of the completed NWM 3D molded object 1100 after the actuator 108 has removed the end effector 110.

[0081] Figure 12A and Figure 12B A first and a second rotated view of a completed NWM 3D molded object 1100 produced by the exemplary two-stage HE-NWM molding process according to one or more embodiments are shown.

[0082] Figure 13 A top isometric view of an exemplary end effector 1300 connected to an actuable arm 1302 is shown in an exemplary two-stage NWM 3D molding process for first-stage NWM object removal, transport, and second-stage molding enhancement and finishing operations, according to various embodiments. The end effector 1300 includes a rotatable mechanical connection 1304 connecting to the actuable arm 1302, and a vacuum filling or distribution chamber 1306 receiving vacuum 1314 via a side vacuum distribution channel 1310 and a vacuum connection hose 1312. The end effector also includes a connector or additional clamp 1308 for attachment and securing to, for example, a lower component of a mold.

[0083] Figure 14 The diagram illustrates rotation about the axis of the rotatable mechanical connector 1304 according to various embodiments. Figure 13 Observed from the view Figure 13 An isometric view of an exemplary uneven contact surface 1400 of an end effector 1300. The uneven contact surface 1400 includes a first instance of a first uneven embossed feature 1402 in a first region and a second instance of a first uneven embossed feature 1402 in a second region. The uneven contact surface 1400 also includes an example of a second uneven embossed feature 1404 in the first region, and an example of a first recessed uneven embossed feature 1406.

[0084] Figure 15 for Figure 14 A plan view 1500 of a first region of an exemplary concave-convex contact surface 1400 of an end effector. As shown, the first region also includes a texture feature 1502 and a second concave-convex shape feature 1504.

[0085] Figure 16An isometric view is shown of an exemplary finishing molding profile 1600 for a second-stage molding base used in a two-stage NWM 3D molding process for second-stage molding reinforcement and finishing, according to various embodiments. The finishing molding profile 1600 may be, for example... Figure 1 The final shaped surface 116 is an embodiment of the process. The finishing shaped concave and convex shape 1600 includes finishing features 1602.

[0086] Figure 17 A first projection view of an exemplary completed NWM 3D modeled object 1700 is shown. The NWM 3D modeled object 1700 can be used as described in various embodiments. Figures 13-15 The exemplary end effector shown and Figure 16 The two-stage HE-NWM molding process shown is used to produce the finely shaped concave and convex form.

[0087] Figure 18 yes Figure 17 The isometric view shown is of the completed NWM 3D molded object 1700, with the finished molded part 1800 shown from the rear. The finished molded part 1800 includes a first recess 1802 and a second recess 1804. The first recess 1802 corresponds to... Figure 15 The second concave-convex shape feature 1504, the second concave portion 1804 corresponds to Figure 14 The first concave-convex shape feature 1406.

[0088] Figure 19 A flowchart illustrating operations in an exemplary process 1900 of a two-stage HE-NWM molding process according to different embodiments is shown. For the sake of brevity in the label blocks, Figure 19 The term "intermediate NWM molded 3D object" is simplified to "IMD object".

[0089] Figure 19 This includes a temperature state progression 1901 arranged above the process 1900 block, which is referenced in the following description of exemplary operation in an instance of process 1900. An exemplary example may include thermal expansion 1902 of a compressed NWM molding blank within a separable mold to produce an intermediate NWM-molded 3D object. See also, for illustrative purposes, [link to example]. Figures 3 to 1 2b, Exemplary implementations of thermal expansion 1902 may include, but are not limited to: Figure 3The compressed HE NWM molding blank 302 is placed inside a separable mold (such as separable mold 102), and then, for example, but not limited to, heated by guiding steam through one or both of the upper part 106 and the lower part 104 of the separable mold 102. As shown at reference point 1901A of temperature state progression 1901, in one aspect, thermal expansion 1902 raises the temperature of the compressed NWM molding blank 302 to a value higher than the melting temperature of the binder material of the compressed NWM molding blank.

[0090] Upon completion of thermal expansion 1902, the operations in process 1900 can proceed to cooling the IMD object 1904 to the upper boundary of the final molding temperature zone. As mentioned above, the upper boundary is below the melt temperature of the NWM adhesive material but above the adhesive curing temperature. Figure 19 The initial cooling temperature is 1901B, and the final molding temperature band upper boundary temperature is 1901C. As the temperature of the IMD object drops to the upper boundary 1901C, the operation in process 1900 continues to separate the separable mold in process 1906, thereby exposing the upper or top surface of the IMD object. It should be understood that in the context of the exposed surface of the IMD object, "upper" and "top" refer to... Figure 1 The exemplary separable mold 102 includes a lower part 104 and an upper part 106. In some applications, the exposed upper surface of the IMD object may be the bottom surface or even the side surface of the final NWM molded object.

[0091] Depending on the specific settings of the upper boundary 1901C and the specific NWM, undesirable degradation may occur from separation 1906 before the IMD object cools to or sufficiently approaches the upper boundary 1901C of the temperature state progression 1901. The cooling rate can be increased, for example, by airflow. Alternatively, the cooling rate can be increased by using cycles of vacuum removal, repressurization, vacuum removal, etc., of vapor condensation.

[0092] When the mold is separated at 1906, the operations in process 1900 can proceed to transporting the IMD object at 1908 to the final molding surface of the molding base. For example... Figure 19 As shown, the operations in transport 1908 may include the end effector of the actuator arm performing a vacuum clamping 1908A on the upper surface, followed by a sequential transport movement 1908B, thereby lifting the IMD object from the separated mold and positioning the IMD object above the final molded surface. Examples of these operations may be... Figure 1 The operable boom 108 positions the contact surface 111 of the end effector 110 onto the exposed surface of the IMD object, such as... Figure 6As shown, the contact surface 602 of the end effector 110 is above the exposed top surface 502 of the exemplary IMD object 402. Then, as Figure 7 As shown, vacuum suction can be initiated to fully clamp the IMD object 402 to bear the weight of the IMD object, and initially bear the bottom surface of the object against the bottom surface 204 of the lower part 104 of the mold (in Figure 2B Any adhesion (as marked above). Reference Figure 8 The exemplary operation of transport operation 1908B can then be implemented by lifting the IMD object 402 from the surface 204 of the lower part 104, and by the actuated boom segment (in Figure 1 Various rotations (visible but not individually numbered) around its pivot axis transport the IMD object to... Figure 9 The location shown. (As indicated) Figure 9 As shown, the position is above the final molded surface 116 having its exemplary final molded feature 116A.

[0093] The operations in process 1900 can then continue to compress multiple parts of the IMD object against one or more final forming surfaces, or between two or more final forming surfaces, or both. For example... Figure 19 As shown, the IMD object begins to compress at 1910 when it is within the final forming temperature band. It will be understood that although the material binder is above its curing temperature, it is below its melting temperature, and therefore can be reformed to a certain extent without the need for undesirable force amplitudes and without the absence of unacceptable stress-induced structural defect rates.

[0094] On one hand, the operation in Compression 1910 can be configured to remove features from the thermal expansion molding of IMD objects.

[0095] refer to Figure 10 An exemplary operation in compression 1910 is shown as an IMD object 1002 molded during the process of having an indentation area corresponding to the final shaped relief 116A.

[0096] In one aspect, the contact surface 602 of the end effector 110 may further include a final shaped protrusion. In another aspect, the contact surface of the end effector 110 may include a final shaped protrusion, and the final shaped surface 116 of the lower shaped base 114 may have a shaped protrusion. For purposes of description, the shaped protrusion (e.g., shaped protrusion 116A) on the final shaped surface 116 of the lower shaped base 114 will be referred to as the “lower” or “base” final shaped protrusion, and on the contact surface of the end effector (e.g., on…) Figure 6The final shaped protrusion on the contact surface 602 shown in the figure will be referred to as the “top”, “upper” or “end actuator” shaped protrusion.

[0097] refer to Figure 19 The operation in process 1900 can then proceed to continue or maintain the compression described above in 1912 until the NWM-molded 3D object cools to the adhesive's curing temperature 1901D.

[0098] refer to Figure 1 , Figure 2A-2B , Figure 3 and Figure 4 A vacuum pump system can be provided to facilitate the removal of moisture, vapor, and associated heat. As described, the vacuum pump can be used, either subsequently or simultaneously with the discharge of vapor pressure from the separable mold 102, to remove moisture (e.g., vapor pressure) from inside the mold. Figure 2B A vacuum is drawn into the mold (202). After evacuation, the mold is maintained at vacuum pressure for another time interval. The vacuum pump can then be stopped, allowing the mold to return to ambient pressure, and the intermediate NWM-molded 3D object can be removed. Alternatively, additional steps can be applied to pressurize the mold multiple times, release steam pressure, and apply vacuum pressure to the mold multiple times. It has been found that more uniform and complete expansion within the mold can be achieved by controlling the pressurization of the mold while applying steam inside and controlling the vacuum pressure applied inside the mold before removing the part from the mold.

[0099] It should be noted that, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural indicators unless the context clearly specifies otherwise. It should be further noted that claims may be drafted to exclude any optional elements. Thus, this statement is intended to support the use of such exclusive terms (e.g., “alone,” “only,” etc.) in the statements of the claim elements, or “negative” limitations (e.g., “wherein [specific feature or element] is absent,” or “except for [specific feature or element],” or “wherein [specific feature or element] is absent (including, etc.)”…).

[0100] When providing ranges of values, it should be understood that, unless the context explicitly specifies otherwise, every intermediate value between the upper and lower limits of the range (to one-tenth of the lower limit unit) and any other stated or intermediate value within the stated range is encompassed within this invention. The upper and lower limits of these smaller ranges may be independently included within the smaller ranges and also within this invention, subject to any specific exclusions from the stated ranges. Where the stated ranges include one or both of these limitations, the ranges excluding one or both of those included limitations are also included in this invention.

[0101] As will be apparent to those skilled in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features that can be readily separated from or combined with features of any other plurality of embodiments without departing from the scope or spirit of the invention. Any of the described methods may be performed in the order of the described events or in any other logically possible order.

[0102] The invention is further described by way of the following non-limiting examples, which further illustrate the invention and are not intended to, nor should they be construed as, limiting the scope of the invention.

Claims

1. A method for molding an object, comprising: thermally expanding a compressed nonwoven material molding blank within a separable mold to form an intermediate nonwoven material molded three-dimensional object; cooling the intermediate nonwoven material molded three-dimensional object to undergo a temperature band having an upper boundary and a lower boundary, the lower boundary being above a solidification temperature of a binder, the upper boundary being below a melting temperature of the binder; while in the temperature band: separating the separable mold so that an exposed surface of the intermediate nonwoven material molded three-dimensional object can be accessed, gripping the intermediate nonwoven material molded three-dimensional object by vacuum suction from an end effector of an actuatable arm, transporting the gripped intermediate nonwoven material molded three-dimensional object to a forming surface of a forming bed by a transport movement of the actuatable arm, and compressing at least a portion of the intermediate nonwoven material molded three-dimensional object against the forming surface; and finishing the intermediate nonwoven material molded three-dimensional object by continuing to compress the at least a portion of the intermediate nonwoven material molded three-dimensional object against the forming surface until cooled to the solidification temperature.

2. The method of claim 1, further comprising: further finishing the intermediate nonwoven material molded three-dimensional object by compressing at least another portion of the intermediate nonwoven material molded three-dimensional object, or the at least a portion, or both, against another finishing surface.

3. The method of claim 1, wherein, Transporting the intermediate nonwoven material molded three-dimensional object further comprises: performing a sequence of movements by the actuatable arm to effect contact with the exposed surface by a contact surface of the end effector; establishing vacuum grip by the contact surface end effector by vacuum suction from a vacuum source to an opening on the contact surface, wherein the vacuum source fluidly connects to the opening on the contact surface via a fluid path conduit; and performing another sequence of movements by the actuatable arm, the other sequence of movements configured to lift the gripped intermediate nonwoven material molded three-dimensional object from the separated mold and transport the removed and gripped intermediate nonwoven material molded three-dimensional object to the forming surface of the forming bed.

4. The method of claim 1, wherein: the compressed nonwoven material molding blank comprises nonwoven material held compressed by a binder; and the thermally expanding comprises heating the compressed nonwoven material molding blank to a melting temperature of the binder.

5. The method of claim 4, wherein the thermally expanding comprises heating a mold blank of an interior of the separable mold, the heating comprising flowing steam to the mold blank via a steam heating conduit carried by an upper piece or a lower piece, or both; and the method further comprises: Cooling the first molded intermediate nonwoven material molded three-dimensional object from above the melting temperature of the adhesive includes cooling at least the interior of the mold to an upper boundary of the temperature band within the separable mold, the mold interior cooling including vacuuming steam from the interior of the separable mold or condensing steam from the interior of the separable mold, or both.

6. The method of claim 1, wherein: the exposed surface of the intermediate nonwoven material molded three-dimensional object has an object surface relief shape; the contact surface of the end effector is configured as a relief contact surface that conforms to the object surface relief shape, the relief contact surface having an end effector final shaped feature; and and finishing the intermediate nonwoven material molded three-dimensional object includes compressing another portion of the intermediate nonwoven material molded three-dimensional object against the end effector final shaped feature, continuing compression against the end effector final shaped feature until cooled to the solidification temperature.

7. The method of claim 6, wherein: the contact surface of the end effector includes an end effector final shaped feature; and and finishing the intermediate nonwoven material molded three-dimensional object includes compressing another portion of the intermediate nonwoven material molded three-dimensional object against the end effector final shaped feature, and continuing compression against the end effector final shaped feature until cooled to the solidification temperature.

8. The method of claim 1, wherein finishing the intermediate nonwoven material molded three-dimensional object includes: prior to placing the nonwoven material molded three-dimensional object on the relief shaped forming surface, disposing an embedable attachment device on the relief shaped forming surface of the forming base; and contacting the relief shaped forming surface against the exposed surface of the intermediate nonwoven material molded three-dimensional object is configured to embed or partially embed the embedable attachment device in the intermediate nonwoven material molded three-dimensional object.

9. The method of claim 1, wherein, heating the mold blank within the interior of the separable mold includes: directing received steam to the interior of the separable mold, including through steam conduits carried by the upper piece of the separable mold or by the lower piece, or both.

10. The method of claim 1, wherein: the lower piece of the separable mold includes a surface having at least some non-vertical sidewalls; and finishing the intermediate nonwoven material molded three-dimensional object includes compressing a wall of the intermediate nonwoven material molded three-dimensional object, the wall formed from a surface having at least some non-vertical sidewalls.

11. The method of claim 10, wherein the compressing further shapes the wall as a vertical wall.

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