Soft article from molding and pressing system using fibre-containing slurry having second element at least partially embedded therein

Abstract

A shaped soft article article includes a first material and a second element at least partially embedded therein. The first material is a one-piece nonwoven material having at least one three-dimensional feature, the unitary nonwoven material is made from a slurry comprising at least one type of natural or synthetic fibers and at least one of a cross-linking agent, a natural and / or synthetic binder, a bio-based and / or synthetic thermoplastic including nanocellulose, and / or a latex. The second element may be functional or decorative.

Description

[0001] Priority Statement

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 461,778, filed April 25, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] The field of the present invention is for the molding of three-dimensional articles, and more specifically for the molding of two-dimensional or three-dimensional articles from an aqueous slurry comprising multiple fibers having a second element at least partially embedded therein. Background Technology

[0004] Current processes for forming soft articles, such as clothing, footwear (e.g., shoe uppers), bags, furniture, medical supplies, cleaning tools and consumables, toys, automotive interior parts, housings and casings of consumer electronics, and other soft articles, are typically wasteful and involve numerous steps. Each manufacturing step is a separate, inefficient, and labor-intensive process, often requiring material transport between steps. Waste (e.g., cut but unused fabric) is often simply discarded, adding to the waste in the process. Additionally, raw materials are often provided in a flat shape and must be shaped into the final desired shape; different equipment and processes are often required to achieve even small variations in the final design, and surface features and / or textures must be added in secondary operations to complete the final design. Furthermore, product customization is difficult and requires additional steps. There is a need in the art to provide a manufacturing process for customizing, color-blocking, decorating, and / or imparting the ability to shape objects with higher and lower stability without requiring additional, labor-intensive, and time-consuming steps such as sewing. The present invention addresses these and other disadvantages of the prior art, as disclosed herein. Summary of the Invention

[0005] According to one aspect of the present invention, a molded flexible article and a method for manufacturing the same are disclosed. The molded flexible article includes a first material and a second element at least partially embedded within the first material. The first material is a monolithic nonwoven material having at least one three-dimensional feature, the monolithic nonwoven material comprising at least one type of natural or synthetic fiber and at least one of a crosslinking agent, a natural and / or synthetic adhesive, a bio-based and / or synthetic thermoplastic including nanocellulose, and / or latex. The second element may be a functional or decorative element.

[0006] According to another aspect of the invention, the second element may be partially embedded in the first material, fully embedded in the first material, extend completely through the first material, or be attached to the outer surface of the first material during the forming process.

[0007] According to another aspect of the invention, additional elements may be added to the first material and / or the second element.

[0008] One advantage of this invention is that decorative elements can enhance the appearance and feel of soft articles without requiring additional post-forming processes.

[0009] Another advantage of the present invention is that functional elements can be added without the need for post-forming processes that add functionality not originally present in the first material, such as, but not limited to, power supplies, electronic devices, and sensors.

[0010] Another advantage of the present invention is that, without the need for post-forming processes, the structural material can be used to (locally) reinforce the first material.

[0011] These and other advantages will be apparent to those skilled in the art in light of this disclosure and the accompanying drawings. Attached Figure Description

[0012] These and other features of the present disclosure will be more readily understood from the following detailed description of various aspects of the disclosure in conjunction with the accompanying drawings, which depict various embodiments thereof, in which:

[0013] Figure 1 An exploded perspective view of one embodiment of the molding apparatus of the present invention is shown;

[0014] Figure 2 A partial perspective exploded view of another embodiment of the molding apparatus of the present invention is shown;

[0015] Figure 3 A top view of one embodiment of the first molded screen is shown;

[0016] Figure 4 A top view of one embodiment of the second molded screen is shown;

[0017] Figures 5A to 5G A schematic cross-sectional view showing the configuration of the first material and the second element of the present invention is shown;

[0018] Figure 5H An embodiment of a second element having a mesh structure is shown; and

[0019] Figures 6A to 6G A series of cross-sectional schematic images illustrating one embodiment of the molding process of the present invention are shown. Detailed Implementation

[0020] Now for reference Figure 1Up to Figure 6, one embodiment of the invention is an article 11 having at least one profile, the article comprising a first material 13 and a second element 15. During the formation of the first material 13, the second element 15 is at least partially embedded in, attached to, and / or extends through the first material 13. In some embodiments, a third material 17 may also be used, as described herein.

[0021] Common articles (or components thereof) formed using the methods and apparatus 10 disclosed herein include clothing, footwear (e.g., shoe uppers), bags, furniture, medical supplies, cleaning tools and consumables, toys, automotive interior parts, housings and casings of consumer electronics, and other soft articles. Examples of clothing articles include, but are not limited to, shirts, shorts, dresses, skirts, trousers, socks, vests, sweaters, scarves, hats, gloves, mittens, and underwear. Examples of bags include, but are not limited to, handbags, wallets, backpacks, school bags, shoulder bags, clutches, suitcases, luggage, and cosmetic bags. Examples of automotive interior parts include, but are not limited to, interior panels, interior trim, seat upholstery and covers, floor mats, dashboard panels and covers, and steering wheel covers. Examples of medical applications include slings, casts, wipes, bandages, prosthetic limbs, support garments, posture corrective garments, braces, canes, crutches, and protective shields. The foregoing list of articles is intended to be illustrative and not restrictive.

[0022] Now for reference Figures 1 to 4 One way to form the first material 13 is via a molding operation. In the illustrated embodiment, the apparatus 10 includes a first pressing unit 12, a first molding screen 14, a second molding screen 16, a lower pressing unit 18, a pressing chamber sleeve 20, and a heating device 22.

[0023] A method and apparatus 10 for use in conjunction with molding a first material 13 includes providing an aqueous solution comprising multiple fibers (“slurry 23”). Slurry 23 may comprise natural fibers, synthetic fibers, or combinations thereof. Examples of natural or bio-based fibers include, but are not limited to, pulp, lyocell, hemp, and wool. Examples of synthetic fibers include, but are not limited to, nylon and polyester. Slurry 23 may additionally comprise starch, surfactants, water-retaining agents, tackifiers, crosslinking agents, binders, and / or pH and charge adjusters. The above listing of components is intended to be exemplary and not limiting. The molding process transforms slurry 23 into a solid fiber molded part 25 having the desired shape and surface features by draining and / or evaporating moisture from slurry 23 during the molding process. A suitable slurry is disclosed in U.S. Patent Application Serial No. 17 / 466,792, the disclosure of which is hereby incorporated by reference.

[0024] Examples of the aforementioned pulp may include (but are not limited to) the following: water (20%-99.99%), fiber (0.0075%-60%), and other additives (0.0025%-20%).

[0025] Slurry 23 can be formed by combining fibers, water, and any other desired ingredients into a mixer (not shown). Once in the mixer, the ingredients are mixed until all ingredients are dispersed and slurry 23 is in the form of a foamy mixture or a homogenized fiber dispersion.

[0026] Subsequent fiber modifiers and / or coatings may be added to the final solid fiber molded part 25, including but not limited to: synthetic, natural or bio-based waxes; latex; polyacrylates; polyvinyl chloride; silicone; and / or polyurethane.

[0027] Now for reference Figure 1 The first pressing unit 12 includes a first inlet 24, which can be used as a port for applying vacuum (i.e., negative pressure) or positive pressure, or for supplying airflow or heat to the interior of the device 10 before, during, or after the molding process. The first inlet 24 may be adapted to receive a removable adapter that can be attached to, for example, a hose in fluid communication with a source of heat, airflow, vacuum, and / or positive pressure (not shown). The first pressing unit also provides structural stability to one side of the device 10, thereby enabling the application of significant pressure (e.g., from a hydraulic device) to the slurry 23 during the molding process. Additional ports may be included in the first pressing unit to provide for, for example, draining water from the slurry 23 during the molding process. Additionally, the first pressing unit 12 may also include one or more slots 34 for receiving a heating device 22.

[0028] Now for reference Figure 1 and Figure 3The first molding screen 14 is typically a perforated molding screen. The first molding screen 14 partially defines the voids 26 in which the slurry 23 is molded into a solid state. The first molding screen may be substantially flat, or more preferably, define a three-dimensional shape. The first molding screen may be a male or female mold. The first molding screen 14 preferably includes a series of openings 28, the size of which is set to allow water to drain and / or steam to pass through during the molding process. The size of the openings 28 is also preferably set to retain fibers in the slurry 23 within the voids as the slurry 23 is molded into a solid state during the molding process. For example, the openings 28 have a diameter preferably in the range of about 0.1 mm to about 10 mm, and openings 28 between about 0.5 mm and about 2 mm have been found to have particular practicality. The size of the openings 28 can be selected based on several factors, including the size of the fibers in the slurry 23, the amount of water required for drainage, and the surface texture of the final molded product. The first molding screen 14 may also include a secondary embossed pattern 30. In the illustrated embodiment, the secondary embossed pattern shape is typically shown as hexagonal. For example, the embossed pattern may protrude into or recess away from the gap 26, or a combination thereof. Furthermore, the secondary embossed pattern 30 is not limited to hexagons and may take any one or more shapes desired by the designer. For example, the embossed pattern may optionally define text on the finished molded product. The device 10 may function in conjunction with a variety of first molding screens 14 that can be replaced according to the desired final product.

[0029] Now for reference Figure 1 , Figure 2 and Figure 4The second molding screen 16, such as the first molding screen 14, is typically a perforated molding screen. The second molding screen 16 partially defines a void 26 in which the slurry 23 is molded into a solid state. In the illustrated embodiment, the first molding screen 14 and the second molding screen 16 together define the entire void 26. However, in some embodiments, additional screens (e.g., third, fourth, etc.) may be used to define the void 26. The second molding screen 16 provides a shape corresponding to (but opposite to) the first molding screen 14, such that the finished molded part has a substantially uniform cross-section. Alternatively, depending on the application of the material output, the second molding screen 16 may have a completely different shape from the first molding screen 14. Similar to the first molding screen 14, the second molding screen 16 can be replaced and customized to exhibit different material properties, including (but not limited to): shape, texture, and pattern. The size of the opening 32 is also preferably set to retain fibers in the slurry 23 within the voids when the slurry 23 is molded into a solid state during the molding process. For example, opening 32 has a diameter preferably in the range of about 0.1 mm to about 50 mm, and opening 28 between about 0.5 mm and about 10 mm has been found to have particular practicality. Even more preferably, the opening is between about 0.5 mm and about 2 mm. The size of opening 32 can be selected based on several factors, including the size of the fibers in slurry 23, the amount of water required for drainage, and the surface texture of the final molded product. Opening 32 may be the same as or different in size and shape from opening 28 in the first molded screen 14. The secondary molded screen 16 may also include a secondary relief pattern 33 similar to that described in conjunction with the first molded screen 14.

[0030] The first molded screen 14 and the second molded screen 16 may be made of high-grade stainless steel, other durable metals including Inconel type, or high-temperature resistant plastics such as polyoxymethylene (e.g., Delrin). ® and fluorocarbon-based polymers (e.g., Teflon) TM The molded screen 14 and the second molded screen 16 may be made of durable ceramics such as silicon carbide, alumina, or other similar materials known to have suitable properties. The material may also be coated to ensure better stability and / or release properties of the component. The first molded screen 14 and the second molded screen 16 may be 3D printed or, for example, machined. Openings in the first molded screen 14 and the second molded screen 16 allow fluid to flow out of the slurry 23 and out of the device 10 under negative or positive pressure applied during the molding process. In some embodiments, support ribs or other features (not shown) may be required to ensure the structural stability of the first molded screen 14 and the second molded screen 16 during repeated use at high temperatures and pressures.

[0031] Now for reference Figure 1 and Figure 2The second pressing unit 18 includes a second inlet 38, which can be used as a port to apply vacuum or pressure, or to provide airflow or heat, to the interior of the device 10 before, during, or after the molding process. The second inlet 38 may be adapted to receive a detachable adapter, which may be able to connect to a hose or the like, for example, in fluid communication with a source of heat, airflow, vacuum, and / or pressure (not shown). The first pressing unit also provides structural stability to one side of the device 10, thereby enabling the application of significant pressure (e.g., from a hydraulic system) to the slurry 23 during the molding process. For example, depending on the desired final product, hydraulic pressure up to 1000 psi may be required. Additional ports may be included in the first pressing unit to provide drainage of water from the slurry 23, for example, during the molding process. Additionally, the second pressing unit 18 may also include one or more slots 40 for receiving a heating device 22.

[0032] The negative and positive pressures applied during the molding process via, for example, the first inlet 24 and the second inlet 38, can vary depending on the specific needs of the molded product. However, in most applications, negative pressures as low as 14.7 psi or positive pressures as high as 500 psi can be applied via the connected inlets 24, 38, and this has proven to be particularly useful.

[0033] Now for reference Figure 1 and Figure 2 The pressing chamber sleeve 20 at least partially surrounds the first pressing unit 12 and the second pressing unit 18 during operation. The pressing chamber sleeve 20 at least partially encloses various aspects of the system, ensuring proper mold and pressing alignment, and ensuring that the device 10 remains aligned under significant pressure and repeated use. The pressing chamber sleeve may be made of high-grade stainless steel, other durable metals (including Inconel type), or high-temperature resistant plastics (such as polyoxymethylene (e.g., Delrin)). ® ), fluorocarbon-based polymers (Teflon) TM It may be made of other similar materials known to have suitable properties. The material may also be coated to ensure better stability and / or release properties of the part.

[0034] Now for reference Figure 1During typical operation of device 10, at least one heating device 22 (e.g., a heating cylinder) may be utilized. In some embodiments, the required heating may be defined as the wattage required to reach a temperature setpoint within a given time. Typical wattages range from 1500W to 2500W; however, this range may vary depending on the size of the mold used, residence time, cycle time, water content, and ambient temperature. Pressure and heat can be used to effectively remove the desired amount of residual fluid (e.g., water) from slurry 23 and bond the fibers together to form the final solid fiber molded part 25. In some embodiments, it may be desirable to remove substantially all water from slurry 23. In other embodiments, the system may need to be adjusted to maintain some or most of the water in slurry 23.

[0035] Now for reference Figures 5A to 5H The second element 15 may include a single object (e.g., see...). Figure 5B ) or multiple objects (for example, see Figure 5B The second element 15 is designed to add physical, visual, structural, and / or functional properties not present in the first material. Examples of known second elements 15 that can provide visual properties different from the first material 13 include: coloring elements in the form of, for example, thermoplastics, fabrics, rubber, wires, 3D printer inks, fibers, contrast fibers, sequins, recycled object fragments, yarns, filaments, tubular structures, seeds, plant materials, wool / fur / hair; textured materials (e.g., woven, braided, or nonwoven substrate fabrics); light-responsive fibers and / or elements; temperature-responsive fibers and / or elements; pressure- or touch-responsive elements; beads; souvenirs; mirrors; and a variety of materials, including but not limited to leather, fabrics, films, coatings, rubber, and vinyl plastics.

[0036] Examples of second elements 15 that provide functions different from those of the first material 13 include both powered and unpowered objects. Examples of powered objects that can be used as second elements 15 include: lamps; tactile elements; sensors; RIFD tags; microchips; communication or memory devices; electronic devices including connectors, ports, and circuits; conductive fibers; optical fibers; electronic devices (such as, but not limited to, speakers, radios, computers, telephones, and televisions); control panels; batteries, capacitors, or other power sources; solar panels or solar collectors; and screens. Examples of unpowered objects that can be used as second elements 15 include: magnets; keys; buckles; and cleaning fluids.

[0037] Examples of second elements 15 that provide structural properties different from those of the first material 13 include: padding, cushioning material, stuffing or wadding; lining, pocket, lining; support and / or structural elements, such as heel stabilizers and toe caps on the upper; closures, such as zippers, buttons, hooks, shoelaces, laces, snaps, magnets and Velcro; and air cushions.

[0038] Continue to refer to Figures 5A to 5E The first material 13 and the second element 15 can be constructed relative to each other in various ways or combinations thereof. For example, the second element 15 can be completely embedded in (i.e., completely enclosed) within the first material 13 (see example). Figure 5A In another embodiment, the second element 15 may be such that at least a portion of the second element 15 is typically reserved for the second element 15 (see, for example...). Figure 5B The second element 15 is partially embedded within the first material 13 in a manner that surrounds it. In other embodiments, in some cases, the second element 15 is bonded to at least a portion of the surface of the first material 13 during the formation of the first material 13, and / or sandwiched between two pieces of the first material 13 (see, for example...). Figure 5C and Figure 5E In these embodiments, additional components (e.g., adhesives) may be added to the mold or included in the slurry 23, these components enhancing adhesion. In a further embodiment, the second element 15 may extend through the first material 13 (see, for example...). Figure 5D ).

[0039] refer to Figure 5F The second element 15 is a powered device (e.g., a lamp) that is completely embedded within the first material 13. In the illustrated embodiment, the second element communicates electronically with the microcontroller 19 and the power supply 21. Although the microcontroller 19 and the power supply 21 are connected via wires and are located outside the first material 13, the invention is not limited thereto, and the microcontroller 19 and / or the power supply 21 may be partially or completely embedded within the first material 13.

[0040] Now for reference Figure 5G Additional elements (e.g., a third element 17) may be added to the article of the invention during the molding operation in a manner similar to that of the second element, or may be added in subsequent operations. For example, Figure 5G The added material layer can be adhered to the second element 15, or optionally to the first material 13 (not shown).

[0041] The second element can have any suitable shape acceptable to the designer. Some shapes may have specific practical uses. For example, Figure 5GThe second element has a web with various holes formed therein, the intention being that, when embedded in the first material 13, the second element will have an enhanced interaction with the first material 13 because the first material 13 is connected through the holes, etc. Although in Figure 5G The hole is shown, but those skilled in the art will understand that there are a number of second elements 15 of different shapes and sizes that will provide enhanced usability in this invention.

[0042] Generally, the second element 15 can be added to the first material 13 during the molding operation. For example, in the molding operation of this embodiment, the second element can be positioned within the mold cavity 26 before the slurry 23 is added. However, the invention is not limited thereto, and the second element 15 can be added after the slurry 23 is added, but before the first material 13 (i.e., the solid fiber molded part 25) is formed. The timing of introducing the second element 15 into the mold cavity 26 or the slurry 23 in the mold cavity 26 depends on many factors, including but not limited to the specifics of the second element 15 and the type of molding operation utilized.

[0043] refer to Figures 6A to 6G During typical operation, a first molded screen 14 is positioned on a first pressing unit 12, and a second molded screen 16 is positioned on a second pressing unit 18. The first pressing unit 12 and the second pressing unit 18 are positioned such that they are slidably engaged within a pressing chamber sleeve.

[0044] The slurry 23 is provided into the gaps 26 partially formed by the second molded screen 16. A second element 15 is added to the slurry 23 inside the gaps 26 such that the second element is at least partially located within the slurry 23.

[0045] Then, the first pressing unit 12, together with the first molded screen 14, partially slides towards the second molded screen 16 and the second pressing unit 18, as... Figure 5B As shown.

[0046] Optionally, a vacuum may be applied to the second inlet 38, causing water from slurry 23 to be expelled and slurry 23 to begin dewatering. Now refer to Figure 6CHeat is applied to the first pressing unit 14 and / or the second pressing unit 18 via one or more heating devices 22, and pressure is applied to the first pressing unit 12 and / or the second pressing unit 18 via, for example, a hydraulic press, causing the first pressing unit 12 to continue sliding relative to the pressing chamber sleeve 20 toward the second pressing unit 18 until it reaches a predetermined final position or the applied pressure. A predetermined amount of heat and pressure is applied for a predetermined amount of time to drain and / or evaporate water from the slurry 23 and to bond the fibers together, thereby producing a solid fiber molded part 25. The secondary relief patterns 30 and openings 28, 32 in the first molding screen 14 and the second molding screen 16 texture the surface of the solid fiber molded part 25. The second element 15 may remain substantially unchanged or may be changed, for example, in shape, due to mold design, or molding temperature and force.

[0047] Now for reference Figure 6D and Figure 6E Short pulses of pressurized fluid (e.g., air, water, etc.) are applied through the second inlet 38, and negative pressure can be applied through the first inlet 24. Now refer to Figure 6F The first pressing unit 12, together with the first molded screen 14 and the final solid fiber molded component 25 in which the second element 15 is at least partially embedded, slides relative to the pressing chamber sleeve 20 away from the second molded screen 16. Now refer to Figure 6G A pulse of pressurized fluid (e.g., air, water, etc.) is applied through the first inlet 24 to release the solid fiber molded part 25 having a second element 15 at least partially embedded therein.

[0048] In some embodiments, the solid fiber molded part 25 may require additional time to dry outside the mold. Additionally, some post-molding forming steps may be performed to achieve the desired shape. Optionally, additional secondary operations, such as, but not limited to, rinsing and / or applying a coating, may be performed on the final solid fiber molded part 25 before and / or after removal from the equipment.

[0049] Although this document describes the molding operation for forming the slurry 23 into a solid fiber molded part 25, other operations may also be used. Other operations include, but are not limited to, 3D printing, casting the solid fiber molded part by pouring the slurry 23 into a mold, and casting the solid fiber molded part by pouring the slurry 23 into a cavity and then pressing it into shape.

[0050] The corresponding structures, materials, actions, and equivalents of all components or steps plus functional elements in the following claims are intended to include any structure, material, or action used to perform a function in conjunction with other claimed elements specifically claimed. The description in this disclosure is for illustrative and descriptive purposes only and is not intended to be exhaustive or limited to the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of this disclosure. Embodiments were chosen and described to best explain the principles and practical application of the invention and to enable others skilled in the art to understand the disclosure of various embodiments with various modifications suitable for the particular intended use.

Claims

1. A shaped soft article article comprising: a first material comprising a unitary nonwoven material having at least one three- dimensional feature; and at least one second element at least partially embedded within the first material; wherein the first material comprises at least one type of natural or synthetic fiber and at least one of a cross-linking agent, a natural and / or synthetic binder, a bio-based and / or synthetic thermoplastic including nanocellulose, and / or a latex.

2. The shaped soft article article of claim 1, wherein there is more than one second element.

3. The shaped soft article article of claim 1, wherein the second element is an electronic device or component thereof.

4. The shaped soft article article of claim 3, wherein the second element is selected from the group comprising a light, a haptic element, a sensor, a RIFD tag, a microchip, a communication or memory device, a speaker, a radio, a computer, a phone, a television, a screen, and a control panel.

5. The shaped soft article article of claim 3, wherein the second element is selected from the group comprising a battery, a capacitor, and a solar panel or solar collector.

6. The shaped soft article article of claim 3, wherein the second element is selected from the group comprising a circuit, a conductive fiber, and an optical fiber.

7. The shaped soft article article of claim 1, wherein the second element is a decorative element.

8. The shaped soft article article of claim 7, wherein the second element at least partially comprises at least one material selected from the group comprising a thermoplastic, a fabric, a rubber, a wire, a 3D printer ink, a fiber, a contrasting fiber, a sequin, a yarn, a filament, a tube, a seed, a plant material, a wool, a fur, a hair, a leather, a cloth, a film, a coating, a rubber, and a vinyl.

9. The shaped soft article article of claim 7, wherein the second element is selected from the group comprising a light-responsive fiber, a temperature-responsive fiber, a pressure-responsive element, a haptically-responsive element, a bead, and a mirror.

10. The shaped soft article article of claim 1, wherein the second element is partially embedded within the first material.

11. The shaped soft article article of claim 1, wherein the second element is fully embedded within the first material.

12. The shaped soft article article of claim 1, wherein the first material defines an outer surface and the second element is adhered to the outer surface of the first material.

13. The shaped soft article article of claim 1, wherein a third element is attached to one of the first material and the second element.

14. The shaped soft article article of claim 1, wherein the second element extends through the first material.

15. A method for making a shaped soft article article, the method comprising the steps of: mixing at least one type of natural or synthetic fiber and at least one of a cross-linking agent, a natural and / or synthetic binder, a bio-based and / or synthetic thermoplastic including nanocellulose, and / or a latex into an aqueous slurry; providing an amount of the slurry into a mold cavity; draining at least some of the water from the aqueous slurry to leave a mixture including at least the fibers; at least partially embedding at least a second element into the aqueous slurry or the mixture; drying the mixture to remove additional water to result in a solid fiber molded article; and removing the solid fiber molded article having the second element at least partially embedded therein from the mold cavity.

16. The method of manufacturing a shaped soft good article of claim 15, wherein more than one second element is at least partially embedded into the aqueous slurry or the mixture.

17. The method of manufacturing a shaped soft good article of claim 15, wherein the second element is an electronic device or component thereof.

18. The method of manufacturing a shaped soft good article of claim 15, wherein the second element is a decorative element.

19. The method of manufacturing a shaped soft good article of claim 15, wherein the second element is partially embedded into the solid fiber molded article when the article is removed from the mold cavity.

20. The method of manufacturing a shaped soft good article of claim 15, wherein the second element is fully embedded into the solid fiber molded article when the article is removed from the mold cavity.

21. The method of manufacturing a shaped soft good article of claim 15, wherein the first material defines an outer surface and the second element is bonded to the outer surface of the first material when the article is removed from the mold cavity.

22. The shaped soft good article of claim 1, wherein the second element extends through the first material when the article is removed from the mold cavity.

23. A method for forming a shaped soft good article, the method comprising the steps of: mixing at least one type of natural or synthetic fiber and at least one of a cross-linking agent, a natural and / or synthetic binder, a bio-based and / or synthetic thermoplastic including nanocellulose, and / or a latex into an aqueous slurry; draining at least some of the water from the aqueous slurry to leave a mixture; at least partially embedding a second element into the mixture; drying the mixture to remove additional water; pressing the mixture into a desired shape in a press including at least one three-dimensional shape; and removing a solid fiber article having the second element at least partially embedded therein from the press.

24. The method of claim 23, wherein more than one second element is at least partially embedded into the aqueous slurry or the mixture.

25. The method of claim 23, wherein the second element is an electronic device or component thereof.

26. The method of claim 23, wherein the second element is a decorative element.

27. The method of claim 23, wherein the second element is partially embedded into the solid fiber article when the article is removed from the press.

28. The method of claim 23, wherein the second element is fully embedded into the solid fiber article when the article is removed from the press.

29. The method of claim 23, wherein the first material defines an outer surface and the second element is bonded to the outer surface of the first material when the article is removed from the press.

30. The shaped soft good article of claim 23, wherein the second element extends through the first material when the article is removed from the press.

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