Systems and methods for manufacturing fiber-based articles using steam forming

Abstract

In the method, a molding blank comprising a nonwoven material held in compression by an adhesive is placed in a separable mold and heated to the melting temperature of the adhesive. The molding blank expands to form an intermediate NWM object having a three-dimensional shape. The intermediate NWM object is cooled through a temperature zone having a high temperature boundary below the melting temperature of the adhesive and a low temperature boundary above the solidification temperature of the adhesive, and further cooled to the solidification temperature of the adhesive. Within the temperature zone, the mold is separated, and the intermediate NWM object is then transferred to a contoured molding surface of a substrate via vacuum suction by an actuatable arm with an end effector. The actuatable arm compresses the intermediate NWM object against the contoured molding surface and optional end effector final molding features, and continues compression until cooled to the solidification temperature.

Description

[Technical Field]

[0001] ● Cross-reference to related applications This application claims priority to U.S. Provisional Application No. 63 / 123,567, filed December 10, 2020, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates generally to forming three-dimensional objects or portions thereof, and more particularly to forming objects or portions thereof using blanks of compressed thermally expandable nonwoven material. [Background technology]

[0003] U.S. Patent Publication No. PCT / US2020 / 022893 ("'893 Publication"), described in U.S. Provisional Application No. 63 / 123,567, describes a technique for forming thermally expandable blanks (e.g., sheets) comprising a specific nonwoven material held in compression by a specific solidified adhesive into various three-dimensional (3D) shaped objects. As described in the '893 Publication, the compressed state in which the solidified adhesive holds the nonwoven material stores a significant amount of kinetic energy. Also, as described in the '893 Publication, the melting temperature of the adhesive is lower than the melting temperature of the nonwoven material. Therefore, by heating the blank to a temperature between the two melting points, the nonwoven material is released to expand toward its pre-compressed state. Summary of the Invention [Problem to be solved by the invention]

[0004] As described in the '893 publication, molding of heat-expanding nonwoven material blanks (hereinafter referred to as "HE NWM blanks") can be achieved, for example, using a two-part, separable mold with an upper and lower portion that, when assembled, form a mold interior with a contoured surface that matches the desired three-dimensional shape. During the molding process, the mold parts are separated (e.g., by lifting the upper portion off the lower portion) to expose the contoured surface within the lower portion. One or more HE NWM blanks are placed on the accessible mold contoured surface of the lower portion, and the mold is reassembled (e.g., by lowering the upper portion onto the lower portion), enclosing the mold interior around the one or more molded blanks, and heated, for example, by introducing steam into the mold interior via a steam passage. When the temperature of the HE NWM blank reaches the adhesive melt temperature, the adhesive becomes liquid, releasing the nonwoven material from its compressed state. The nonwoven material expands outward toward the pre-compressed dimensions of the HE NWM blanks through the force of kinetic energy stored in compression until it reaches the contoured surface of the mold interior. Then, by turning off the heat and introducing airflow, etc., the temperature of the now expanding NWM and adhesive is lowered over time below the adhesive melting temperature and eventually to the adhesive solidification temperature. The molded NWM three-dimensional object can then be removed from the mold.

[0005] In certain applications, a drawback of the aforementioned techniques is that some changes in the shape of the molded NWM three-dimensional object may occur after removal from the mold. [Means for solving the problem]

[0006] Embodiments provide high-throughput capabilities for first-stage molding and second-stage multi-configurable feature augmentation and finishing. Benefits and features provided by two-stage HE-NWM molding according to various embodiments include, for example, but not limited to, the ability to remove a three-dimensional object formed from an HE-NWM molded blank from the molding die before it has fully cooled to its bond-set temperature. Secondary benefits may include, but are not limited to, higher throughput of the first-stage HE-NWM molding process due to not having to wait for the product to cool sufficiently before removal.

[0007] Features and advantages include maintaining an essentially optimal distribution of shape stabilizing forces on the final molded NWM three-dimensional object without occupying heated molding resources until the object has sufficiently cooled to an adhesive solidification state, as provided by the actuatable arms, contoured contact surface end effectors, and final molding surfaces according to various embodiments.

[0008] Other features and advantages include thermal expansion molding for vertical sidewalls of the NWM three-dimensional object using mold sidewalls with clearance angles, i.e., sloping back from the vertical direction of the final product, which can avoid the difficulty in lifting the upper part of the mold after molding and removing the molded NWM object from the lower part.

[0009] An example of a disclosed method according to various embodiments includes a method of molding an object. The method includes thermally expanding a compressed nonwoven material (NWM) molding blank in a separable mold to form an intermediate NWM-molded three-dimensional (3D) object, and cooling the intermediate NWM-molded three-dimensional object through a temperature zone having a high-temperature boundary and a low-temperature boundary to further cool to a solidification temperature of the adhesive, where the low-temperature boundary is higher than the adhesive solidification temperature and the high-temperature boundary is lower than the adhesive melting temperature. Within the temperature zone, the exemplary method includes separating the separable mold to make an exposed surface of the intermediate NWM-molded three-dimensional object accessible, gripping the intermediate NWM-molded three-dimensional object by vacuum suction from an end effector of an actuatable arm, transporting the gripped intermediate NWM-molded three-dimensional object to a molding surface of a molding substrate by a transport motion of the actuatable arm, and compressing at least a portion of the intermediate NWM-molded three-dimensional object against the molding surface. Further, the exemplary method includes finishing the intermediate NWM molded three-dimensional object by continuing to compress at least a portion of the intermediate NWM molded three-dimensional object against the molding surface until it cools to a solidification temperature.

[0010] An example of a disclosed system according to various embodiments includes an end effector device for removing an expansible object from a mold, the mold having a top inner surface and a bottom inner surface, each surface facing the expansible object, the end effector device including an expansible object contact surface similar to at least a portion of the top inner surface of the mold, at least one robotic arm connected to the expansible object contact surface, the at least one robotic arm configured to move the expansible object contact surface to contact a top of the expansible object, and at least one vacuum suction system connected to the expansible object contact surface, the at least one vacuum suction system configured to remove heat and moisture while providing sufficient vacuum pressure to hold the expansible object against the expansible object contact surface.

[0011] A disclosed exemplary system according to various embodiments includes a separable mold including a lower part and an upper part that, when assembled, form a molding vessel, and a steam channel that receives supplied steam and conveys at least a portion of the steam to the molding vessel. The mold is configured, when assembled, to enclose one or more HE-NWM blanks, which may include NWM compressed in solidified adhesive, within the molding vessel. The mold is configured, at least in part, to perform heat shaping of the blanks in response to the supplied steam to fill the molding vessel and form an intermediate NWM-molded three-dimensional object. The exemplary system may also include a mold separation device configured to separate the upper part from the lower part, leaving the intermediate NWM-molded three-dimensional object supported by the lower part with an exposed upper surface. The exemplary system further includes an end effector connected to the actuatable arm and having a contact surface primarily corresponding to the contour of the exposed upper surface. The actuatable arm is configured to, for example, in response to a control signal from the control controller, perform the transport of the intermediate NWM molded three-dimensional object by positioning a contact surface against the exposed upper surface and establishing an adhesive grip with the contact surface of the exposed upper surface via a vacuum path through an opening in the contact surface to lift the intermediate NWM molded three-dimensional object from the lower part of the mold and transport the intermediate NWM molded three-dimensional object to a contoured lower final molding surface of a molding substrate adjacent to the separable mold. The actuatable arm, the end effector, the contact surface of the end effector, and the contoured lower support surface are configured to apply a specific pressure to the intermediate NWM molded three-dimensional object to augment and finish the molding of features, and to maintain a stabilizing pressure against the final molding of the NWM molded three-dimensional object until the adhesive is fully solidified.

[0012] Another example method according to various embodiments includes a mold molding method including providing a mold including a top and a bottom, the mold configured to transfer heat from steam to the top and bottom of the mold and configured to remove moisture from the interior of the mold by vacuum suction, and placing an expansive object in the mold to form a configuration that uses the heat from steam when the top is placed on the bottom of the mold, with the expansive object disposed between the top and bottom of the mold. This exemplary method further includes applying vacuum suction to the mold during and / or after molding to remove heat and moisture from the mold, and opening the mold such that the top separates from the bottom of the mold, exposing at least a portion of the expansive object while the expansive object remains disposed on the bottom of the mold. The exemplary method also includes placing an inflatable contact surface of an end effector device over the exposed portion of the inflatable while applying sufficient vacuum to cool and hold the inflatable against the inflatable contact surface of the end effector device, whereby the inflatable contact surface of the end effector device cools and holds, thereby setting the configuration to a first configuration; and removing the inflatable in the first configuration from the bottom of the mold.

[0013] This Summary identifies exemplary features and aspects and is not an exclusive or exhaustive description of the disclosed subject matter. The inclusion or omission of a feature or aspect from this Summary is not intended to indicate the relative importance of such feature or aspect. Additional features are described both explicitly and implicitly, as will be understood by those skilled in the art upon reading the following detailed description and viewing the drawings that form a part thereof. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a functional block schematic diagram of one example of a system supporting a two-stage HE-NWM forming process, according to one or more exemplary embodiments. [Figure 2A]FIG. 2A shows a top plan view of an exemplary assembled separable mold 200 for a molding process, according to one or more embodiments. [Figure 2B] FIG. 2B is a front view of an exemplary assembled separable mold 200 at cross-sectional projection 2B-2B of FIG. 2A for a molding process, according to one or more embodiments. [Figure 3] FIG. 3 is an enlarged cross-sectional front view of an exemplary separable mold at cross-sectional projection 2B-2B of FIG. 2A with an HE-NWM formed blank compressed within the mold. [Figure 4] FIG. 4 shows a front cross-sectional view in the cross-sectional projection of FIG. 3 of an intermediate NWM three-dimensional object produced by the first-stage HE-NWM forming process of the compressed HE-NWM forming blank. [Figure 5] FIG. 5 shows a cross-sectional front view in the cross-sectional projection of FIGS. 3 and 4, showing the exposed top surface of the NWM molded three-dimensional object after the top part of the mold has been removed. [Figure 6] FIG. 6 shows a front cross-sectional view of an exemplary effector according to an exemplary embodiment that provides a contact surface configured for the top surface of a first stage NWM three-dimensional object that is placed on an intermediate NWM molded three-dimensional object by the actuatable arm of FIG. [Figure 7] FIG. 7 shows a front cross-sectional view of the exemplary end effector of FIG. 6 with contact surface and activated vacuum suction against the top surface of the intermediate NWM molded three-dimensional object for further transport to second stage augmentation and finishing according to one or more embodiments. [Figure 8] Figure 8 shows a front cross-sectional view of the end effector of Figure 7, together with the contact surface against the top surface of the intermediate NWM molded three-dimensional object after lifting the first stage NWM molded three-dimensional object from the bottom of the separable mold. [Figure 9] FIG. 9 shows a front cross-sectional view of the end effector of FIG. 7 transporting and positioning a first-stage NWM molded three-dimensional object onto an exemplary finishing molding surface and exemplary finishing contour features of an exemplary second-stage molding substrate for second-stage molding augmentation and finishing according to one or more embodiments. [Figure 10] Figure 10 shows a front cross-sectional view of the end effector of Figure 8 after positioning the first stage NWM molded three-dimensional object on the second stage molding substrate of Figure 9 and pressing the intermediate NWM molded three-dimensional object against the finishing molding surface and its finishing molding contour features for second stage molding augmentation and finishing according to one or more embodiments. [Figure 11] Figure 11 shows a front cross-sectional view of an exemplary finished NWM three-dimensional mold after the second stage of augmentation and finishing illustrated in Figure 10 has cooled the finished NWM three-dimensional mold below the adhesive solidification temperature, fixing the shape and dimensions of the three-dimensional mold, and the actuatable arm has removed the end effector. [Figure 12A] FIG. 12A shows a first rotational view of a finished NWM three-dimensional molded object produced by the described exemplary two-stage HE-NWM molding process, according to one or more embodiments. [Figure 12B] FIG. 12B shows a second rotational view of a finished NWM three-dimensional molded object produced by the described exemplary two-stage HE-NWM molding process, according to one or more embodiments. [Figure 13] FIG. 13 shows a top isometric view of an exemplary end effector connected to an actuatable arm for first-stage NWM object removal and transport and second-stage molding augmentation and finishing operations in an exemplary two-stage NWM three-dimensional molding process according to various embodiments. [Figure 14] FIG. 14 illustrates another isometric view of an exemplary contoured contact surface of the end effector of FIG. 13 according to various embodiments. [Figure 15] 15 is a plan view of an exemplary contoured contact surface of the end effector of FIG. 14. FIG. [Figure 16] FIG. 16 shows an isometric view of another exemplary finishing molding profile feature of another exemplary second stage molding substrate for another second stage molding augmentation and finishing in a two-stage NWM three-dimensional molding process according to various embodiments. [Figure 17]Figure 17 shows a first projection view of another exemplary finished NWM three-dimensional molded object that can be produced by a two-stage HE-NWM molding process according to various embodiments using the exemplary end effector illustrated in Figures 13-15 and the final molded contour illustrated in Figure 16. [Figure 18] FIG. 18 is a perspective isometric view of the backside of the finished NWM three-dimensional molding shown in FIG. [Figure 19] FIG. 19 illustrates a flowchart of operations in an exemplary process of a two-stage HE-NWM forming process according to various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0015] FIG. 1 is a functional block schematic diagram of one example of a system 100 that can support a two-stage HE-NWM molding process, according to one or more exemplary embodiments. The system 100 includes a separable mold 102 that can include an upper component 106 and a lower component 104. As described in more detail with reference to FIGS. 2A and 2B , the upper component 106 and the lower component 104 are configured to accommodate one or more HE-NWM formed blanks on a generally upwardly facing lower forming surface of the lower component, and the upper component 106 is configured with a generally downwardly facing upper forming surface that, upon assembly of the components of the mold 102, complements the forming surface of the lower component 104 to form a forming cavity and enclose the one or more formed blanks. The lower component 104 and the upper component 106 may include steam passages for the molding process, as described in more detail in a later section and in the '837 publication. The steam passages distribute the supplied steam internally, thereby heating the separable mold 102 parts, and transfer the supplied steam into the forming bath to directly heat the HE-NWM forming blank.

[0016] The system 100, according to various embodiments, further includes an actuatable robotic arm 108 (alternatively referred to herein simply as an "actuatable arm" 108) and an end effector 110 connected to the tip of the actuatable arm 108. Located on a portion of the end effector 110 in the orientation and position shown in FIG. 1 when the actuatable arm 108 is facing downward is a contact surface, examples of which are described in more detail with reference to FIGS. 6-10, 14-15, and elsewhere herein. In overview, the contact surface may be contoured using one or more blanks of HE NWM material to fit the top surface of the three-dimensional object to be molded in the separable mold 102. The end effector 110 further includes a vacuum suction channeling system. The vacuum suction channeling system extends from the connection of the vacuum suction tube 112 to a plenum chamber or equivalent, as represented by the straight housing shown above the upper housing of the end effector 110, and from the interior volume of the plenum chamber or equivalent, through tubes or passages within the end effector 110 to the vacuum passage opening on the contact surface.

[0017] The functions of the actuatable arm 108 and the end effector 110 according to various embodiments include transporting the NWM-molded three-dimensional object from the lower part 104 to an adjacent final molding substructure or base 114 after steam heating of the HE-NWM, and subsequently placing the NWM-molded three-dimensional object on a lower final molding surface 116 of the structure 114. The operation of the exemplary actuatable arm 108 for such transport and placement can be performed, for example, under the control of a control processor, for example, within the actuatable arm 108 or connected by a network. The operation includes positioning a contact surface of the end effector 110 on an upper exposed surface of the NWM-molded three-dimensional object by moving the actuatable arm 108, activating a suction grip with the contact surface, for example, by controlling a vacuum flow valve, followed by lifting the gripped NWM molded object, and manipulating the arm 108 to place the object on the lower final molding surface 116.

[0018] It will be appreciated that an essential feature of the two-stage HE-NWM molding process according to various embodiments is that second-stage processing, such as conveying the NWM-molded three-dimensional object to the lower final molding surface 116, begins after the NWM-molded three-dimensional object has cooled below the high temperature boundary of a temperature zone (referred to herein for convenience and consistency as the "secondary molding temperature zone").

[0019] The hot boundary is below the melting temperature of the adhesive but above the solidification temperature of the adhesive.

[0020] The process according to various embodiments allows, among other features, to take advantage of the constant workability of NWM formed three-dimensional objects within the forming temperature range.

[0021] The features and advantages provided by the actuatable arm 108 and end effector 110 in combination with the lower final forming surface 116 include maintaining optimally distributed shape stabilizing forces on the final NWM molded three-dimensional object until the object has cooled sufficiently to the solidified state of the adhesive.

[0022] The functions of actuatable arm 108 and end effector 110 also include what, for purposes of explanation, may alternatively be referred to herein as "molding augmentation and finishing processes."

[0023] Features of system 100 that provide such functionality, according to one or more embodiments, include contouring of the contact surface of the end effector and contouring of the lower final forming surface 116. Other features, according to various embodiments, include using the end effector 110 to place attachment components, decorative components, other components, and devices on the lower final forming surface 116 for compression embedding within the NWM molded three-dimensional object before the NWM molded three-dimensional object cools below a temperature band.

[0024] Another feature of the two-stage HE-NWM molding process according to various embodiments is the completion of the molding augmentation and finishing process, or at least substantial completion of non-minor molding, before the NWM molded three-dimensional object is cooled below the low temperature boundary of the temperature band, or at least before further molding is performed at an unacceptable cost. Example costs may include an unacceptable risk of causing structural defects in the final NWM molded three-dimensional object. Costs may also include, for example, reduced tool life or reduced life of the actuatable arm 108 due to wear and breakage resulting from the higher forces required for molding at lower temperatures.

[0025] FIG. 2A shows a top view of an assembled embodiment of the two-piece separable mold 100 of FIG. 1. FIG. 2B shows a front view at cross-sectional projection 2B-2B of FIG. 2A. The embodiment of FIG. 2 includes an embodiment of a lower part 104 and an upper part 106 superimposed thereon. The complementary inner surfaces of the assembled lower part 104 and the upper part 106 superimposed thereon enclose a mold interior 202. The molding surface of the mold interior 202 includes a contoured bottom molding surface 204 formed by features on the upper part of the lower part 104, which is complemented by a contoured top molding surface 206 formed by features on the lower part of the upper part 106. For purposes of explanation, the contoured bottom molding surface 204 and the contoured top molding surface 206 are collectively referred to as the "contoured interior molding surfaces 204 / 206."

[0026] It will be understood that the illustrations of contoured interior molding surfaces 204 / 206 in Figures 2A and 2B are general representations of what can be complex geometries and configurations in a variety of applications and embodiments.

[0027] For purposes of illustration, contoured molded top surface 206 includes any configuration of molding features including first top surface molding feature 206a, second top surface molding feature 206b, and optional other features 206n only if nth top surface molding feature 206n is visible.

[0028] FIG. 3 is a front elevation view of the exemplary two-part separable mold 102 of FIGS. 2A-2B at cross-sectional projection 2B-2B of FIG. 2A, with an exemplary compressed heat-expandable nonwoven material (HE-NWM) molded blank 302 positioned inside the mold.

[0029] An exemplary process of the method according to various disclosed embodiments, including an example starting with an HE-NWM formed blank 302 in the exemplary two-part separable mold 102 of FIG. 3, is described in the following paragraphs.

[0030] Before proceeding with exemplary features and processes of systems and methods according to various embodiments, certain features, options, and configurations of example compressed HE-NWM formed blanks that may be used in the implementation of such systems and methods will be described with reference to accompanying Figures 3-12B. Further, for academic purposes, for example, a description may be found in the referenced '893 publication.

[0031] In overview, the formation of an example HE-NWM forming blank 302 begins with a nonwoven material. The nonwoven material can be made from a mass of fibers including adhesive fibers and one or more other fibers. The adhesive fibers can be, for example, polyesters such as ELK®, E-PLEX®, and EMF-type high modulus LMF, which are commercially available from Teijin Limited, Toray Chemical Korea Inc., and Huvis Corporation, respectively. These exemplary adhesive fibers have melting temperatures of, for example, 80°C-150°C, which are below the melting or decomposition temperatures of the one or more other fibers. When melted, the adhesive fibers zigzag along the outside of the one or more other fibers. When hardened, the adhesive fibers create a mass of one or more other fibers, with adjacent fibers secured to one another at various locations by the adhesive, which causes the adhesive fibers to melt and reharden, creating a nonwoven structure. Therefore, these nonwoven fabrics are also called "thermally bonded nonwoven fabrics."

[0032] The process of forming the HE-NWM forming blank 302 involves compressing the nonwoven material, heating it to the melting temperature of the adhesive, and maintaining the compression until the adhesive cools and re-solidifies. Because the compressed fiber orientation is different from the original fiber orientation, the compressed state of the NWM fibers held by the solidified adhesive effectively stores kinetic energy. Therefore, it will be understood that in order for the blank to store the kinetic energy of compression, its dimensions, i.e., the compressed dimensions held by the solidified adhesive, must be less than the original dimensions (height, width, or length) of the nonwoven.

[0033] Vertically lapped ("V-Lap") nonwoven materials are preferred for some applications, such as seating and bedding components, because they are stiff and resilient in the vertical direction, which is the direction that resists the weight of a person's back or buttocks. Blanks formed from V-Lap nonwovens can be compressed 50%, 60%, 70%, 80%, or 90% from their original height and can subsequently expand toward or beyond their original height upon heating.

[0034] Preferably, the thermally bonded nonwoven fabric in accordance with the disclosed embodiments has at least 5% by weight of adhesive, with up to 95% by weight of one or more other fibers. The percentages may depend on application-specific requirements. In some applications, the thermally bonded nonwoven fabric may also contain additional materials, such as flame-retardant ("FR") compounds, fragrance compounds, antimicrobial compounds or materials, polymer coatings, metal or ceramic particles, etc.

[0035] An example ratio of adhesive to one or more other fibers of a nonwoven fabric used in the practice of disclosed embodiments may range from 5:95 to 95:5.

[0036] Examples of thermal bonded nonwovens that may be used in the implementation techniques according to disclosed embodiments include, but are not limited to, any thermal bond made using any of the exemplary combinations of materials and corresponding percentages shown in Table 1. TIFF0007802794000001.tif214170

[0037] Examples of thermally bonded nonwovens that may be used in the implementation techniques according to the disclosed embodiments include, but are not limited to, any thermally bonded fabric made of hollow fibers, for example, hollow polyethylene terephthalate (PET).

[0038] Examples of thermally bonded nonwovens that may be used in the implementation techniques according to the disclosed embodiments may include, but are not limited to, any thermally bonded nonwoven made of bicomponent fibers, sometimes referred to as core-sheath fibers.

[0039] The adhesive fibers used to make nonwoven fabrics that can be used in the techniques according to the disclosed embodiments can also include sheath-core fibers where the sheath is polyester or some other material with a low melting temperature.

[0040] Examples of nonwoven fabrics that are not preferred in the practice of the present invention include any thermally bonded nonwoven fabric made from fibers that melt at a temperature below the melting temperature of the adhesive fibers, and any thermally bonded nonwoven fabric made solely from adhesive.

[0041] Optionally, in an implementation technique according to one or more disclosed embodiments, blanks may be stacked to form a sheet. The stacking may be blank-to-blank or blank-to-blank with non-expanding materials such as foam, fabric (e.g., knitted material), rubber, metal, metal alloy, polymer, ceramic, and paper material. The sheet may also be cut to a desired size and shape, for example, using a suitable computer-controlled or manual cutting machine.

[0042] A "nonwoven fabric" is a manufactured sheet, web, or batt of natural and / or man-made fibers or filaments bonded together by any of a variety of means. The fabrication of nonwoven products is well described in "Nonwoven Textile Fabrics," Kirk-Othmer Encyclopedia of Chemical Technology, 3rd Edition, Vol. 16, July 1984, John Wiley & Sons, pp. 72-124, and in "Nonwoven Textiles," Carolina Academic Press, November 1988. Nonwoven fabrics are commercially available from numerous manufacturers.

[0043] In some applications, plates / blanks made of NWM in a vertically folded ("V-Lap") configuration may offer advantages in terms of support or comfort. In this case, "vertical" refers to, for example, the direction that opposes the weight of a person's back or buttocks. A V-Lap nonwoven blank or plate can be compressed 50%, 60%, 70%, 80%, 90%, etc., from its original height dimension and then expanded toward, up to, or beyond its original height dimension upon heating. Vertical folding may be performed using methods described in U.S. Patent Application Publication No. 2008 / 0155787 and U.S. Patent No. 7,591,049, each of which is incorporated herein by reference. Vertically folded nonwovens are commercially available from various commercial vendors.

[0044] Nonwoven fabrics in accordance with the disclosed embodiments of the present invention can be made from a mass of fibers that can include adhesive fibers and one or more other fibers. The adhesive fibers have a melting temperature lower than the melting or decomposition temperature of the one or more other fibers, e.g., the adhesive fibers typically have a melting temperature of 80°C-150°C. (Polyester is a typical example of adhesive fibers used in the manufacture of nonwoven fabrics. Elastic polyester adhesive fibers include ELK®, E-PLEX®, and EMF-type high modulus LMF, available from Teijin Limited, Toray Chemical Korea Inc., and Huvis Corporation, respectively.) Once melted, the adhesive fibers generally zigzag along the outside of one or more other fibers and harden upon cooling, with the adhesive resulting from the melting and re-hardening of the adhesive fibers securing adjacent fibers to one another at various locations throughout the nonwoven, creating a nonwoven that is essentially a mass of one or more other fibers. These nonwovens are often referred to as thermally bonded nonwovens. Thermally bonded nonwovens in accordance with the practice of the present invention will have at least 5% by weight of adhesive, with up to 95% by weight of one or more other fibers. Depending on the needs of the article manufacturer, the adhesive may comprise 5%-50% by weight of the nonwoven, with the remainder being one or more other fibers or one or more other fibers plus other 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, sulfamic acid and its derivatives, boric acid, ammonium phosphate, ammonium polyphosphate, ammonium sulfate, ammonium sulfamate, ammonium chloride, and ammonium bromide.

[0045] Depending on the application, the ratio of adhesive to one or more other fibers in the nonwoven fabric for the implementation techniques according to the disclosed embodiments may range from 5:95 to 95:5.

[0046] Hollow fibers, such as hollow polyethylene terephthalate (PET), may be used in the techniques according to the disclosed embodiments. Additionally, nonwoven fabrics that may be useful in the techniques according to the disclosed embodiments may be formed using bicomponent fibers, which may be referred to as sheath-core fibers. Bonding fibers used in making nonwoven fabrics that may be used in the techniques according to various embodiments may include sheath-core fibers, where the sheath is polyester or some other low-melting temperature material.

[0047] As mentioned above, FIG. 3 shows a front cross-sectional view of the exemplary separable mold 102 at cross-sectional projection 2B-2B of FIG. 2A with the exemplary compressed HE-NWM molded blank 302 formed as described above within the mold.

[0048] FIG. 4 shows a cross-sectional front view in the cross-sectional projection of FIG. 3 of an intermediate NWM formed three-dimensional object 402 produced by the first stage HE-NWM forming process of the compressed HE-NWM formed blank 302.

[0049] 5 is a cross-sectional front view of the cross-sectional projection of FIGS. 3 and 4 showing the exposed top surface 502 of the intermediate NWM molded three-dimensional object after removal of the top part 106 of the mold. The top surface 502 is shown along with a first top contour 502A of the intermediate object, which corresponds to the first top contour 206a of FIG. 2A and the exemplary contoured molded top surface 206 of FIG. 2B, and a second top contour 502b and an nth top contour 502n of the intermediate object, which correspond to the second top contour 206b and the nth top contour 206n of FIG. 2A and 2B, respectively.

[0050] FIG. 6 shows a front cross-sectional view of an example of an end effector 110, according to an illustrative embodiment. The end effector in FIG. 6 provides a contact surface 602 configured for the top or upper surface 502 of an intermediate NWM molded three-dimensional object 402, which is placed on the intermediate NWM molded three-dimensional object by actuation of the actuatable arm 108 in FIG. 1 . The contact surface 602, according to various embodiments, can be configured with various contours, such as the example shown in FIG. 6 (visible but not separately labeled), to correspond to each of the first top surface contour 502A, second top surface contour 502B, and nth top surface contour 502n of the intermediate object. Accordingly, the contact surface 602 is also referred to herein as a “contoured contact surface” 602.

[0051] In one embodiment, the contoured contact surface 602's contoured features can be identical to the molded top surface features of the upper part 106 of the separable mold 102. Figure 6 shows an example of such a configuration, in which the first top surface contour 502A, the second top surface contour 502B, and the nth top surface contour 502n of the intermediate object are identical to the first top surface contoured feature 206a, the second top surface contoured feature 206b, and the nth top surface contoured feature 206n of the contoured molded top surface 206 of Figures 2A-2B. Such a configuration, along with a second-stage molding augmentation and finishing operation on the bottom surface of the intermediate NWM molded three-dimensional object 402, as described below, can provide finishing and fixing of the contour of the top of the final NWM product to match the original contoured molded top surface 206. Benefits and advantages of such a configuration may include, but are not limited to, a solution to undesirable post-molding expansion that may occur when a molded NWM three-dimensional object is removed from its thermally expanded mold before it has fully cooled to the NWM bond solidification temperature.

[0052] In another embodiment, the contact contour features of contact surface 602, or some of such features, may be in addition to, augment, or otherwise differ from contoured shaped upper surface 206 of FIGS. 2A-2B.

[0053] Referring to FIG. 6, the exemplary end effector 110 includes multiple vacuum lines 604, each establishing a fluid connection from an opening in the contact surface 602 to a vacuum plenum 606. It will be understood that the vacuum lines 604 are merely examples of vacuum raceways. Alternative embodiments include, but are not limited to, tubular structures. For illustrative purposes, FIG. 6 shows the vacuum activating with representative flow arrows.

[0054] FIG. 7 illustrates a front cross-sectional view of the exemplary end effector 110 of FIG. 6 with a contact surface 602 and activated vacuum suction against the top surface 502 of the intermediate NWM molded three-dimensional object 402 for further transport to second-stage augmentation and finishing, according to one or more embodiments.

[0055] 8 shows the same cross-sectional front view of the end effector 110 as in FIG. 7 , with the contact surface 602 against the top surface 502 of the intermediate NWM molded three-dimensional object 402 after lifting the object 402 from the lower part 104 of the separable mold 102. The position visible in FIG. 8 is a moment in the motion sequence or trajectory performed by the actuatable arm 108, for example under control as described above, to transport the intermediate NWM molded three-dimensional object 402 from the lower part 104 of the now-separated mold 102 to the second-stage molding substrate 114 of FIG. 1 for second-stage augmentation and finishing according to one or more embodiments.

[0056] 9 shows a front cross-sectional view of the end effector 110 of FIG. 7 carrying and placing a first-stage NWM molded three-dimensional object onto the exemplary finishing molding surface 116 and finishing contour feature 116a of the second-stage molding substrate 114 of FIG. 1. To illustrate various features of the second-stage augmentation and finishing according to various embodiments, the perspective view of the second-stage molding substrate 114, its finishing molding surface 116, and finishing contour feature 116a in FIG. 9 is at the cross-sectional projection 9-9 of FIG. 1. An operation in the second-stage augmentation and finishing process according to disclosed embodiments can include the actuatable arm 108 lowering the end effector 110 to compress the underside of the gripped intermediate NWM molded three-dimensional object 402 onto the finishing molding surface 116 and its exemplary finishing contour feature 116a. Although not explicitly visible, compression can also complement or augment the characteristics of the top surface 502 of the intermediate NWM molded three-dimensional object 402, as described above, depending in part on the particular configuration of the contoured contact surface 602.

[0057] Figure 10, in the same front cross-sectional view as Figure 8, shows the end effector 110 forcing the intermediate NWM molded three-dimensional object 402 against the finishing molding surface 116 and its finishing molding contour feature 116a after positioning the first-stage NWM molded three-dimensional object 402 on the second-stage molding substrate 114 of Figure 9 for second-stage molding augmentation and finishing.

[0058] Figure 11 shows a front cross-sectional view of an exemplary finished NWM three-dimensional molded object 1100 after the second stage of augmentation and finishing illustrated in Figure 10 cools the finished NWM three-dimensional molded object below the adhesive solidification temperature, fixing the shape and dimensions of the three-dimensional molded object, and the actuatable arm 108 removes the end effector 110.

[0059] 12A and 12B show a first and second rotational view of a finished NWM three-dimensional object 1100 produced by the described exemplary two-stage HE-NWM molding process, according to one or more embodiments.

[0060] 13 shows a top isometric view of an exemplary end effector 1300 connected to an actuatable arm 1302 for first-stage NWM object removal and transfer and second-stage molding augmentation and finishing operations in an exemplary two-stage NWM three-dimensional molding process according to various embodiments. The end effector 1300 comprises a rotatable mechanical connection 1304 to the actuatable arm 1302 and a vacuum plenum or vacuum distribution chamber 1306 that receives vacuum 1314 through a vacuum connection hose 1312 via a side vacuum distribution channel 1310. The end effector also comprises a connector or mounting clamp 1308 for attachment and fastening to, for example, a lower part of a mold.

[0061] 14 shows an isometric view of the example contoured contact surface 1400 of FIG. 13 according to various embodiments, as viewable by rotating FIG. 13 about the axis of the rotatable mechanical connection 1304. The contoured contact surface 1400 includes a first instance of a first contour embossed feature 1402 in a first region and a second instance of the first contour embossed feature 1402 in a second region. The contoured contact surface 1400 also includes a first instance of a second contour embossed feature 1404 in the first region and an instance of a first concave contour feature 1406 in the first region.

[0062] Figure 15 is a plan view of a first region 1500 of the example contoured contact surface 1400 of an end effector of Figure 14. As shown, the first region further includes a texture feature 1502 and a second concave contour feature 1504.

[0063] 16 shows an isometric view of an exemplary finishing molding profile 1600 of a second stage molding substrate for second stage molding augmentation and finishing in a two-stage NWM three-dimensional molding process according to various embodiments. The finishing molding profile 1600 may be, for example, an embodiment of the finishing molding surface 116 of FIG. 1. The finishing molding profile 1600 comprises a finishing feature 1602.

[0064] FIG. 17 shows a first projection view of an exemplary finished NWM three-dimensional molded object 1700 that can be produced by a two-stage HE-NWM molding process according to various embodiments using the exemplary end effector illustrated in FIGS. 13-15 and the finished molding profile illustrated in FIG. 16.

[0065] Figure 18 is an isometric view of the finished NWM three-dimensional molded part 1700 illustrated in Figure 17, showing the finished molded part 1800 from the underside. The finished molded part 1800 includes a first recess 1802 and a second recess 1804. The first recess 1802 corresponds to the second concave contour feature 1504 in Figure 15, and the second recess 1804 corresponds to the first concave contour feature 1406 in Figure 14.

[0066] 19 shows a flowchart of operations in an exemplary process 1900 of a two-stage HE-NWM molding process according to various embodiments. For ease of block labeling, "intermediate NWM molded three-dimensional object" is abbreviated as "IMD object" in FIG. 19 .

[0067] 19 includes a temperature state progression 1901 positioned on a block of process 1900, which will be referenced in the following description of operations in an instance of exemplary process 1900. For example, the instance includes the production of an intermediate NWM molded three-dimensional object by thermal expansion 1902 of a compressed NWM molded blank within a separable mold. Referring to FIGS. 3-12B by way of example, an example of thermal expansion 1902 includes placing a compressed HE NWM molded blank 302 within a separable mold, such as separable mold 102, as shown in FIG. 3, and heating the compressed HE NWM molded blank 302, for example, but not limited to, via passing steam through one or both of the top and bottom parts 106 and 104 of the separable mold 102. As indicated by reference point 1901A of temperature state progression 1901, in one embodiment, thermal expansion 1902 raises the temperature of the compressed NWM molded blank 302 to a value above the melting temperature of the adhesive of the compressed NWM molded blank.

[0068] Upon completion of the thermal expansion 1902 operation in process 1900, process 1900 may proceed with cooling 1904 of the IMD object to a high temperature boundary of a final molding temperature zone. As previously mentioned, the high temperature boundary is below the melting temperature of the NWM adhesive but above the adhesive set temperature. FIG. 19 illustrates the temperature at the start of cooling as 1901B and the high temperature boundary of the final molding temperature zone as 1902C. In response to the temperature of the IMD object decreasing to the high temperature boundary 1901C, operations in process 1900 proceed to step 1906 of separating the separable mold, thereby exposing the upper surface or top of the IMD object. It will be understood that, in the context of the exposed surface of the IMD object, “upper” and “top” refer to the bottom part 104 and top part 106 of the exemplary separable mold 102 of FIG. 1 . In some applications, the exposed top surface of the IMD object may be the bottom or the side of the final NWM mold.

[0069] Depending on the particular setting of the hot boundary 1901C and the particular NWM, there may be undesirable degradation from the separation 1906 before the IMD object cools to or sufficiently near the hot boundary 1901C of the temperature condition progression 1901. The cooling rate may be increased, for example, by airflow. Optionally, as described in the '837 publication, the cooling rate may be increased using cycles of vacuum removal of vapor condensation, repressurization, vacuum removal, etc.

[0070] After separating the molds 1906, operations in method 1900 may proceed to transferring the IMD object to the final molding surface of the molding substrate 1908. As shown in FIG. 19 , the operation in transferring 1908 includes the end effector of the actuated arm performing a vacuum gripping 1908a of the top surface and then performing a continuous transfer action 1908b that lifts the IMD object from the separated mold to place the IMD object on the final molding surface. An example of these operations is the actuable arm 108 of FIG. 1 positioning the contact surface 111 of the end effector 110 on the exposed surface of the IMD object, as shown in FIG. 6 , where the contact surface 602 of the end effector 110 is above the exposed top surface 502 of the exemplary IMD object 402. Then, as shown in Figure 7, vacuum suction can be activated to grip the IMD object 402 sufficiently to withstand the weight of the IMD object and any adhesion of the bottom surface of the object to the bottom surface 204 of the mold bottom part 104 (previously labeled in Figure 2B). Then, with reference to Figure 8, an example operation to perform transfer operation 1908b can lift the IMD object 402 from the surface 204 of the bottom part 104 and transfer the IMD object to the position illustrated in Figure 9 by various rotations of the actuatable arm segments about their pivot axes (visible in Figure 1 but not separately numbered). The position shown in Figure 9 is above the final molding surface 116 having the exemplary final molding feature 116a.

[0071] Operations in process 1900 then proceed to step 1910, in which a portion of the IMD object is compressed against one or more final molding surfaces, or between two or more final molding surfaces, or both. As shown in Figure 19, compression step 1910 begins while the IMD object is within the final molding temperature zone. It will be appreciated that because the adhesive is above its solidification temperature but below its melting temperature, it can be remolded without requiring an undesirable amount of force and without an unacceptable incidence of stress-induced structural defects.

[0072] In one embodiment, the operations in the compression step 1910 may be configured to remove features from the thermal expansion mold of the IMD object.

[0073] Referring to FIG. 10, an exemplary operation in a compaction step 1910 is shown as a work-in-progress formed IMD object 1002 having a recessed region corresponding to the final formed contour 116a.

[0074] In one embodiment, the contact surface 602 of the end effector 110 may also include a final molding contour. In another embodiment, the contact surface of the end effector 110 may include a final molding contour, and the final molding surface 116 of the lower molding substrate 114 may include a molding contour. For purposes of explanation, the molding contour on the final molding surface 116 of the lower molding substrate 114, such as molding contour 116a, will be referred to as the "lower" or "base" final molding contour, and the final molding contour on the contact surface of the end effector, such as contact surface 602 shown in FIG. 6, will be referred to as the "top," "upper," or "end effector" molding contour.

[0075] Referring to FIG. 19, operations in process 1900 may then proceed to step 1912 of continuing or maintaining said compression until the in-process NWM molded three-dimensional object cools to the solidification temperature 1901D of the adhesive.

[0076] Referring to Figures 1, 2A-2B, 3, and 4, a vacuum pump system can be provided to facilitate removal of moisture, steam, and associated heat. Examples are described in more detail in the '837 publication. As described, after or concomitantly with venting steam pressure from the separable mold 102, a vacuum pump can be used to draw a vacuum within the interior of the mold, such as the interior 202 of the mold in Figure 2B. After drawing the vacuum, the mold is held at vacuum pressure for another period of time. The vacuum pump is then stopped, the mold is returned to atmospheric pressure, and the intermediate NWM molded three-dimensional object can be removed. In another embodiment, additional steps can be applied to pressurize the mold multiple times, vent steam pressure, and apply vacuum pressure to the mold multiple times. It has been found that controlling the pressurization of the mold when adding steam to the mold and controlling the application of vacuum to the mold before removing the part from the mold can result in a more uniform and complete expansion. Examples are described in more detail in the '837 publication.

[0077] It should be noted that, as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. It should further be noted that the claims may be drafted to exclude optional elements. Accordingly, this statement is intended to support the use of exclusive terms such as "solely" or "only" in connection with the recitation of claim elements in the claims, or "negative" limitations such as "without [the particular feature or element]," "excluding [the particular feature or element]," or "wherein [the particular feature or element] is not present (not included, etc.)..."

[0078] Where a range of values ​​is given, it is understood that, unless otherwise specified, every value between the upper and lower limits of that range, to the tenth of the unit of the lower limit of the range, and every other stated value or value between that stated range, is included within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also included within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.

[0079] As will be apparent to one skilled in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has individual components and features which may be readily separated or combined with the features of any of the various other embodiments without departing from the scope or spirit of the invention. Any described method can be carried out in the order of events recited or in any other order which is logically possible.

[0080] The present invention is further described by the following non-limiting examples which further illustrate the present invention but are not intended to, and should not be construed to, limit the scope of the invention.

Claims

1. 1. A method of forming an object, comprising: forming an intermediate nonwoven material (NWM) molded three-dimensional (3D) object by thermally expanding a compressed NWM molded blank in a separable mold; cooling the intermediate NWM molded three-dimensional object through a temperature zone comprising a high temperature boundary and a low temperature boundary to further cool to a solidification temperature of the adhesive; In the temperature range, Separating the separable mold to make an exposed surface of the intermediate NWM molded three-dimensional object accessible; gripping the intermediate NWM-formed three-dimensional object by vacuum suction from an end effector of an actuatable arm; conveying the gripped intermediate NWM-molded three-dimensional object to a molding surface of a molding substrate by a conveying motion of the actuatable arm; compressing at least a portion of the intermediate NWM-molded three-dimensional object against the molding surface; finishing the intermediate NWM-molded three-dimensional object by continuing the compressing of at least the portion of the intermediate NWM-molded three-dimensional object against the molding surface until cooling to the solidification temperature; and the cold boundary is greater than the solidification temperature of the adhesive; the high temperature boundary is lower than the melting temperature of the adhesive; A method characterized by:

2. further finishing the intermediate NWM-formed three-dimensional object by compressing at least another portion of the intermediate NWM-formed three-dimensional object, or at least the portion, or both, against another finishing surface; consisting of The method of claim 1.

3. The step of transporting the intermediate NWM-molded three-dimensional object includes: performing a movement sequence with the actuatable arm to effect contact with an exposed surface with a contact surface of the end effector; establishing a vacuum grip with the contact surface of the end effector by vacuum attraction to the opening on the contact surface from a vacuum source fluidly connected to the opening on the contact surface via a fluid conduit; performing another motion sequence configured to lift, by the actuatable arm, the gripped intermediate NWM-molded three-dimensional object from the separable mold and transfer the removed, gripped intermediate NWM-molded three-dimensional object to the molding surface of the molding substrate; Including, The method of claim 1.

4. The compressed NWM forming blank comprises a nonwoven material held in a compressed state by the adhesive; The step of thermally expanding includes heating the compressed NWM forming blank to the melting temperature of the adhesive. The method of claim 1.

5. the step of thermally expanding includes heating the forming blank within the separable mold; the heating step includes passing steam through steam heat conduits in the upper part, the lower part, or both, to the forming blank; The method comprises: cooling the NWM molded three-dimensional object during first stage molding beyond the melting temperature of the adhesive, including in-mold cooling within the separable mold to at least the high temperature boundary of the temperature zone; and the in-mold cooling includes evacuating steam from the interior of the separable mold, or evacuating condensed steam, or both; The method of claim 4.

6. the exposed surface of the intermediate NWM-molded three-dimensional object comprises an object surface contour; a contact surface of the end effector configured as a contoured contact surface that matches the contour of the object surface and includes a final molded feature of the end effector; The step of finishing the intermediate NWM-molded three-dimensional object includes: compressing another portion of the intermediate NWM-formed three-dimensional object against the final formed feature of the end effector; continuing the compressing of the other portion of the intermediate NWM-formed three-dimensional object against the final forming feature of the end effector until cooling to the solidification temperature; Including, The method of claim 1.

7. the contact surface of the end effector comprises the final formed feature of the end effector; The step of finishing the intermediate NWM-molded three-dimensional object includes: compressing another portion of the intermediate NWM-formed three-dimensional object against the final formed feature of the end effector; continuing the compressing of the other portion of the intermediate NWM-formed three-dimensional object against the final forming feature of the end effector until cooling to the solidification temperature; Including, The method of claim 6.

8. The step of finishing the intermediate NWM-molded three-dimensional object includes: placing an embeddable mounting device within the end effector before a contact surface contacts a top surface of the intermediate NWM-formed three-dimensional object; configuring the contact of the contact surface against the exposed surface of the intermediate NWM-formed three-dimensional object to embed or partially embed the embeddable mounting device within the intermediate NWM-formed three-dimensional object; Including, The method of claim 1.

9. The step of finishing the intermediate NWM-molded three-dimensional object includes: placing an embeddable mounting device on the contoured molding surface of the molding substrate prior to placing the NWM-molded three-dimensional object on the contoured molding surface; configuring contact of a contact surface against the exposed surface of the intermediate NWM-formed three-dimensional object to embed or partially embed the embeddable mounting device within the intermediate NWM-formed three-dimensional object; Including, The method of claim 1.

10. The step of heating the forming blank within the separable mold includes: directing the received steam into the interior of the separable mold, including directing the steam through a steam conduit in an upper part of the separable mold, or a steam conduit in a lower part of the separable mold, or both; Including, The method of claim 1.

11. the separable mold bottom part has a surface with at least some non-vertical sidewalls; the step of finishing the intermediate NWM-formed three-dimensional object includes compressing a wall of the intermediate NWM-formed three-dimensional object; the wall is formed by the surface with at least some of the non-vertical sidewalls. The method of claim 2.

12. The compression forms the wall into a vertical wall. The method of claim 11.

13. The separable mold lower part provides an internal molding surface lower part having a molding sidewall with a relief angle having a surface extending in a plane that is deflected by the relief angle from true 90 degrees relative to a molding horizontal reference plane when assembled inside the separable mold; The step of thermally expanding the compressed NWM forming blank within the separable mold expands a portion of the NWM forming blank compressed against the forming sidewall with a relief angle to form an intermediate NWM forming three-dimensional object having a sidewall with a relief angle, The step of finishing the intermediate NWM-molded three-dimensional object includes: providing said molding surface with vertical 90 degree molding sidewalls; a compressing step configured to press the relief angled sidewall against the 90 degree vertical molding sidewall to reform the relief angled sidewall into a 90 degree vertical NWM sidewall; continuing the step of compressing the 90 degree vertical NWM sidewall against the 90 degree vertical mold sidewall until cooled to the solidification temperature; Including, The method of claim 1.

14. 1. A method of forming an object, comprising: providing a mold having a top and a bottom, the mold configured to transfer heat from steam to the top and bottom of the mold, and configured to evacuate moisture from an interior of the mold by vacuum suction; placing an expansive material in the mold with the expansive material disposed between the top and bottom of the mold to form a structure that uses the heat from steam when the top is placed on the bottom; removing said heat and moisture from said mold by applying said vacuum to said mold during and / or after molding; opening the mold so that the top of the mold separates from the bottom, leaving the expandable material disposed on the bottom of the mold, to expose at least some portion of the expandable material; placing an inflatable object contact surface of an end effector device over an exposed portion of the inflatable object while applying the vacuum sufficient to cool and hold the inflatable object against the inflatable object contact surface of the end effector device, the inflatable object contact surface of the end effector device cooling and holding the inflatable object to set the configuration in a first configuration; removing the expansible material in the first configuration from the bottom of the mold; further forming the expandable article of the first configuration into an expandable article of a second configuration; consisting of A method characterized by:

15. The expandable material is a fiber-based nonwoven material.

15. The method of claim 14.

16. 1. A method of forming an object, comprising: providing a mold having a top and a bottom, the mold configured to transfer heat from steam to the top and bottom of the mold, and configured to evacuate moisture from an interior of the mold by vacuum suction; placing an expansive material in the mold with the expansive material disposed between the top and bottom of the mold to form a structure that uses the heat from steam when the top is placed on the bottom; removing said heat and moisture from said mold by applying said vacuum to said mold during and / or after molding; opening the mold so that the top of the mold separates from the bottom, leaving the expandable material disposed on the bottom of the mold, to expose at least some portion of the expandable material; placing an inflatable object contact surface of an end effector device over an exposed portion of the inflatable object while applying the vacuum sufficient to cool and hold the inflatable object against the inflatable object contact surface of the end effector device, the inflatable object contact surface of the end effector device cooling and holding the inflatable object to set the configuration in a first configuration; removing the expansible material in the first configuration from the bottom of the mold; imparting one or more contours to one or more top and side surfaces of the expansible object using one or more contoured expansible object contacting surfaces of the end effector device that contact the expansible object in the first configuration during the removing step; and one or more of the contours protrude from one or more of the top and side surfaces of the expandable object during the removing step; A method characterized by:

17. the removing step is performed using a robotic arm of the end effector device to remove the expansible material in the first configuration held against the end effector device and move the expansible material in the first configuration to a position away from the bottom of the mold.

15. The method of claim 14.

18. 1. A method of forming an object, comprising: providing a mold having a top and a bottom, the mold configured to transfer heat from steam to the top and bottom of the mold, and configured to evacuate moisture from an interior of the mold by vacuum suction; placing an expansive material in the mold with the expansive material disposed between the top and bottom of the mold to form a structure that uses the heat from steam when the top is placed on the bottom; removing said heat and moisture from said mold by applying said vacuum to said mold during and / or after molding; opening the mold so that the top of the mold separates from the bottom, leaving the expandable material disposed on the bottom of the mold, to expose at least some portion of the expandable material; placing an inflatable object contact surface of an end effector device over an exposed portion of the inflatable object while applying the vacuum sufficient to cool and hold the inflatable object against the inflatable object contact surface of the end effector device, the inflatable object contact surface of the end effector device cooling and holding the inflatable object to set the configuration in a first configuration; removing the expansible material in the first configuration from the bottom of the mold; adding one or more connectors to the surface of the expansile object by placing one or more connectors on the expansile object contacting surface of the end effector device; consisting of A method characterized by:

19. one or more of the connectors are selected from a temperature activated fastener or a temperature activated adhesive; 20. The method of claim 18.

20. 1. An end effector device for removing an expansible object from a mold having top and bottom inner surfaces, each surface facing the expansible object, an expansible contact surface similar to at least a portion of the upper inner surface of the mold; At least one robotic arm connected to the inflatable contact surface, the at least one robotic arm configured to move the inflatable contact surface to contact a top of the inflatable; at least one vacuum suction system connected to the expansible contact surface, the at least one vacuum suction system configured to remove heat and moisture while providing sufficient vacuum pressure to hold the expansible against the expansible contact surface; consisting of An end effector device characterized by:

21. the expandable contact surface is contoured to impart one or more contours to the expandable; The end effector device of claim 20.

22. The expansive material contact surface is substantially the same as the upper inner surface of the mold. The end effector device of claim 20.

23. the expansible contact surface has a different geometric contour than the upper inner surface of the mold; The end effector device of claim 20.

24. 1. A method of forming an object, comprising: providing a mold having a top and a bottom, the mold configured to transfer heat from steam to the top and bottom of the mold, and configured to evacuate moisture from an interior of the mold by vacuum suction; placing an expansive material in the mold with the expansive material disposed between the top and bottom of the mold to form a structure that uses the heat from steam when the top is placed on the bottom; removing said heat and moisture from said mold by applying said vacuum to said mold during and / or after molding; opening the mold so that the top of the mold separates from the bottom, leaving the expandable material disposed on the bottom of the mold, to expose at least some portion of the expandable material; placing an inflatable object contact surface of the end effector device over the exposed portion of the inflatable object while applying the vacuum sufficient to cool and hold the inflatable object against the inflatable object contact surface of the end effector device, the inflatable object contact surface of the end effector device cooling and holding the inflatable object to set the configuration in a first configuration, thereby creating the inflatable object in the first configuration; removing the expansible material in the first configuration from the bottom of the mold; the lower component has a surface with at least some non-vertical sidewalls; finishing the expansive article in the first configuration includes compressing a wall of the expansive article in the first configuration; The wall is formed by the surface with at least some of the non-vertical sidewalls. There are, A method characterized by:

25. the compressing step further forms the walls vertically.

25. The method of claim 24.

26. The expandable material is a fiber-based nonwoven material. consisting of 25. The method of claim 24.

Images