Element Scrims in Fiber-Bound Materials for Localized Functions
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Solution Overview
Problem
Existing engineered articles formed from stock materials require cutting, layering, and combining discrete pieces, leading to increased costs, bulk, waste, and limited design options, while traditional adhesives and connections introduce inefficiencies and errors.
Innovation Solution
Fiber binding through entanglement creates a non-uniform engineered material by manipulating fibers and incorporating scrims, allowing for intended characteristics at specific locations without additional adhesives or connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stock materials are cut into individual pieces and layered/combined to form engineered articles, then design options and functional characteristics can be achieved, but costs increase, bulk increases, waste increases, and manufacturing efficiency decreases
Solution Approach 1:
The patent applies segmentation by dividing the engineered material into distinct fiber layers and scrim layers that can be independently designed and positioned. Each layer serves specific functional purposes (e.g., comfort, support, breathability), allowing customization of design options while maintaining manufacturing efficiency through a unified entanglement process rather than assembling pre-cut discrete pieces.
Solution Approach 2:
The patent merges multiple functional layers (fiber layers and scrim layers) into a single integrated engineered material through hydroentanglement. This combining eliminates the need to assemble separate discrete pieces, reducing manufacturing steps, bulk, and waste while achieving the same design flexibility and functional characteristics.
2Strength
If traditional adhesives and connections are used to bond materials, then structural integrity is achieved, but manufacturing complexity increases, costs increase, and errors increase
Solution Approach 1:
The patent replaces mechanical bonding systems (adhesives, stitches, connectors) with a hydroentanglement process that uses high-pressure water jets to mechanically interlock fibers and scrims. This substitution achieves structural integrity without the complexity and potential errors associated with traditional adhesives and connections, while also eliminating associated costs and environmental concerns.
3Ease of manufacture
If uniform stock materials are used throughout, then manufacturing simplicity is maintained, but functional versatility and design customization are limited
Solution Approach 1:
The patent applies local quality by creating different fiber layers and scrim layers with distinct properties (e.g., different fiber types, densities, orientations, and functions) positioned at specific locations within the engineered material. This allows each region to provide tailored functional characteristics (comfort, support, breathability) while the overall manufacturing process remains relatively simple through the entanglement method.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting fiber-bound engineered materials are lightweight, customizable, efficient to manufacture, and provide unique functional characteristics at intended locations, reducing waste and manufacturing inefficiencies.
Implementation Method 1
The fiber layer binds with additional fibers through entanglement such that a mechanical connection between the entangled fibers is created
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~3D
AI summary
A fiber-bound engineered material is provided that imparts an intended characteristic at an intended relative location. A fiber layer is entangled with additional fibers in a manner to create a non-uniform engineered material. The lack of uniformity of a fiber-bound engineered material may be accomplished through manipulation of the fibers and/or through fiber binding a scrim. The fiber layer binds with additional fibers through entanglement such that a mechanical connection between the entangled fibers is provided. This entanglement allows the fibers to bind without supplemental adhesives, interlacing, or connections. Variations in the fibers and/or inclusion of scrim materials prior to entanglement allows for an intended characteristic (e.g., a functional characteristic) at an intended relative location (e.g., a position determined by an article to be formed therefrom).