Fiber-Bound Engineered Materials via Carrier Screen Entanglement
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Solution Overview
Problem
Traditional methods of forming engineered articles from stock materials often result in increased costs, bulk, waste, and limited design options due to the need for cutting, layering, and combining discrete pieces, which can introduce inefficiencies and unintended characteristics.
Innovation Solution
A fiber-bound engineered material is created through entangling fiber layers with additional fibers, allowing for non-uniform functional characteristics without the use of adhesives or interlacing, and incorporating scrim materials to achieve specific properties at intended locations within the article.
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 can be achieved, but costs increase, bulk increases, waste increases, and manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the continuous fiber layer into different zones with distinct functional characteristics. Each zone contains specifically positioned fibers or scrim materials that provide targeted properties (e.g., moisture transport, structural support) at intended locations within the final article, eliminating the need to cut and layer multiple discrete pieces.
Solution Approach 2:
The patent implements local quality by creating non-uniform fiber distribution and properties within the continuous layer. Different regions of the fiber layer are engineered with specific fiber types, densities, and configurations to provide location-specific functions such as moisture wicking in certain areas and structural integrity in others, all from a single continuous material.
2Manufacturing precision
If stock materials are cut into individual pieces and layered/combined, then engineered characteristics can be achieved, but material waste increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning fibers and scrim materials in their final intended locations within the continuous fiber layer before the lapping process. This pre-arrangement ensures that engineered characteristics are built-in during manufacturing rather than requiring post-processing cutting and assembly, thereby eliminating material waste from off-cuts and trimmings.
3Manufacturing precision
If discrete pieces are layered and combined, then functional characteristics can be achieved, but costs increase
Solution Approach 1:
The patent merges multiple functions and material layers into a single continuous fiber layer. By incorporating different fiber types, densities, and scrim materials throughout the continuous structure, the patent eliminates the need for multiple separate manufacturing steps involving cutting, layering, and bonding discrete pieces, thereby reducing labor, equipment, and material costs while maintaining functional characteristics.
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 material is lightweight, customizable, and efficient to manufacture, offering infinite design possibilities while maintaining engineered characteristics, such as moisture transport and structural integrity, and reducing waste and manufacturing errors.
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 method of forming a fiber-bound engineered material utilizing carrier screens is provided that imparts an intended characteristic at an intended relative location. Also provided are articles formed of fiber-bound engineered materials manufactured utilizing carrier screens. A fiber layer is placed adjacent at least one carrier screen and 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.