Fibrous Molded Soft Goods With Light-Formed 3D Surface Patterns
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Solution Overview
Problem
Current manufacturing processes for soft goods are wasteful, labor-intensive, and inefficient, with difficulties in creating patterns or prints on 3-dimensional items, especially for customized or post-order products, and on textured items.
Innovation Solution
A method involving an aqueous slurry of fibers and reactive ingredients, such as light reactive agents, is used to create molded articles with surface features by applying heat, pressure, and light exposure to induce fiber bonding and chemical cross-linking, allowing for patterns or prints to be applied during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used for soft goods, then production can proceed with conventional methods, but the process is wasteful, labor-intensive, and inefficient with difficulty in creating patterns or prints on 3-dimensional items
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated process. The molding form incorporates both the shaping function and the pattern transfer function, allowing the article to be formed and patterned simultaneously from a fiber slurry, eliminating separate production steps and reducing material waste
Solution Approach 2:
The pattern is pre-formed on the molding form surface before the fiber slurry is applied. This preliminary preparation of the molding form with the desired pattern allows the design to be transferred directly during the molding process, enabling efficient customization without additional post-processing steps
2Ease of manufacture
If traditional manufacturing processes are used, then production can proceed conventionally, but it is labor-intensive and requires transport of materials between steps
Solution Approach 1:
Multiple manufacturing operations are merged into one continuous process. The fiber slurry is deposited directly into the patterned molding form, consolidated in place, and cured without removal or repositioning, eliminating material transport between steps and simplifying the manufacturing process
Solution Approach 2:
The molding form serves multiple functions simultaneously: it provides the three-dimensional shape, transfers the surface pattern, and facilitates consolidation and curing of the fiber article. This multi-functionality reduces the number of separate tools and processes needed
3Adaptability or versatility
If patterns or prints are applied after production, then customized or post-order patterns can be created, but it is difficult and time-consuming
Solution Approach 1:
The desired pattern is pre-formed on the molding form surface before fiber deposition. This allows customization to be built into the tooling itself, enabling different patterns to be produced by changing molds rather than applying patterns after production, maintaining both customization and efficiency
Solution Approach 2:
The molding form can incorporate different pattern regions or interchangeable pattern inserts, allowing specific areas or entire surfaces to be customized according to design requirements while maintaining the same manufacturing process
4Manufacturing precision
If traditional molding methods are used, then simple shapes can be produced, but creating surface features or textures on the molded article is difficult
Solution Approach 1:
The molding form surface is prepared with specific local characteristics such as textures, patterns, or coatings in the desired locations. These local surface properties are transferred directly to the fiber article during molding, creating precise surface features without complex additional processing
Solution Approach 2:
The molding form acts as an intermediary that carries the desired surface pattern and texture information. By preparing the mold surface with the target pattern, the complex task of creating surface features is simplified to a matter of mold preparation rather than complex post-processing
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
Enables efficient creation of customized patterns or prints on 3-dimensional items, including textured surfaces, reducing waste and labor through a streamlined process.
Implementation Method 1
applying at least one of heat and pressure to cause at least one of fiber to fiber bonding and chemical cross-linking between the plurality of fibers
Implementation Method 2
applying at least one of heat and pressure to cause at least one of fiber to fiber bonding and chemical cross-linking between the plurality of fibers
Implementation Method 3
exposing the solid fibrous molded article to a light source such that the light from the lights source reacts with the light reactive agent to create at least one surface feature
Data Source
AI summary
The present invention discloses a molded article having a surface feature created by a light reactive agent interacting with light from a light source, and a method for making the same. The article is molded from a slurry comprised of an aqueous solution that includes a plurality of fibers and a light reactive agent. The slurry is molded into a three-dimensional solid fibrous molded part. The solid fibrous molded part is exposed to a light source such that the light reacts with the light reactive agent to create at least one surface feature. The surface feature can be, for example, a texture or a color change.