Methods and systems for manufacturing a composite textile

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Solution Overview

Problem

Separating and reusing remnants of composite textiles, particularly nonwoven textiles, is challenging due to entanglement with other material layers, leading to contamination and reduced reusability.

Innovation Solution

Cut pattern pieces from the fiber web before entanglement, using unrolled material layers affixed to cores for separation and reuse, and employ cutting tools like lasers with automated control to facilitate easy separation of remnants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If material layers are entangled to form composite textile, then structural integrity and composite properties are improved, but separation difficulty and remnant reusability worsen

Engineering Contradiction:

Improvestructural integrityVSAvoidseparation difficulty

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent divides the composite textile into separate material layers by cutting pattern pieces before entanglement. This segmentation allows each layer to be processed independently, enabling easy separation of remnants while maintaining the integrity of the final composite structure. The layers are cut separately from their respective rolls, then stacked and entangled only in the pattern piece regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs cutting operations on material layers before they are entangled with other layers. This preliminary action of cutting pattern pieces from unrolled material layers allows for easy collection and separation of remnants after cutting, while the entanglement process is applied only to the cut pattern pieces to form the final composite textile.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If material layers are entangled to form composite textile, then composite properties are improved, but remnant contamination worsens

Engineering Contradiction:

Improvecomposite propertiesVSAvoidremnant contamination

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

By cutting pattern pieces from separate material layers before entanglement, the patent segments the manufacturing process so that remnants from different layers remain separate and uncontaminated. Each layer's remnant consists only of material from that specific layer, maintaining purity for potential reuse or recycling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cutting operation is performed preliminarily on unrolled material layers before entanglement occurs. This timing allows remnants to be collected and separated while the material is still in its unentangled state, preventing cross-contamination between different material layers that would occur if cutting happened after entanglement.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If pattern pieces are cut from entangled composite textile, then manufacturing process is simplified, but remnant separation and reusability worsen

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidremnant separation

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent reverses the conventional sequence by performing cutting operations on unrolled material layers before entanglement, rather than cutting from the entangled composite. This preliminary cutting action simplifies remnant separation while maintaining manufacturing efficiency through automated cutting tools and coordinated material feed systems.

Inventive Principle:

Principle #10Preliminary action

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 easy separation and reuse of nonwoven remnants with high homogeneity, suitable for recycling and repurposing, enhancing the utility of composite textiles.

Implementation Method 1

employ cutting tools like lasers with automated control to facilitate easy separation of remnants

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS12528282B2Methods and systems for manufacturing a composite textile

Publication Date: 2026.01.20 NIKE INC

AI summary

This disclosure relates to a composite textile that can be sustainable, as well as methods and systems for constructing the composite textile and recollecting and harvesting excess material (e.g., remnants). In at least some examples, a first pattern piece is cut from a first material layer, and a second pattern piece is cut from a second material layer. In addition, the first pattern piece can be separated from the first material layer, which can leave a first remnant, and the second pattern piece can be separated from the second material layer, which can leave a second remnant. Once separated, the first pattern piece can be stacked atop the second pattern piece, and the stacked pattern pieces can be entangled to form a composite pattern piece. The remnant associated with the first material layer can be separated from the remnant associated with the second material layer and reused.