Zonal Scrim Fiber-Bound Materials for Non-Uniform Functional Zones
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Solution Overview
Problem
Existing engineered materials require cutting and layering of stock materials, leading to increased costs, bulk, waste, and limited design options due to uniform functional characteristics.
Innovation Solution
Fiber-bound engineered materials are created through entanglement of fibers with additional fibers, allowing non-uniform functional characteristics at intended locations without adhesives or additional connections, using techniques like barbed-needle, structured-needle, and fluid entanglement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stock materials are cut into individual pieces and layered 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 continuous fiber layer into different functional zones using scrims. The scrim acts as a barrier that prevents fiber migration between zones, allowing different functional characteristics to be established in different regions of the same continuous material, thus achieving design versatility without cutting the material into separate pieces
Solution Approach 2:
The patent implements local quality by creating zonal scrims that provide specific functional characteristics to particular regions of the engineered material. Different zones can have different fiber compositions, densities, or structural properties tailored to specific performance requirements, while the rest of the material maintains its continuous structure for manufacturing efficiency
2Manufacturing precision
If stock materials are cut and layered to create engineered articles, then specific functional characteristics can be achieved, but material waste and manufacturing costs increase
Solution Approach 1:
The patent applies preliminary action by pre-establishing functional zones within the continuous fiber layer using scrims before the final product is formed. The scrims are positioned and secured in advance to define where different functional characteristics should occur, eliminating the need for post-manufacturing cutting and reducing material waste
Solution Approach 2:
The patent implements parameter changes by varying fiber properties (such as fiber type, density, or orientation) in different zones of the continuous layer, controlled by the scrim placement. This allows precise functional characteristics to be achieved through parameter variation rather than through cutting and assembling different material pieces
3Ease of manufacture
If uniform stock materials are used throughout, then manufacturing is simple, but design flexibility and location-specific functional characteristics are limited
Solution Approach 1:
The patent applies local quality by introducing scrims at specific locations within the continuous fiber layer to create zones with different functional characteristics. This allows the majority of the material to remain simple and uniform for easy manufacturing, while specific local regions gain enhanced design flexibility and location-specific functionality
Solution Approach 2:
The patent implements universality by using a single continuous fiber layer structure that can serve multiple functions through zonal segmentation. The same basic material structure provides both manufacturing simplicity and design flexibility simultaneously, as the scrim placement can be adjusted to create different functional zones within the universal continuous layer framework
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 materials are lightweight, customizable, efficient to manufacture, and can achieve intended characteristics at specific 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
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).