UNITARY SHAPED SOFT GOODS ARTICLE HAVING VARIABLE PHYSICAL CHARACTERISTICS BETWEEN DIFFERENT REGIONS

Abstract

The present invention is directed to a shaped soft goods article that is unitary non-woven material having at least one three-dimensional shape. The article includes a first region substantially formed of a first formula and a second region substantially formed of a second formula. Between the first and second regions, there is an intermingling region that includes at least some of the first formula and the second formula. The first and second formulas are both comprised of at least one type of natural or synthetic fibers and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex; however, the first and second formulas differ in at least one characteristic. An intermingling region exists where the first region (and first formula) intermingle with the second region (and second formula) meet.

Description

FIELD OF THE INVENTION

The field of the invention is apparatus and method for molding a three-dimensional unitary soft goods article and, more specifically, for molding a three-dimensional unitary soft goods article from at least two different aqueous slurries that each contain a plurality of fibers.

BACKGROUND OF THE INVENTION

The current process for creating soft goods, such as clothing, footwear (e.g., shoe uppers), bags, furniture, medical supplies, cleaning tools and consumables, toys, automotive interior parts, cases and housings for consumer electronics, and other soft goods is often wasteful and includes numerous steps. Within each manufacturing step is a separate, inefficient, labor-intensive process that often requires transport of materials between the steps. Scrap materials (e.g., cloth that is cut but not used) are often simply discarded, adding to the waste in the process. Additionally, raw materials are typically provided in flat shapes and must be formed into the final desired shape, different equipment and processes must frequently be employed when small changes in the final design are implemented, and surface feature and/or texture final design must be added in a secondary operation. There is a need in the industry to be able to form a unitary solid fibrous molded part that has different physical or visual characteristics in the various regions of the part without the need for expensive, time-consuming and labor-intensive post-forming operations. These and other shortcomings in the prior art are addressed by the present invention, as disclosed herein.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a shaped soft goods article is a unitary non-woven material having at least one three-dimensional shape. The article includes at least a first region substantially comprised of a first formula and a second region substantially comprised of a second formula. An intermingling region that includes at least some of the first formula and the second formula is formed where the first region and second region generally meet and the first and second formulas intermingle. The first and second formulas are both comprised of at least one type of natural or synthetic fibers and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex. The first and second are different from each other in at least one characteristic.

According to another aspect of the present invention, the first formula and the second formula differ in any manner, including visually (e.g., colorant) and/or structurally (e.g., the first formula may include a high percentage of fibers).

According to a further aspect of the invention, the article may include a third (or more) region comprised of a third formula. The third formula is different from at least one of the first and second formula.

One advantage of the present invention is the ability to design a unitary fibrous molded part that can vary in characteristics from region to region throughout without the requirement of secondary operations.

Another advantage of the present invention is the ability to design a unitary fibrous molded part that can visually vary from region to region throughout without the requirement of secondary operations.

A further advantage of the present invention is the ability to design a unitary fibrous molded part that can vary structurally from region to region throughout without the requirement of secondary operations.

These and other advantages will be apparent to one of skill in the art in light of the present disclosure and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which:

FIG. 1 shows a diagrammatic set up for adding at least some of the desired ingredients of the slurry into a mixer;

FIG. 2 shows a diagrammatic set up for mixing the slurry, providing an amount of a single formula of the slurry into a molding form, and removing the solid fibrous molded part from the molding form;

FIG. 3 shows a form into which a first formula and a second formula are being poured;

FIG. 3A shows a robotic arm agitating the first and second formulas in the form;

FIG. 4 shows a solid fibrous molded part comprising a region created from a first formula and a second region created from a second formula being placed into a press;

FIG. 5 shows a shoe upper attached to a shoe sole wherein the shoe upper was at least partially formed in the press shown in FIG. 4;

FIG. 6 shows a form having at least two dividers wherein a first formula is poured into a first region, a second formula is poured into a second region, and a third formula is poured into a third region;

FIG. 7 shows a shoe upper attached to a shoe sole wherein the shoe upper was at least partially formed in the press shown in FIG. 4; and

FIG. 8 shows a handbag having at least one region comprised of a first formula and a second region comprised of a second formula.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1-8, the present invention is an article 10 that includes at least a first region 11 comprised of a first formula 15 and second region 13 comprised of a second formula 17 wherein the first formula 15 differs from the second formula 17 in at least one physical characteristic (described infra.). As will be described herein, additional regions in the article can also be included wherein the additional regions (e.g., a third region 27) can be comprised of additional formulas (e.g., a third formula 19) wherein the third formula 19 (optionally) differs from the first and/or second formulas Associated apparatus and methods for making the article are also described herein.

Common articles formed using the methods and apparatus disclosed herein include, but are not limited to, footwear, clothing and various other apparel, bags and various other accessories, automotive interior upholstery and parts, consumer goods, furniture upholstery, and soft medical products. Examples of footwear include, but are not limited to, shoe uppers. Examples of clothing articles include, but are not limited to, shirts, shorts, gowns and other medical clothing, dresses, skirts, pants, socks, vests, sweaters, scarves, hats, gloves, mittens, and undergarments. Examples of bags include, but are not limited to, handbags, purses, backpacks, bookbags, satchels, clutches, travel cases, luggage and toiletry cases. Examples of automotive interior parts include, but are not limited to, interior panels, interior trim, seat covers, floor mats, dashboard covers and steering wheel covers. Examples of consumer goods include, but are not limited to, laptop/computer housings, soft circuit board coverings, phone cases, soft cleaning products and feminine hygiene products. Examples of furniture upholstery include, but are not limited to, chair and couch coverings, and wall coverings or panels. Examples of soft medical products include, but are not limited to, bandages and various other coverings, slings, and various other stabilization elements, to include soft goods for internal body use.

The present disclosure is generally directed to the creation of a shoe upper in accordance with the present invention; however, one of skill in the art would understand that any of the above articles could be created using the teachings herein without departing from the spirit or scope of the present invention. For example, FIG. 8 shows the creation of a handbag having a first region 11 and a second region 13. The examples described in detail herein, as well as the above listing of articles are intended to be exemplary and non-limiting.

The present invention includes a solid molded fibrous part 14 that is formed from having at least a first region formed substantially from a first formula and a second region substantially formed from a second formula. The first and second formulas are both aqueous slurry that includes a plurality of fibers 16

The first formula 15 is created by mixing a slurry 20 that can include natural fibers, semi-synthetic fibers, synthetic fibers or a combination thereof. Natural fibers include wood fibers, plant fibers, fungus (e.g., mycelium), and animal fibers. Wood fibers include, but are not limited to, hardwood and/or softwood fibers, bleached and/or unbleached, virgin and/or recycled. Plant-based fibers can include, but are not limited to, cotton, flax, hemp, jute, ramie, bamboo, sisal, abaca, kapok, coir, and general agricultural waste. Animal fibers can include, but are not limited to, wool, silk, cashmere, alpaca, llama, mohair, yak, camel hair, qiviut, vicuna, angora, and horsehair. The semi-synthetic fibers can include, but are not limited to, cellulose-based fibers such as rayon, viscose, modal, Tencel, Lyocell, and acetate. Synthetic fibers can include, but are not limited to, polyester, nylon, olefin, spandex/elastane, acrylic, PVC, aramid, microfiber. Additionally, sustainable synthetic fibers such as polylactic acid (PLA) fibers and polyhydroxyalkanoates (PHA) fibers can be used. One or more fiber types are added and any other ingredient, such as, but not limited to, biobased and/or synthetic molecules/polymers, and additives can be added to the material to be used, either before formation (while in a fluid state), after the material is dried or after the item (or part of the item) is formed. Biobased molecules/polymers can be added as binding agents and/or retention agents in order to enhance the wet and dry strength of the solid fibrous molded part 14. These biobased molecules/polymers include, but are not limited to, chitosan, starches, ionic starches, cellulosic materials such as, but not limited to, carboxymethylcellulose, nanofibrillated cellulose, nanocelulose, natural rubber latex, collagen, gelatine, alginate, polylactic acid, polyglycolic acid, and polyhydroxyalkanoates. Additionally, synthetic molecules/polymers and synthetic molecules/polymers with a certain amount of biobased carbon can be used in the materials, such as, but not limited to, polyurethane emulsions, thermoplastic materials, and resins, such as polyaminoamide-epichlorohydrin (PAE) in order to improve mechanical strength. One suitable slurry is disclosed in U.S. patent application Ser. No. 17/466,792, the disclosure of which is hereby incorporated by reference. The slurry 20 can be created by combining the fibers 16, water 26 and any other ingredients desired into a mixer 28. FIG. 1 shows an exemplary set up where a series of ingredient sources 30 are in communication with the mixer that enable an amount of various ingredients to be provided (e.g., pumped or gravity fed) into the mixer 28, as desired. In the example shown, up to six ingredient sources 30 are provided. In addition, a water source 32 and a source for fibers 16 are also provided for adding desired amounts of fiber 16 into the mixer 28. Once in the mixer 28, the ingredients are mixed, generally until all ingredients are fully mixed and/or dispersed, and the slurry takes on the form of a mixture, foam, or a homogeneous fiber dispersion. An example of the aforementioned slurry may contain, but is not limited to, the following content: water (20-99.99%), fibers (0.0075-60%), other additives (0.0025-20%).

Referring now to FIGS. 2 and 4, once the desired ingredients are combined and mixed in the mixer 28, and the mixed slurry 20 can then be poured, pumped or gravity fed into a molding form 34. Notably, FIG. 2 is provided as an exemplary figure depicting this process with a single formula. In the embodiment shown, the molding form 34 includes a first mold portion 36 and a second mold portion 38. The first mold portion 36 includes a screen 40 with openings 42 that generally allow water to drain therethrough but retains the solid fibers. The second mold portion 38 includes a desired two- or three-dimensional shape that is at least partially imparted onto the solid fibrous molded part 14. In particular, FIG. 4 shows that a three-dimensional shape may be of particular utility in various applications. The solid fibrous molded part 14 that exits the form 34 has one or more regions of increased thickness and, conversely, regions of reduced thickness in order to provide the desired physical characteristics (e.g., strength, toughness, flexibility, etc.) desired of the final product after pressing.

Optionally, the screen 40 in the first mold portion may also have a two- or three-dimensional shape that is at least partially imparted onto the solid fibrous molded part 14. As the water is removed from the slurry 20 through the screen, heat and/or pressure may be applied to achieve fiber to fiber bonding, polymer to polymer bonding, and polymer to fiber bonding, as well as chemical cross-linking. In some embodiments, some or substantially all of the water is removed from the slurry 20. In other embodiments, it may be desirable to retain some or all of the water depending on the intended final design. The solid fibrous molded part 14 can be removed from the mold form 34 and, optionally, further dried.

The second formula 17 can be created using substantially the same process described above in connection with the first formula 15, provided that the second formula 17 includes at least one difference in visual, physical or chemical characteristics relative to the first formula 15. For example, the second formula 17 may have an increased (or decreased) strength/structural characteristic, different finish, different color, different environmental response reaction, texture and/or surface features, or different hardness/softness characteristics. In order to achieve the various differences between the first formula 15 and the second formula 17, the second formula may include, e.g., a higher (or lower) fiber count, different fiber types, different reactive ingredients, different process additives and/or colorants.

FIGS. 3 and 6 depict a process wherein a form is provided, and more than one formula 15, 17 are provided into the form 34. In FIG. 3, a first formula 15 and a second formula 17 are provided into the form 34 at generally opposed ends such that a first region 11 is substantially filled with the first formula 15 and a second regional 13 is substantially filled with the second formula 17. Naturally, the first region 11 and the second region 13 generally meet at an intermingling region 21 where the first formula 15 and the second formula 17 meet and intermingle. One of skill in the art would understand that the degree of intermingling can be, optionally, controlled. For example, and now referring to FIG. 3A, a robotic arm 23 is shown agitating the first and second formulas 15, 17 together at or near the intermingling region 21. Naturally, while the process is shown as automated, one of skill in the art would understand that numerous methods are available for agitating. Additionally, the degree of intermingling between various slurry 20 formulas 15, 17 can also be at least be partially chemically by, for example, adjusting the viscosity, fiber composition, and/or pH to achieve the desired effect and final product.

While not shown, the dispensing of the slurries 20 can also be automated through the use of, e.g., the robotic arm 23, as well.

One of skill in the art would understand that the rate at which the various slurries 20 are provided in mold form 34 can also affect the intermingling of formulas 15, 17. For example, increasing the rate of dispensing the slurries 20 into the mold form will generally increase the intermingling between the regions 11, 13, 27 and slower dispensing of the slurries 20 will generally decrease the intermingling between the regions 11, 13, 27.

Referring now to FIG. 6, conversely, the amount of intermingling can also be controlled by limiting the interaction between different formulas 15, 17, 19 by using, e.g., physical dividers 25. FIG. 5 shows a form 34 having a series of dividers 25 that generally separate a series of regions 11, 13, 27. Three formulas 15, 17, 19 are shown being provided to some or all of the regions 11, 13, 27 defined by the form 34 and the dividers 25. In this embodiment, the first, second and third formulas 15, 17, 19 are provided into the form 34 and, initially, the regions 11, 13, 27 are separated by dividers 25. Prior to fully the slurries 20 of the various formulas 15, 17, 19 setting (as described supra.), the dividers 25 are removed. Generally speaking, early removal of the dividers 25 will permit greater intermingling between the regions 11, 13, 27 and later removal of the dividers 25 will permit greater intermingling between the regions 11, 13, 27. The dividers 25 may be removed all at together or separately, quickly or slowly, depending on the physical characteristics of the various formulas and the designer's desired effect of the final article 10.

In operation, the components to a slurry 20 for a first formula 15, including at least water 26, a single type of fiber or a plurality of fiber types 16, and additives are provided to a mixer 28. The components are mixed until the slurry 20 is a mixture, foam, or a homogeneous suspension.

The components to a slurry 20 for a second formula 17, including at least water 26, a single type of fiber or a plurality of fiber types 16, and additives are provided to a mixer 28. The second formula 17 differs from the first formula 15 in at least one characteristic. The components are mixed until the slurry 20 is a mixture, foam, or a homogeneous suspension.

Optionally, the components to a slurry 20 for a third formula 19 (or more), including at least water 26, a single type of fiber or a plurality of fiber types 16, and additives are provided to a mixer 28. The third formula 17 optionally differs from the first formula 15 and/or second formula 17 in at least one characteristic. The components are mixed until the slurry 20 is a mixture, foam, or a homogeneous suspension.

The slurries 20 of the first formula 15 the second formula 17 (and optional additional formulas) are then added to the molding form 34. The molding form 34 may include dividers 25 separating the various regions 11, 13, 27 within the molding form 34. In embodiments lacking dividers, the slurries 20 will meet at intermingling region(s) 21. None, some, most, or all of the water (depending on final product material) from the slurries 20 is removed by, e.g., draining and/or drying, effectively dehydrating the substance during the process of converting the slurry 20 to a solid fibrous molded part 14. During the molding process, heat and/or pressure can be applied to the mold form to further eliminate water from the slurry 20 and achieve, e.g., fiber to fiber bonding, polymer to polymer bonding, and polymer to fiber bonding, as well as chemical cross-linking. In embodiments where dividers 25 are present, the dividers 25 are removed prior to completion of the bonding and formation of the solid fibrous molded part 14.

After removal from the molding form 34, the solid fibrous molded part 14 that includes regions having different characteristics due to the differences in the formulas of the slurries utilized is, in some instances, permitted to continue to dry and/or subjected to an additional forming operation. Referring to FIG. 4 in particular, the solid fibrous molded part 14 may include regions of varied thickness.

Optionally, the solid fibrous molded part 14 is then pressed (see e.g., FIG. 4) into the final desired shape of the article 10 (see e.g., FIGS. 5, 7 and 8) or affixed to additional items (e.g., shoe sole or handbag handle).

One of skill in the art will understand that, unless specifically stated otherwise, the terms such as first region, second region, third region, etc. and first formula, second formula, third formula are intended to refer to corresponding elements during and after any forming processes. For example, the first formula is intended to the slurry comprised of the first formula as well as the portion of the article that is substantially formed from the first formula.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. A shaped soft goods article, comprising: a first region substantially comprised of a first formula;a second region substantially comprised of a second formula;an intermingling region that includes at least some of the first formula and the second formula;wherein the first formula is comprised of at least one type of natural or synthetic fibers and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex;wherein the second formula is comprised of at least one type of natural or synthetic fibers and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex;wherein the first and second are different from each other in at least one characteristic; andwherein the shaped soft goods article is unitary non-woven material having at least one three-dimensional shape.

2. The shaped soft goods article of claim 1 wherein the first region is visually different from the second region.

3. The shaped soft goods article of claim 2 wherein the first region is comprised of a different percentage of at least one colorant than the second region.

4. The shaped soft goods article of claim 1 wherein first region is structurally different from the second region.

5. The shaped soft goods article of claim 1 wherein the first region is comprised of a different percentage of at least one type of fibers than the second region.

6. The shaped soft goods article of claim 1 that also includes a third region comprised of a third formula, wherein the third formula is comprised of at least one type of natural or synthetic fibers and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex.

7. The shaped soft goods article of claim 6 wherein the third formula is different from at least one of the first and second formulas in at least one characteristic.

8. The shaped soft goods article of claim 7 wherein the third formula is different from both of the first and second formulas in at least one characteristic.

9. A method of forming a soft goods article comprising the following steps: mixing an amount of a first formula, the first formula including at least one type of natural or synthetic fibers, water and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex into an aqueous slurry;mixing an amount of a second formula, the second formula including at least one type of natural or synthetic fibers, water and at least one of crosslinkers, natural and/or synthetic adhesives, biobased and/or synthetic thermoplastics, including nanocellulose, and/or latex into an aqueous slurry, wherein the second formula is different from the first formula in at least one characteristic;providing a mold form;pouring the aqueous slurry of the first formula and the aqueous slurry of the second formula into the mold form such that the aqueous slurry of the first formula is in a first region and the aqueous slurry of the second formula is in a second region and the aqueous slurry of the first formula and the aqueous slurry of the second formula intermingle in an intermingling region generally between the first and second regions; andremoving at least some of the water from the mold form through at least one of a draining and drying process to leave behind a solid fibrous molded part that defines a first region formed from the slurry of the first formula and a second region formed from the slurry of the second formula.

10. The method of forming a soft goods article of claim 9 including the additional step of pressing the solid fibrous molded part into a desired shape in a press that includes at least one three-dimensional shape.

11. The method of forming a soft goods article of claim 9 wherein the first region of the solid fibrous molded part is visually different from the second region.

12. The method of forming a soft goods article of claim 11 wherein the first region of the solid fibrous molded part is comprised of a different percentage of at least one colorant than the second region.

13. The method of forming a soft goods article of claim 9 wherein first region of the solid fibrous molded part is structurally different from the second region.

14. The method of forming a soft goods article of claim 13 wherein the first region of the solid fibrous molded part is comprised of a different percentage of at least one type of fibers than the second region.

15. The method of forming a soft goods article of claim 9 including the additional step of at least initially positioning a divider between the first region and the second region in the mold form prior to pouring the aqueous slurry of the first formula and the aqueous slurry of the second formula into the mold form.

16. The method of forming a soft goods article of claim 9 including the additional step of agitating an intermingling region after pouring the aqueous slurry of the first formula and the aqueous slurry of the second formula into the mold form in order to cause a mixing of the first formula and second formula to intermingle.