Piana Nonwovens, LLC.

Tintoria Piana US, Inc.

Tesla, Inc.

Persico Spa

Andy Hollis

Andrea Piana

Eric McCann

Sang-hoon Lim

Mehran Jafari

Helias Andriessen

Michael Stephen DeFranks

Jorge C Fialho

Forrest Wen Liau

Stefan Kuzmanovski

Sergio Battista Gastaldi

Michael Stephen Defranks

Matteo Radi

Sam Lim

Giuseppe Magoni

Alfio Borgatti

Andrea Fumagalli

Eric Mccann

Andreas Piana

A mobile molding system, comprising a vehicle and one or more molds arranged on the vehicle configured for receiving one or more expandable nonwoven substrates, heating said one or more expandable nonwoven substrates so as to cause said one or more expandable nonwoven substrates to expand and fill the one or more molds with one or more expanded nonwoven containing articles of three dimensional shape, and releasing said one or more expanded nonwoven containing articles of three dimensional shape from the one or more molds is provided. Methods for manufacturing three dimensional objects using the mobile molding system are also provided.

Systems and methods for mobile molding and bonding

Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.

Self-rising board molding

In an example method, a NWM molding blank, including a non-woven material held in compression by a binder, is placed in a separable mold, and heated to a melting temperature of the binder. The molding blank expands, forming as an intermediate NWM object a NWM molded object with a 3D geometric form. The intermediate NWM object is cooled through a temperature band with an upper boundary and a lower boundary, and further cooled to a solidifying temperature of the binder. The upper boundary is above the solidifying temperature and the upper boundary is lower than the binder melting temperature. While in the temperature band, the mold is separated, rendering accessible an exposed surface of the intermediate NWM object. The object is then transported to a contoured forming surface of a forming base, by an actuatable arm having an end effector gripping the exposed surface via vacuum suction, lifting the object from the mold and placing the object on the contoured forming surface. Optionally, the end effector contact surface includes a final forming feature. The actuatable arm compresses the intermediate NWM object against the contoured forming surface, and the optional end effector final forming feature and continues compressing until cooling to the solidifying temperature.

System and method of manufacturing fiber based articles with steam molding

A three-dimensional component is produced in a simplified molding operation. Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. Boards can be formed by laminating two or more blanks together and/or by laminating the blanks with other materials, including non-expendable materials. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. In addition, the boards or blanks may be cut to create desired shapes of parts that can be placed in the mold.

Self rising board molding

Footwear with vertically lapped nonwoven layers in upper and sole structures for enhanced breathability and moisture wicking is disclosed. Exemplary vertically lapped nonwoven dual layers comprise one or more hydrophobic layers and one or more hydrophilic layers that are adhered to each other by a plurality of methods and are further integrated into the inside of the upper and sole of the footwear so that the hydrophilic layer is in direct contact with the feet. The hydrophilic part of the dual layer wicks sweat or bodily fluid from the wearer into the nonwoven and transports the moisture to the hydrophobic layer for fast evaporation, thus keeping the feet dry. The nonwoven footwear is environmentally friendly as the nonwoven layers can be made of recycled materials and may be fully recyclable.

Vertically lapped nonwoven in footwear

A cushion having a fibrous foam architecture. The cushion has a trim cover and a number of fibrous layers attached to the trim cover. One or more structural properties of a fibrous layer can be controlled to differ from that of other layers.

Fibrous foam architecture

A mobile product manufacturing demonstration, apparatus and method is intended to cut through the clutter and rise above the noise of typical marketing language and tactics, replacing the same with demonstrable, real-world demonstrations of how a producer is making a difference in terms of environmentally conscious manufacturing and good environmental stewardship. The mobile product manufacturing demonstration, apparatus and method includes a vehicle for transportation between rural townships and urban centers which itself is preferably battery powered, hydrogen powered, or powered by some other environmentally friendly mechanism. On board is a plurality of display stations which allow the public to interact with and/or manipulate materials used in the recycling and/or manufacturing process. Thus, the consumers will be able to see, hear, and feel (through touch and/or manipulation) how the products are made from recycled or recyclable materials.

Mobile product manufacturing demonstration, apparatus and method

A fibrous nonwoven material which is vertically lapped in its entirety or which includes one or more lapped regions which include vertically lapped fibers provides for padding to be applied to a substrate (e.g., an article of interest such as a handle for sporting equipment or tool, or on the inside of a motorcycle or bicycle helmet, etc.). The skin contacting surface of the nonwoven has regions which are relatively thicker than other regions, and air, sweat, and the like are allowed to easily pass through these regions for cooling, wicking of fluid and enhanced breathability. The lapped nonwoven includes a backing material which helps define the pad shape and which permits securing to a substrate. A hook and loop fastener may be affixed to the lapped nonwoven at the backing material so as to allow retrieval and replacement of the nonwoven on the substrate. An acquisition layer on the surface can be used on the surface of the nonwoven, and a carded consolidated web may be positioned within the nonwoven. The nonwoven may take a variety of shapes including the shape of a strip and the shape of a koozie.

Lapped nonwoven with attachable backing and applications thereof

Customers obtain customized textile materials by selecting style, shape, size, pattern and color for an undyed textile product. Based on a selection made by the customer, the textile product is transformed by a dyeing operation performed on a single item to yield a product, such as a shirt, pants, or jacket, which has a color and pattern of his or her own choosing, in the size and style he or she desires. The process can be performed in a retail setting using a dye machine which allows the process to be viewed by the customer. Preferably, the textile material is constructed from yarns which include cationic cotton alone or in combination with natural cotton or other natural or synthetic fibers, and using anionic dyes, such as a fiber reactive dye, such that the dye is exhausted during the process and effluent from the dye machine is environmentally friendly without excess dye, salts, and alkalis.

Customer-created textiles and method of producing same

Customers obtain customized textile materials by selecting style, shape, size, pattern and color for an undyed textile product. Based on a selection made by the customer, the textile product is transformed by a dyeing operation performed on a single item to yield a product, such as a shirt, pants, or jacket, which has a color and pattern of his or her own choosing, in the size and style he or she desires. The process can be performed in a retail setting using a dye machine which allows the process to be viewed by the customer. Preferably, the textile material is constructed from yarns which include cationic cotton alone or in combination with natural cotton or other natural or synthetic fibers, and using anionic dyes, such as a fiber reactive dye, such that the dye is exhausted during the process and effluent from the dye machine is environmentally friendly without excess dye, salts, and alkalis. To enhance the educational and entertainment experience of the customer, the dyeing operation can be performed in a transparent tank or water kettle in the retail outlet so that the customer can view, for example, the garment as it is being dyed to the customer's specifications.

Growing community of inventors

Evans, GA, United States of America

Andy Hollis