巴西专利BR112014027003B1 METHODS OF MANUFACTURING TEXTURED ELEMENTS

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专利摘要:
textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements The present invention relates to a method of manufacturing a textured element which may include (a) collecting a plurality of filaments on a textured surface to form a non-woven textile and (b) separate the non-woven textile from the textured surface. another method of manufacturing a textured element may include depositing a plurality of thermoplastic polymer filaments onto a first surface of a polymer layer to (a) form a non-woven textile and (b) bond the filaments in the polymer layer. a textured surface can then be separated from a second surface of the polymer layer, the second surface being opposite the first surface and the second surface having a textured surface texture.
公开号:BR112014027003B1
申请号:R112014027003-1
申请日:2013-05-24
公开日:2021-08-24
发明作者:Carrie L. Davis；Bhupesh Dua；James A. Niegowski
申请人:Nike Innovate C.V.；
IPC主号:

专利说明:

FUNDAMENTALS
[001] A variety of products is at least partially formed from textiles. As examples, articles of clothing (eg, shirts, pants, socks, jackets, underwear, shoes), containers (eg, backpacks, bags) and upholstery for furniture (eg, chairs, sofas, car seats) are often formed from several textile elements that are joined by sewing or adhesive bonding. Textiles can also be used in bed covers (eg sheets, blankets), tablecloths, towels, flags, tents, candles and parachutes. Textiles used for industrial purposes are often referred to as technical textiles and may include structures for automotive and aerospace applications, filter materials, medical textiles (eg bandages, pads, implants), geotextiles for dike reinforcement, agrotextiles for crop protection and industrial clothing that protects or insulates against heat and radiation. In this way, textiles can be incorporated into a variety of products for both personal and industrial purposes.
[002] Textiles can be defined as any fabrication of fibers, filaments or yarns having a generally two-dimensional structure (ie, a length and a width that are substantially greater than the thickness). In general, textiles can be classified as mechanically manipulated textiles or non-woven textiles. Mechanically manipulated textiles are often formed by weaving or interweaving (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines. Nonwoven textiles are membranes or mats of filaments that are bonded, fused, interwoven or otherwise joined. As an example, a non-woven textile can be formed by randomly depositing a plurality of polymer filaments onto a surface, such as a moving conveyor. Various engraving or calendering processes can also be used to ensure that the non-woven textile has a substantially constant thickness, imparts texture to one or both surfaces of the non-woven textile, or even bonds or fuses the filaments together within the non-woven textile. While direct extruded non-woven textiles are formed from filaments having a cross-sectional thickness of 10 to 100 microns, blown non-woven textiles are formed from filaments having a cross-sectional thickness less than 10 microns. SUMMARY
[003] A method of manufacturing a textured element may include (a) collecting a plurality of filaments on a textured surface to form a non-woven textile and (b) separating the non-woven textile from the textured surface. Another method of manufacturing a textured element may include (a) depositing a plurality of filaments onto an endless moving loop of textured non-stick paper to form a non-woven textile and (b) separating the non-woven textile from the non-stick paper with texture. A further method of manufacturing a textured element may include (a) extruding a plurality of substantially separate filaments that include a thermoplastic polymer material and (b) depositing the filaments onto a moving surface to form a non-woven textile and print a texture. of the moving surface in the non-woven textile.
[004] A method of manufacturing a textured element may include depositing a plurality of thermoplastic polymer filaments onto a first surface of a polymer layer to (a) form a non-woven textile and (b) bond the filaments in the layer of polymer. A textured surface can then be separated from a second surface of the polymer layer, the second surface being opposite the first surface and the second surface having a textured surface texture.
[005] The advantages and characteristics of the innovation characterizing aspects of the invention are particularly highlighted in the appended claims. To gain an improved understanding of the advantages and characteristics of the innovation, however, reference may be made to the following descriptive matter and accompanying figures which describe and illustrate various configurations and concepts relating to the invention. DESCRIPTIONS OF THE FIGURES
[006] The preceding summary and the following detailed description will be better understood when read in conjunction with the accompanying figures.
[007] Figure 1 is a perspective view of a textured non-woven textile.
[008] Figure 2 is a cross-sectional view of the textured non-woven textile as defined by cut line 2 in Figure 1.
[009] Figures 3A to 3F are perspective views corresponding to figure 1 and representing additional configurations of the textured non-woven textile.
[010] Figures 4A to 4F are cross-sectional views corresponding to figure 2 and representing additional configurations of textured non-woven textile.
[011] Figure 5 is a schematic perspective view of a system used in the manufacturing process for textured non-woven textiles.
[012] Figures 6A to 6E are perspective views of portions of the manufacturing process.
[013] Figures 7A to 7E are cross-sectional views of the manufacturing process, as defined respectively in figures 6A to 6E.
[014] Figure 8 is a schematic perspective view of another configuration of the system.
[015] Figures 9A to 9C are perspective views representing additional configurations of the system.
[016] Figure 10 is a cross-sectional view corresponding to Figure 7A and representing another configuration of the system.
[017] Figures 11A to 11F are perspective views of another manufacturing process.
[018] Figures 12A to 12F are cross-sectional views of the manufacturing process as defined respectively in figures 12A to 12F. DETAILED DESCRIPTION
[019] The following discussion and accompanying figures reveal various textured element configurations that incorporate a non-woven textile, as well as methods for fabricating the textured elements. While textured elements are disclosed below as being incorporated into various articles of clothing (e.g. shirts, pants, shoes) for purposes of example, textured elements may also be incorporated into a variety of other products. For example, textured elements can be used in other types of clothing, containers and upholstery for furniture. Textured elements can also be used in bed covers, tablecloths, tablecloths, flags, tents, candles and parachutes. Various configurations of textured elements can also be used for industrial purposes, such as in automotive and aerospace applications, filter materials, medical textiles, geotextiles, agrotextiles and industrial apparel. As such, textured elements can be used in a variety of products for both personal and industrial purposes. SETTING THE ELEMENT WITH TEXTURE
[020] A textured element 100 in the configuration of a non-woven textile is shown in Figure 1 as having a first surface 101 and an opposing second surface 102. The textured element 100 is formed primarily from a plurality of filaments 103 that include a thermoplastic polymer material. Filaments 103 are randomly distributed throughout textured element 100 and are bonded, fused, interwoven or otherwise joined to form a non-woven textile structure of relatively constant thickness (i.e., distance between surfaces 101 and 102) . An individual filament 103 may be located on the first surface 101, on the second surface 102, between the surfaces 101 and 102, or on both the surfaces 101 and 102. Depending on the manner in which the textured element 100 is formed, multiple portions of a filament individual filament 103 may be located on first surface 101, different portions of individual filament 103 may be located on second surface 102 and other portions of individual filament 103 may be located between surfaces 101 and 102. woven within textured element 100, the various strands 103 may curl, extend over and under each other, and pass through various areas of textured element 100. In areas where two or more filaments 103 touch, the polymer material The thermoplastic forming the filaments 103 can be bonded or fused to join the filaments 103 together. In this way, the filaments 103 are effectively joined together in a variety of ways to form a non-woven textile with a cohesive structure within the textured element 100.
[021] Although the textured element 100 has a relatively constant thickness, the areas of the first surface 101 include a texture 104. In this example, the texture 104 has a configuration of a plurality of curved, wave-like or wavy lines. Referring to Figure 2, the texture 104 forms various indentations, depressions or other discontinuities in the first surface 101 having a hemispherical, curved or generally rounded shape. In reality, these discontinuities make texture 101 perceptible through sight, tactile touch, or both. That is, a person can see and/or feel texture 104 in areas of textured element 100. In addition to enhancing the aesthetics of textured element 100, texture 104 can enhance physical properties of textured element 100, such as stability , abrasion resistance and water permeability.
[022] The plurality of curved, wave-like or wavy lines presents an example of a configuration that is suitable for texture 104. As another example, Figure 3A represents texture 104 as being various x-shaped features. Texture 104 can also be used to convey information, as in the series of alphanumeric characters that are formed on the first surface 101 in Figure 3B. Similarly, texture 104 may be symbols, trademarks, indicia, designs, or any other feature that may be formed on the first surface 101. While texture 104 may be generally linear features, texture 104 may also be larger notches in areas of the first surface. surface 101, as shown in Figure 3C. Texture 104 may also be used to impart the appearance of other materials to textured element 100. As an example, texture 104 may include a plurality of elongated, non-linear notches in first surface 101, as depicted in Figures 3D and 3E, that impart the appearance of leather or a leather-style structure to the textured element 100. More particularly, the texture 104 includes notches in the first surface 101 that can (a) intersect or be separated from one another, (b) exhibit widths and varying or constant depths or (c) appear to be randomly located. As another example, texture 104 may include a plurality of randomly located indentations on first surface 101, as depicted in Figure 3F, which also impart the appearance of leather or a leather-style structure to textured element 100. An advantage of forming texture 104 to exhibit the appearance of leather is that textured element 100 can be used as a faux leather or a substitute for conventional faux leather or faux leather. As such, the configuration of texture 104 can vary significantly to include a variety of shapes and features.
[023] The discontinuities in the first surface 101 that form the texture 104 may have the hemispherical, curved or generally rounded shape mentioned above. In other examples, however, the discontinuities forming texture 104 may have other shapes or configurations. As an example, Figure 4A depicts texture 104 as being square, V-shaped, and irregular notches. Referring to Figure 4B, the depth of the indentations forming the texture 104 may vary. Additionally, Figure 4C depicts texture 104 as being formed on both surfaces 101 and 102, with some notches being aligned and some not aligned. The texture 104 can also be raised compared to other areas of the first surface 101, as shown in Figure 4D, to form bumps, bulges or other outwardly projecting features. Furthermore, the texture 104 may be a relatively large notch, as shown in Figure 4E, which may correspond with the areas of the texture 104 in Figure 3C. As such, the configuration of texture 104 can vary significantly to include a variety of notches, depressions, or other discontinuities in the first surface 101.
[024] As another example of textured element 100, Figure 4F represents the first surface 101 as being formed from a layer of crust 105. For comparison purposes, filaments 103 extend between and form surfaces 101 and 102 on each. of the configurations discussed above. The crust layer 105, however, may be a layer of polymer material that does not include the filaments 103. Furthermore, the texture 104 can be applied to the crust layer 105, thereby forming indentations, depressions or other discontinuities in portions. of the first surface 101 formed from the crust layer 105. As mentioned above, the texture 104 can impart the appearance of leather or a leather-style structure to the textured element 100. The combination of the crust layer 105 and the appearance of the leather ( for example, through texture 104) can produce an enhanced synthetic leather or substitute for conventional leather or synthetic leather.
[025] Fibers are often defined, in textile terminology, as having a relatively short length ranging from a millimeter to a few centimeters or more, while filaments are often defined as having a longer length than fibers or even even an indeterminate length. As used herein, the term "filament" or variations thereof is defined to encompass lengths of both the fibers and the filaments in the definitions of textile terminology. Thus, the filaments 103 or other filaments cited herein can generally be of any length. As an example, therefore, filaments 103 can have a length ranging from one millimeter to hundreds of meters or more.
[026] The filaments 103 include a thermoplastic polymer material. In general, a thermoplastic polymer material melts when heated and returns to a solid state when cooled. More particularly, the thermoplastic polymer material changes from a solid state to a softened or liquid state when subjected to sufficient heat and then the thermoplastic polymer material changes from a softened or liquid state to a solid state when sufficiently cooled. As such, the thermoplastic polymer material can be melted, molded, cooled, melted again, molded again, and cooled again through multiple cycles. Thermoplastic polymer materials can also be welded or thermally bonded to other textile elements, sheets, sheets, polymer foam elements, thermoplastic polymer elements, thermoset polymer elements, or a variety of other elements formed from various materials. In contrast to thermoplastic polymer materials, many thermoset polymer materials do not melt when heated, simply burning in place. Although a wide range of thermoplastic polymer materials can be used for the 103 filaments, examples of some suitable thermoplastic polymer materials include thermoplastic polyurethane, polyamide, polyester, polypropylene and polyolefin. While any of the thermoplastic polymer materials mentioned above can be used for textured element 100, thermoplastic polyurethane has several advantages. For example, many thermoplastic polyurethane formulations are elastomeric and stretch above one hundred percent, while exhibiting relatively high stability or tensile strength. Compared to some other thermoplastic polymer materials, thermoplastic polyurethane easily forms thermal bonds with other elements, as discussed in more detail below. Also, thermoplastic polyurethane can form foam materials and can be recycled to form a variety of products.
[027] Although each of the filaments 103 can be entirely formed from a single thermoplastic polymer material, individual filaments 103 can also be at least partially formed from multiple polymer materials. As an example, an individual filament 103 may have a core and sheath configuration, wherein an outer coating of the individual filament 103 is formed from a first type of thermoplastic polymer material and an inner core of the individual filament 103 is formed from a second type of thermoplastic polymer material. As a similar example, an individual filament 103 may have a two-component configuration, wherein one half of the individual filament 103 is formed of a first type of thermoplastic polymer material and an opposite half of the individual filament 103 is formed of a second type. of thermoplastic polymer material. In some configurations, an individual filament 103 can be formed from both a thermoplastic polymer material and a thermoset polymer material with either coating and core or two-component arrangements. While all filaments 103 can be formed entirely from a single thermoplastic polymer material, filaments 103 can also be formed from multiple polymer materials. As an example, some of the filaments 103 can be formed from a first type of thermoplastic polymer material, while the other filaments 103 can be formed from a second type of thermoplastic polymer material. As a similar example, some of the filaments 103 can be formed from a thermoplastic polymer material, while the other filaments 103 can be formed from a thermoset polymer material. In this way, each filament 103, portions of filaments 103 or at least some of the filaments 103 can be formed from one or more thermoplastic polymer materials.
[028] The thermoplastic polymer material or other materials used for the textured element 100 (ie, filaments 103) can be selected to have various stretching properties and the materials can be considered elastomeric. Depending on the specific product in which textured element 100 is to be incorporated, textured element 100 or filaments 103 may stretch between ten percent to more than eight hundred percent prior to failure by breakage. For many articles of clothing, in which stretch is an advantageous property, the textured element 100 or filaments 103 can stretch at least one hundred percent before failure by breakage. As a related matter, the thermoplastic polymer material or other materials used for textured element 100 (i.e., filaments 103) can be selected to have various recovery properties. That is, textured element 100 can be formed to return to an original shape after being stretched, or textured element 100 can be formed to remain in an elongated or stretched shape after being stretched. Many products that incorporate textured element 100, such as garments, can benefit from properties that allow textured element 100 to return or otherwise recover to an original shape after being stretched by one hundred percent or more.
[029] The textured element 100 can be formed as a direct extruded or blown material. Whereas direct extruded nonwoven textiles are formed from filaments having a cross-sectional thickness of 10 to 100 microns, blown nonwoven textiles are formed from filaments having a cross-sectional thickness less than 10 microns. In many configurations, therefore, an individual filament 103 will have a thickness between 1 micron and 100 microns. Textured element 100 can be direct extruded, blown, or a combination of direct extruded and blown. Furthermore, textured element 100 can be formed to have direct extruded and blown layers, or it can also be formed such that filaments 103 are combinations of direct extruded and blown.
[030] In addition to differences in the thickness of the individual filaments 103, the overall thickness of textured element 100 can vary significantly. With reference to the various figures, the thickness of textured element 100 and other elements may be amplified or otherwise increased to show details or other features associated with textured element 100, thereby presenting clarity in the figures. For many applications, however, the thickness of the textured element 100 can be in a range of 0.5mm to 10.0mm, but can vary considerably beyond that range. For many garments, for example, a thickness of 1.0 to 3.0 millimeters may be appropriate, although other thicknesses may be used.
[031] Based on the above discussion, the textured element 100 has the general structure of a non-woven textile formed from filaments 103. At least one of the surfaces 101 and 102 includes the texture 104, which can have various configurations. For example, texture 104 can be lines, letters, numbers, symbols or areas. Texture 104 may also resemble biological matter such as leather. Additionally, the various filaments 103 can be formed from a thermoplastic polymer material. As discussed below, the thermoplastic polymer material in textured element 100 provides significant variety in the way in which textured element 100 can be used or incorporated into products.
[032] An advantage of the textured element 100 relates to versatility. More particularly, textured element 100 can be (a) modified in numerous ways to impart various properties, including fusion of regions, molding to have a three-dimensional shape, and stitching, (b) joined with other elements through thermal bonding, (c ) incorporated into various products and (d) recycled, for example. Additional information relating to these concepts can be found in (a) US Patent Application 12/367,274, filed February 6, 2009 and entitled Thermoplastic Non-Woven Textile Elements and (b) US Patent Application 12/579,838, filed at October 15, 2009 and titled Textured Thermoplastic Non-Woven Elements, both orders being incorporated herein by reference. Furthermore, texture 104 can be used with textured element 100 when modified, joined or incorporated into products to enhance the aesthetic and physical properties (e.g., stability, abrasion resistance, permeability) of the products. MANUFACTURING PROCESS
[033] A system 200 that is used in a process for manufacturing, forming or otherwise constructing textured element 100 is depicted in Figure 5. Although system 200 is shown as fabricating the configuration of textured element 100 depicted in the figures 1 and 2, system 200 can be used to make other nonwovens, a variety of textured nonwovens, and any of the textured element 100 configurations depicted in Figures 3A through 3F and 4A through 4F. Furthermore, while system 200 provides an example of an approach to fabricating textured element 100, a variety of other systems can also be used. Similarly, various modified versions of system 200, which can be discussed below, may also produce textured element 100.
[034] The primary elements of the system 200 are a filament extruder 210, a non-stick paper 220, a conveyor 230, a pair of rollers 240, a post-processing apparatus 250 and a take-up roller 260. In general operation, a plurality of filaments 103 is extruded from or otherwise formed by filament extruder 210. Individual filaments 103 are deposited or collected on release paper 220 to form a layer of filaments 103. Release paper 220 moves with conveyor 230 towards the rollers 240, thereby moving the layer of filaments 103 to rollers 240. The combination of the non-stick paper 220 and the layer of filaments 103 passes through and is compressed by rollers 240 to (a) produce a uniform thickness in the textured element 100 and ( b) ensuring that the texture of the release paper 220 is printed onto the layer of filaments 103. After compressed, the layer of filaments 103 and the release paper 220 are separated. The layer of filaments 103 then enters post-processing apparatus 250 to enhance the properties of textured element 100. After post-processing is complete, a relatively long length of textured element 100 is grouped onto pickup roller 260.
[035] The fabrication process for textured element 100 will now be discussed in more detail. To begin the manufacturing process, a plurality of individual filaments 103, which are substantially separated and disjoined at that point, are extruded from or otherwise formed by filament extruder 210. The primary components of filament extruder 210 are a hopper 211 , a melt pump 212 and a spinner 213. In forming the filaments 103, a thermoplastic polymer material (e.g., polymer pellets) is placed in the hopper 211, melted in the melt pump 212 and then extruded from the spinner. 213. Although the thickness of filaments 103 can vary, filaments 103 generally have a thickness in the range of 1 to 100 microns. The non-woven textile of textured element 100 can therefore be direct extruded, blown, or a combination of direct extruded and blown.
[036] As individual filaments 103 are being extruded from filament extruder 210, release paper 220 and conveyor 230 are moving below spinner 213. For reference purposes in the various figures, the direction in which the release paper is 220 and the conveyor 230 are moving is identified by an arrow 201. With reference to Figures 6A and 7A, a textured surface 221 of the release paper 220 is facing upwards and is exposed. Textured surface 221 includes a number of protrusions 222 that lend texture to the release paper 220. Although the release paper 220 and textured surface 221 are generally planar, the protrusions 222 project onto the release paper 220. As shown, the protrusions 222 (a) are curved, similar to a wave or wavy lines, and (b) have a hemispherical, curved or generally rounded shape, both of which are similar to the texture 104 in Figures 1 and 2. In general, the protrusions 222 have a height in a range of 0.05 to 3.0 millimeters, although height may vary. In this range, the protrusions 222 are more than mere irregularities in the textured surface 221, but they are not so large as to impart a three-dimensional or generally non-planar appearance to the release paper 220. As such, the protrusions 222 have a corresponding height. with the overall dimensions of textures in textiles and similar products. As an alternative to protuberances 222, textured surface 221 may form depressions or indentations that would also provide textured element 100 with texture. , many configurations have a width of at least 30 centimeters to form the textured element 100 with sufficient area to make garments and a variety of other products, with protrusions 222 extending across at least a portion of that width.
[037] Release paper 220 is used to provide an example of a way of incorporating a textured surface into system 200. In general, release paper 220 is a relatively thin layer that (1) does not bind or otherwise joins with the thermoplastic polymer material forming textured member 100 and (b) includes a texture (i.e., protrusions 222 on textured surface 221) that is suitable for imparting a corresponding texture (i.e., texture 104) to the textured element 100. Despite the use of "paper" in the term "non-stick paper", the non-stick paper 220 may be solely or primarily formed from polymer materials or other materials not generally found in paper (eg, pulp wood). As alternatives to the non-stick paper 220, other textured materials can be used, such as a textured metallic film. Furthermore, the release paper 220 or corresponding components may be absent from the system 200 when, for example, the surface of the conveyor 230 is textured.
[038] Continuing with fabrication of textured element 100, release paper 220 moves with conveyor 230 to a position that is under or adjacent to spinner 213 of filament extruder 210. Although filaments 103 are substantially separate and disjointed when exiting the filament extruder 210, the individual filaments 103 are deposited or collected onto the release paper 220 to begin the process of forming the non-woven textile of textured element 100, as shown in Figures 6B and 7B. Furthermore, the filaments 103 extend around and over the various protuberances 222 to begin the process of imparting texture to the layer of filaments 103.
[039] The filament extruder 210 produces a constant and stable volume of filament 103. Additionally, the non-stick paper 220 and the conveyor 230 are continuously moving relative to the spinner 213 at a constant speed. As a result, a relatively uniform thickness of filaments 103 clumps on the release paper 220. By modifying (a) the volume of the filaments 103 that are produced by the filament extruder 210 or (b) the speed of the release paper 220 and the conveyor 230, the layer of filaments 103 deposited on the release paper 220 can have any desired thickness.
[040] After passing adjacent to the filament extruder 210, a complete layer of filaments 103 is grouped onto the release paper 220, as shown in Figures 6C and 7C. Although the layer of filaments 103 is relatively uniform in thickness, some surface irregularities may be present due to the random manner in which the filaments 103 are deposited onto the release paper 220. Like that stage, the release paper 220 and the layer of filaments 103 pass between rollers 240, as shown in Figures 6D and 7D. The rollers 240 compress the release paper 220 and the layer of filaments 103 to (a) ensure that the texture of the release paper 220 is printed onto the layer of filaments 103 and (b) remove surface irregularities that are present in the layer of filaments 103 In reality, therefore, textured element 100 is pressed against textured surface 221 to produce texture 104 and a uniform thickness. Additionally, rollers 240 can be heated to raise the temperature of the layer of filaments 103 during compression.
[041] At this point in the manufacturing process for the textured element 100, the layer of filaments 103 separates from the non-stick paper 220, as depicted in Figures 6E and 7E. Although a relatively short distance is shown between the rollers 240 and the area where the release paper 220 separates from the layer of filaments 103, that distance can be modified to ensure that the layer of filaments 103 is sufficiently cooled. The filament layer 103 now enters the post-processing apparatus 250. Although shown as a single component, the post-processing apparatus 250 may be of multiple components that further refine the properties of the filament layer 103. As an example, the post-processing apparatus 250 can pass heated air through layer of filaments 103 to (a) further bond filaments 103 together, (b) heat set filaments 103 or the membrane formed in textured element 100, (c) shrinking the layer of filaments 103, (d) preserving or modifying loft and density in the layer of filaments 103 and (e) curing the polymer materials in textured element 100. Other post-processing steps may include dyeing, cutting , perforation, sanding, sueding and printing.
[042] After the layer of filaments 103 leaves the post-processing apparatus 250, fabrication of the textured element 100 is effectively complete. The textured element 100 is then accumulated on the pickup roller 260. After a sufficient length of the textured element 100 is accumulated, the pickup roller 260 can be shipped or otherwise transported to another manufacturer, used to form various products or used for other purposes.
[043] The manufacturing process discussed above has several advantages over conventional processes for forming non-woven textiles. In some conventional processes, calender rollers are used to impart texture. More particularly, calender rolls are placed within a manufacturing system to (a) heat a non-woven textile and (b) print a texture onto the non-woven textile. The process of removing the first textured calender rolls, installing the second textured calender rolls, and aligning the new calender rolls can require numerous individuals and significant time. In system 200, however, the release paper 220 is replaced by a new release paper 220, which can be performed by fewer individuals and relatively quickly. Additionally, calender rolls are relatively expensive, while non-stick paper 220 is relatively inexpensive. Thus, system 220 has the advantages of (a) increasing the efficiency of the manufacturing process, (b) reducing the number of individuals needed to make process modifications, (c) reducing the time the process is not in operation and (d) reduce costs associated with the equipment. MANUFACTURING VARIATIONS
[044] The fabrication process discussed above in relation to system 200 presents an example of a fabrication process suitable for textured element 100. Numerous variations of the fabrication process will now be discussed. For example, Figure 8 depicts a portion of the system 200 in which the release paper 200 forms an endless loop. That is, the release paper 200 follows conveyor 230, passes through rollers 240, and then returns to again follow conveyor 230. In fact, release paper 200 forms a circuit and is used repeatedly to form texture 104 on the element with texture 100. Another example is shown in Figure 9A, in which a vacuum pump 202 draws air through several perforations 271 in the non-stick paper 220, effectively creating negative pressure on the textured surface 221. In operation, negative pressure can help with (a) collecting filaments 103 on textured surface 221 and (b) shaping layer of filaments 103 with protuberances 222. Referring to Fig. 9B, a configuration is shown where (a) non-stick paper 220 is absent and (b) conveyor 230 includes a textured surface 231 with a plurality of protrusions 232. Continuing with that example, Figure 9C depicts a configuration in which vacuum pump 202 pulls. air through several perforations 271 in conveyor 230. Additionally, Figure 10 depicts a configuration in which protrusions 222 of release paper 220 are replaced by a plurality of indentations 223. As with protrusions 222, indentations 223 may have a depth in a range of 0.1 to 3.0 millimeters, for example.
[045] In the manufacturing process discussed above, the non-woven material of textured element 100 is formed on a textured surface (eg, textured surface 221). After fabrication, therefore, the non-woven material of the textured element 100 also forms the texture 104. That is, the texture 104 forms various indentations, depressions, or other discontinuities in the non-woven material. As a variation, Figure 4F depicts texture 104 as being formed in crust layer 405. A fabrication process for producing a similar configuration will now be discussed. Referring to Figures 11A and 12A, a layered element 270 is located on the conveyor 230 and includes a textured layer 271 and a crust layer 272. The textured layer 271 has a textured surface 273 that is in contact with the crust layer 271 and includes a plurality of protrusions 274. As an example, texture layer 271 may be similar to non-stick paper 220. Crust layer 272 is a polymer layer and may be formed from filament thermoplastic polymer material 103, a different thermoplastic polymer material or another polymer. Furthermore, the crust layer 272 includes a number of notches 275 corresponding with the protrusions 274.
[046] As the conveyor 230 moves, the layered element 270 is positioned under a heating element 280, as depicted in Figures 11B and 12B. Heating element 280 can be an infrared heater, resistance heater, convection heater, or any other device capable of raising the temperature of the crust layer 272. Although the temperature of the crust layer 272 at this point in the manufacturing process may vary. , the temperature of the crust layer 272 is often raised to at least the glass transition temperature of the thermoplastic polymer material forming the crust layer 272. Following heating, the layered element 270 moves with the conveyor 230 to a position that is under or adjacent to spinner 213 of filament extruder 210. Although filaments 103 are substantially separated and disjointed when exiting filament extruder 210, individual filaments 103 are deposited or collected onto heated crust layer 272 to begin the process of forming the non-woven fabric of the textured element 100, as shown in Figures 11C and 12C. The filaments 103 that are in contact with the crust layer 272 can bond with the crust layer 272.
[047] After passing adjacent to the filament extruder 210, a complete layer of filaments 103 is collected over the crust layer 272, as depicted in Figures 11D and 12D. Although the layer of filaments 103 is relatively uniform in thickness, some surface irregularities may be present due to the random manner in which the filaments 103 are deposited onto the crust layer 272. filaments 103 pass between rollers 240, as shown in Figures 11E and 12E. Rollers 240 compress layered member 270 and layer of filaments 103 to (a) ensure that filaments 103 bond with layer of crust 272, (b) remove surface irregularities that are present in layer of filaments 103. Additionally, rollers 240 can be heated to raise the temperature of the layer of filaments 103 during compression.
[048] At this point in the manufacturing process for textured element 100, texture layer 271 is separated from crust layer 272, as depicted in Figures 11F and 12F. More particularly, the combination of the filament layer 103 and the crust layer 272 is separated from the texture layer 271. Various post-processes can now be performed to refine the properties of the filament layer 103 and the crust layer 272, thereby completing the fabrication process and forming a structure similar to the textured element variation 100 in Figure 4F.
[049] The invention is disclosed above and in the accompanying figures with reference to a variety of configurations. The purpose served by the disclosure, however, is to present an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications can be made to the configurations described above without departing from the scope of the present invention as defined by the appended claims.

权利要求:
Claims (16)
[0001]
1. Method of manufacturing a textured element CHARACTERIZED by comprising: collecting a plurality of filaments on a textured surface to form a non-woven textile and to print a textured surface texture on the non-woven textile, wherein the textured surface is one of (a) a non-stick paper and (b) a non-stick paper coupled to a moving conveyor; and separating the non-woven textile from the textured surface, wherein the non-woven textile retains the texture of the textured surface after being separated from the textured surface.
[0002]
The method of claim 1, further including a step of extruding a thermoplastic polymer material to form the filaments.
[0003]
The method of claim 1, further including a step of compressing the non-woven textile against the textured surface.
[0004]
The method of claim 1, further including a step of admitting air through the textured surface.
[0005]
The method of claim 1, further including a step of selecting the textured surface to have at least one of (a) a plurality of protrusions with a height in a range of 0.1 to 3.0 millimeters and (b) a plurality of notches with a depth in a range of 0.1 to 3.0 millimeters.
[0006]
The method of claim 1, comprising: extruding a plurality of substantially separate filaments that include a thermoplastic polymer material; and depositing the filaments onto a movable surface to (a) join the filaments to form a non-woven textile and (b) print a movable surface texture on the non-woven textile, wherein the movable surface is one of (a) a non-stick paper and (b) a non-stick paper coupled to a carrier.
[0007]
The method of claim 6, characterized in that it further includes a step of compressing the non-woven textile against the moving surface.
[0008]
The method of claim 6, further including a step of admitting air through the moving surface.
[0009]
9. The method according to claim 1, characterized in that it comprises: positioning an extruder proximal to a non-stick paper having (a) a width of at least 30 centimeters in a direction that is perpendicular to a direction of movement of the moving surface and ( b) a texture that extends across at least a portion of the width and includes a plurality of protrusions having a height in a range of 0.1 to 3.0 millimeters, extruding a plurality of separate and disjointed filaments from the extruder, the filaments having a thickness in the range of 1 to 100 microns and the filaments including a thermoplastic polymer material, deposit the filaments onto the non-stick paper to form a non-woven textile, the bulges extending to a surface of the non-woven textile to print the texture from the moving surface on the non-woven textile, press the non-woven textile against the non-stick paper; and separating the non-woven textile from the moving surface.
[0010]
The method of claim 9, characterized in that it further includes a step of admitting air through the release paper.
[0011]
11. Method according to claim 9, CHARACTERIZED by the fact that the non-stick paper is a movable non-stick paper.
[0012]
12. Method according to claim 9, CHARACTERIZED by the fact that the non-stick paper is coupled to a carrier.
[0013]
13. Method of manufacturing a textured element CHARACTERIZED by: depositing a plurality of filaments onto an endless moving circuit of textured non-stick paper to form a non-woven textile; and separate the non-woven fabric from the textured non-stick paper.
[0014]
The method of claim 13, further including a step of forming the filaments of a thermoplastic polymer material.
[0015]
The method of claim 13, further including a step of compressing the non-woven textile against the textured non-stick paper.
[0016]
The method of claim 13, further including a step of admitting air through the textured release paper.

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同族专利:

公开号 | 公开日

US20130320584A1|2013-12-05|

KR20140144733A|2014-12-19|

CN104334780A|2015-02-04|

KR101699141B1|2017-01-23|

US8906275B2|2014-12-09|

JP2015522722A|2015-08-06|

US20150123305A1|2015-05-07|

US9732454B2|2017-08-15|

EP2855752A1|2015-04-08|

EP2855752B1|2019-09-25|

BR112014027003A2|2017-06-27|

WO2013181082A1|2013-12-05|

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法律状态:
2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |

2019-09-03| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

2021-04-06| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

2021-07-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

2021-08-24| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/05/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

申请号 | 申请日 | 专利标题

US13/482,182|US8906275B2|2012-05-29|2012-05-29|Textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements|

US13/482,182|2012-05-29|

PCT/US2013/042581|WO2013181082A1|2012-05-29|2013-05-24|Textured elements incorporating non-woven textile materials and methods for manufacturing the textured elements|

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