Fiber-bound engineered materials formed utilizing carrier screens

Patent metadata

Field	Value
Publication number	US-11325345-B2
Application number	US-201716480119-A
Country	US
Kind code	B2
Filing date	Nov 30, 2017
Priority date	Feb 3, 2017
Publication date	May 10, 2022
Grant date	May 10, 2022

Abstract

A method of forming a fiber-bound engineered material utilizing carrier screens is provided that imparts an intended characteristic at an intended relative location. Also provided are articles formed of fiber-bound engineered materials manufactured utilizing carrier screens. A fiber layer is placed adjacent at least one carrier screen and 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.

First claim

What is claimed is:

1. A method of forming fiber-bound engineered components that can be incorporated into an article, the method comprising:
placing a plurality of substantially identical discrete fiber layers each made of a first plurality of fibers within discrete locations along a length of a continuous elongated carrier screen having a plurality of apertures through which fluid can pass and functioning as a conveyor belt for the discrete fiber layers, the discrete locations each comprising only a portion of a total area of the carrier screen;
placing a discrete scrim made of a second plurality of fibers on top of and in registration with each discrete fiber layer such that each scrim overlies its associated discrete fiber layer to form an assembly; and
as to each assembly, entangling at least a portion of the first plurality of fibers with at least a portion of the second plurality of fibers by passing a fluid stream through the apertures of the carrier screen to form a fiber-bound engineered component.

2. The method of claim 1 , wherein the fiber-bound engineered components are components of an article of footwear, an apparel component, or a sporting equipment component.

3. The method of claim 1 , wherein the discrete scrims are adhered to a fugitive backing.

4. The method of claim 1 , further comprising placing a further carrier screen over the discrete scrims to sandwich the discrete fiber layers and the discrete scrims between the two carrier screens prior to entangling.

5. The method of claim 4 , wherein at least one of the carrier screens is formed of a mesh comprising, at least in part, a monofilament polymeric yarn, fiberglass filament, plastic fiber, polyester fiber, a polymer extrusion, a film, cut netting, woven aluminum, woven bronze, or a multiple-material woven composition.

6. The method of claim 4 , wherein at least one of the carrier screens is formed of a mesh including a plurality of warp apertures and a plurality of fill apertures, wherein the at least one carrier screen includes 14 to 20 warp apertures per square inch and 14 to 30 fill apertures per square inch.

7. The method of claim 4 , wherein at least one of the carrier screens is formed of a mesh including a plurality of warp apertures and a plurality of fill apertures, wherein the at least one carrier screen includes 16 to 20 warp apertures per square inch and 16 to 20 fill apertures per square inch.

8. The method of claim 1 , further comprising placing a further discrete fiber layer on top of and in registration with each discrete scrim prior to entangling, the further discrete fiber layers each comprising a third plurality of fibers so that, within each assembly, at least a portion of the third plurality of fibers is entangled with at least a portion of the second plurality of fibers.

9. The method of claim 1 , wherein the carrier screen and its discrete fiber layers are wound up as a continuous roll.

10. The method of claim 9 , further comprising unwinding the carrier screen from the continuous roll.

11. A method of forming a plurality of fiber-bound engineered components that can be incorporated into articles, the method comprising:
providing a carrier screen having a plurality of apertures through which fluid can pass, the carrier screen being configured as a continuous elongated screen;
placing a plurality of discrete fiber elements on a surface of the carrier screen at discrete spaced locations along a length of the carrier screen;
sequentially delivering each discrete fiber element to a first station with the carrier screen;
sequentially placing a discrete scrim on top of and in registration with each discrete fiber element at the first station to form a plurality of composite elements on the carrier screen;
sequentially delivering each composite element to a second station with the carrier screen; and
sequentially entangling the discrete fiber element and the discrete scrim of each composite element together at the second station by passing a fluid stream through the apertures of the carrier screen to form the plurality of fiber-bound engineered components.

12. The method of claim 11 , wherein the carrier screen is wound up to form a continuous roll and wherein sequentially delivering each discrete fiber element to a first station and sequentially delivering each composite element to a second station comprises unwinding the carrier screen from the roll.

13. The method of claim 12 , wherein the discrete scrims are provided on a continuous elongated fugitive backing that is applied to the carrier screen at the first station.

14. The method of claim 13 , wherein the fugitive backing is wound up to form a further continuous roll and wherein sequentially placing a discrete scrim on top of and in registration with each discrete fiber element comprises unwinding the fugitive backing from its roll.

15. The method of claim 14 , further comprising covering the plurality of composite elements with a further carrier screen at a third station to sandwich the composite elements between the two carrier screens prior to entangling, the further carrier screen also being configured as a continuous elongated screen having a plurality of apertures through which fluid can pass.

16. The method of claim 15 , wherein the further carrier screen is wound up to form a continuous roll and wherein covering the plurality of composite elements comprises unwinding the further carrier screen from its roll.

17. A method of forming a plurality of fiber-bound engineered components that can be incorporated into articles, the method comprising:
providing a carrier screen having a plurality of apertures through which fluid can pass, the carrier screen being configured as a continuous elongated screen;
placing a plurality of first discrete fiber elements on a surface of the carrier screen at discrete spaced locations along a length of the carrier screen;
sequentially delivering each first discrete fiber element to a first station with the carrier screen;
sequentially placing a discrete fluid-impervious scrim on top of and in registration with each first discrete fiber element at the first station to form a plurality of first composite elements on the carrier screen;
sequentially delivering each first composite element to a second station with the carrier screen;
sequentially placing a second discrete fiber element on top of and in registration with each first discrete fiber element to form a plurality of second composite elements on the carrier screen at the second station, each second composite element including a discrete fluid-impervious scrim positioned between the two discrete fiber elements;
sequentially delivering each second composite element to a third station with the carrier screen; and
sequentially entangling the first and second discrete fiber elements of each second composite element together at the third station by passing a fluid stream through the apertures of the carrier screen to form the plurality of fiber-bound engineered components, each fiber-bound engineered component having a discrete fluid-impervious scrim encased between two discrete fiber elements.

Assignees

• Nike Inc

Inventors

• Dua Bhupesh
• Greene Pamela S
• Kilgore Bruce J
• Rushbrook Thomas J

Classifications

• B32B5/022

  Non-woven fabric · CPC title

• A43B1/0072

  made at least partially of transparent or translucent materials · CPC title

• D04H5/03

  by fluid jet · CPC title

• A43B23/0205

  characterised by the material (material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08) · CPC title

• A43B23/026

  Laminated layers · CPC title