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公开(公告)号：US11780177B2
公开(公告)日：2023-10-10
申请号：US17761023
申请日：2020-03-16
Applicant: PIANA NONWOVENS, LLC
Inventor： Andy Hollis , Michael Stephen Defranks , Eric McCann , Mehran Jafari , Helias Andriessen , Sang-hoon Lim , Andrea Piana , Alfio Borgatti
CPC classification number: B29C70/12 , B29C35/049 , B29C35/16 , B29C70/18 , B29C70/46 , B29C70/54 , B29L2031/751 , B29L2031/771
Abstract: 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.
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公开(公告)号：US20200338876A1
公开(公告)日：2020-10-29
申请号：US16842829
申请日：2020-04-08
Applicant: Piana Nonwovens, LLC.
Inventor： Andrea Piana , Michael Stephen DeFranks , Eric McCann , Andy Hollis , Sang-hoon Lim , Helias Andriessen , Mehran Jafari
Abstract: 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.
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公开(公告)号：US11993027B2
公开(公告)日：2024-05-28
申请号：US17814555
申请日：2022-07-25
Applicant: Piana Nonwovens, LLC.
Inventor： Andrea Piana , Andy Hollis , Mehran Jafari , Helias Andriessen , Sang-hoon Lim , Eric McCann
IPC: B29C70/34 , B29C70/12 , B29C70/54 , B29K267/00 , B29L31/00
CPC classification number: B29C70/12 , B29C70/34 , B29C70/545 , B29K2267/00 , B29L2031/751
Abstract: 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.
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公开(公告)号：US11472132B2
公开(公告)日：2022-10-18
申请号：US16594279
申请日：2019-10-07
Applicant: Piana Nonwovens, LLC.
Inventor： Andrea Piana , Andy Hollis , Mehran Jafari , Helias Andriessen , Sang-hoon Lim , Eric McCann
IPC: B29C70/34 , B29C70/12 , B29C70/54 , B29L31/00 , B29K267/00
Abstract: 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.
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公开(公告)号：US20220363018A1
公开(公告)日：2022-11-17
申请号：US17814555
申请日：2022-07-25
Applicant: Piana Nonwovens, LLC.
Inventor： Andrea Piana , Andy Hollis , Mehran Jafari , Helias Andriessen , Sang-hoon Lim , Eric McCann
Abstract: 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.
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Patent Agency Ranking
公开(公告)号：US20220098770A1
公开(公告)日：2022-03-31
申请号：US17471233
申请日：2021-09-10
Applicant: Piana Nonwovens, LLC.
Inventor： Mehran Jafari , Sang-hoon Lim , Andy Hollis , Andrea Piana , Eric McCann , Helias Andriessen
IPC: D04H1/4382 , D04H1/435 , B60N2/64 , B63B29/04 , B64D11/06
Abstract: A cushion or pad device is provided. The device comprises at least one layer of nonwoven material defining a volume with length, width, and depth dimensions, wherein the vertically lapped nonwoven material comprises at least one bulk fiber, wherein the bulk fiber comprises a thermoplastic polyester; and at least one elastomeric binder fiber. Methods of preparing the cushion or pad device are also provided.
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公开(公告)号：US20200298506A1
公开(公告)日：2020-09-24
申请号：US16594279
申请日：2019-10-07
Applicant: Piana Nonwovens, LLC.
Inventor： Andrea Piana , Andy Hollis , Mehran Jafari , Helias Andriessen , Sang-hoon Lim , Eric McCann
Abstract: 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.
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公开(公告)号：US20190248103A1
公开(公告)日：2019-08-15
申请号：US16247907
申请日：2019-01-15
Applicant: Piana Nonwovens
Inventor： Andrea Piana , Mehran Jafari , Eric McCann , Sam Lim , Andy Hollis , Helias Andriessen
Abstract: 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.
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公开(公告)号：US11771971B2
公开(公告)日：2023-10-03
申请号：US16842829
申请日：2020-04-08
Applicant: Piana Nonwovens, LLC.
Inventor： Andrea Piana , Michael Stephen DeFranks , Eric McCann , Andy Hollis , Sang-hoon Lim , Helias Andriessen , Mehran Jafari
IPC: A63B69/00 , B29C70/00 , B32B5/00 , B32B37/00 , B32B39/00 , B29C70/34 , B32B5/02 , B32B5/26 , B29L31/00
CPC classification number: A63B69/0048 , B29C70/342 , B32B5/022 , B32B5/26 , B32B37/0046 , B32B39/00 , B29L2031/771 , B32B2262/0276 , B32B2262/0284 , B32B2367/00 , B32B2605/003
Abstract: 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.
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公开(公告)号：US11186063B2
公开(公告)日：2021-11-30
申请号：US16247907
申请日：2019-01-15
Applicant: Piana Nonwovens
Inventor： Andrea Piana , Mehran Jafari , Eric McCann , Sam Lim , Andy Hollis , Helias Andriessen
Abstract: 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.
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