DE102019208275A1 - Method for providing a nonwoven fabric - Google Patents

Abstract

A method for providing a nonwoven fabric (1000; 4000), comprising reversible positioning of a casting mold (100, 200, 300, 400, 500; 600; 700; 800) on a conveyor (30) which is spread through a shower (10) from Fleece fibers (11) moved.

Description

Technical area

The present invention relates to methods of providing nonwoven fabrics, casting molds used in such methods, and nonwoven fabrics obtained by such methods.

Description of the prior art

Nonwovens are made from fibers or yarns that are randomly arranged and bonded together by a chemical, mechanical, heat or solvent-based treatment. In contrast to woven or knitted fabrics, the fibers or yarns in nonwovens are typically not provided in a regular mesh structure or loop structure.

Nonwovens are extremely versatile because they can be specifically engineered to have desired properties. For example, they can be designed to be very durable and stable, uniform, heat-resistant and / or ecological. Therefore, nonwoven fabrics are used for a variety of products and articles including apparel and footwear such as shoes or sports accessories.

Usually, nonwovens are provided in the form of flat layers. Fibers are extruded and placed, preferably uniformly, on a moving conveyor belt or other flat surface. In order to finally obtain generally three-dimensionally shaped products such as clothing or shoes - or at least parts thereof - from these layers, further processing is necessary. Further processing steps are also required in order to provide such layers with details such as specific textures. This means that the layers are cut, welded, embroidered, sewn and / or connected in post-processing. For example, from the EP 2,397,594 known to (heat) press the layers into cast parts with the desired shape and / or details. However, such additional steps inevitably affect the properties of the web, making it difficult to obtain a fabric with exactly the properties desired, not to mention their impact on the overall production times.

In an alternative approach that is derived from the DE 10 2016 223 571 is known, the fibers are extruded directly onto a three-dimensionally shaped substrate, the substrate having holes through which the fibers are sucked in order to distribute them uniformly, in particular on concave and / or convex surfaces of the substrate. However, the provision of such a special, perforated, three-dimensionally shaped substrate is a relatively long and complex process. Furthermore, such substrates are generally limited in size and cannot simply be modified in the event of changing conditions. In particular, such substrates cannot simply be reused for similar but not identical articles, which is why the use of this approach is - at least economically - inefficient.

Another approach is from the U.S. 9,732,454 and the US 2013/0285294 known. Here, extruded fibers are placed on a conveyor belt which has corresponding, complementary structures, for example in the form of depressions and / or elevations. In the same way, the actual conveyor belt can be wrapped with an additional layer that has the corresponding, complementary structures instead of the conveyor belt as such. In both cases this allows a limited number of predetermined textures to be obtained; Changing the conveyor belt or the wrapping layer to obtain a different texture will usually be too laborious and therefore impossible in the production of nonwovens on an industrial scale.

Therefore, there is a need for a method which reduces the number of processing steps necessary to obtain nonwoven fabrics with various desired shapes and details.

Summary of the invention

This need is at least partially covered by a method according to claim 1.

A first aspect of the present invention relates to a method for providing a nonwoven fabric, comprising the reversible positioning of a casting mold on a conveying means which moves through a shower of nonwoven fibers.

The reversible positioning of a casting mold on a conveyor means you can change the casting mold as you wish and thereby provide nonwovens with different shapes and details. In fact, each mold can be different so that nonwoven fabrics of various shapes and sizes can be provided sequentially in an arbitrary order. The positioning and / or changing of molds can also be carried out while the conveyor is in operation. Unlike the solutions in the prior art, a complete stop of the conveyor is necessary to z. B. to replace the conveyor belt is not required for the present invention.

This in turn can allow an increased individualization of the nonwovens and the corresponding goods, while the speed and production efficiency is maintained on an industrial scale: Personalized substrates, e.g. corresponding to an individualized last of a tailor-made sports shoe or at least parts thereof, can simply be transferred to a conveyor during normal Operationally positioned without stopping or at least slowing down production or even requiring special production processes and / or equipment.

Indeed, the present invention not only allows the speed and efficiency to be maintained on an industrial scale, but it can actually increase them. By positioning cast parts in the desired shape and details on the conveyor, the nonwovens that leave the production line can already be completely finished: Since they are given the desired shape and details during production, there is no need for extensive post-processing.

Finally, the present invention extends the applicability of conventional production methods. While these are typically applied to two-dimensional structures, i. Obtaining layers of nonwoven fabrics as described above allows the present invention to obtain three-dimensional structures thereof, while changes to existing production facilities are not required. One can simply continue to use conventional two-dimensional production techniques to obtain three-dimensional, textured fabrics and articles.

In short, the present invention significantly expands the application possibilities as well as the modularity and flexibility of conventional methods for obtaining nonwovens.

In one embodiment, a reversibly positioned casting mold can have at least one depression and / or elevation. These can be used to obtain the desired shape and / or detail in the resulting nonwoven fabric. Depressions and / or elevations can have any shape and / or size. A casting mold can only have one depression and / or elevation. Alternatively, a casting mold can have several depressions and / or elevations. Depressions and / or elevations can be arranged as desired. Alternatively, depressions and / or elevations can be arranged regularly and / or symmetrically. Similarly, depressions and / or elevations can be arranged partially arbitrarily and partially symmetrically. Depressions and / or elevations can be combined, i.e. an elevation can have one or more depressions and vice versa. A recess can also be in the form of a hole, i. it can break through the mold.

In some embodiments, a reversibly positioned casting mold can be a solid sheet or plate that can have at least one depression and / or elevation as described above. In other embodiments, a reversibly positioned mold can be obtained by combining two or more substrates so that they at least partially overlap. This can further increase the production modularity and flexibility made possible by the present invention. For example, different substrates can be combined in order to obtain a desired, possibly three-dimensional shape. As a result, a large number of different casting molds can be obtained from a relatively small and limited number of different substrates. At the same time, this allows substrates to be reused, so that production and operating costs are reduced. For example, the same substrate can be used for a plurality of shoe uppers and different second substrates can be positioned on the first substrate to reveal different details, e.g. Preserve textures in the resulting uppers. In general, more than two substrates can be combined if desired and / or as needed. In some embodiments, the substrates can be substantially planar plates and / or templates. These plates and / or templates can have a common outer contour, but different details. At least one of the substrates can also have one or more depressions and / or elevations as described above for the casting mold itself.

Alternatively, a reversibly positioned mold may be formed from a frame surrounding a grid or mesh. The grid or mesh can be formed from metal or plastic wires. Alternatively, the grid or net can be formed from ribbons of plastic or cloth or paper materials. The wires or ribbons may be arranged uniformly to form holes between the wires or ribbons that are regular in shape. Alternatively, the wires or ribbons can be arranged in an arbitrary manner. In contrast to the above embodiment in which the mold is formed from a solid sheet, this embodiment allows much tighter delimitations between the recesses and / or holes in the resulting nonwoven fabric.

In a further aspect, the present invention relates to a method for providing a nonwoven fabric, comprising providing a casting mold comprising one or more substrates, wherein at least one first substrate comprises a plurality of openings, reversibly blocking at least one of the plurality of openings at least partially; and transferring a plurality of nonwoven fibers onto the one or more substrates including the at least one reversibly blocked opening.

In some embodiments, these substrates can be substantially planar plates and / or templates. These plates and / or templates can have a common outer contour, but different details. The openings can have any shape and / or size. They can be arranged randomly or at least in parts regularly and / or symmetrically. On the one hand, these openings can serve as details that are ultimately printed on the resulting nonwoven fabric, similar to the one or more depressions and / or elevations, as described above. On the other hand, air - or any other gas for this purpose - can flow through the openings and thus effectively guide the fibers towards or away from the openings. By blocking at least one of these openings, this effect can be suppressed for these one or more openings, as a result of which a different shape and / or texture of the resulting nonwoven fabric is achieved, at least in a region that corresponds to the part of the casting mold comprising the reversibly blocked opening becomes.

By reversibly at least partially blocking at least one of the plurality of openings, this effect can be used in a controlled and targeted manner. In particular, one can comprise a single or a few base substrates, e.g. use a number of uniformly distributed openings which can be blocked and / or released depending on the desired shape and / or details of the nonwoven fabric to be obtained, rather than providing different substrates with different arrangements of openings. This greatly benefits the possibility of individualization without having to sacrifice production speed and efficiency. Furthermore, there is no need for complex post-processing, since the present aspect allows the provision of nonwovens with the desired shape and / or details already during production.

In short, similar to that described above in relation to the first aspect of the present invention, this second aspect not only allows the modularity and flexibility of conventional nonwoven production methods to be further increased, but can even reduce production costs since it allows substrates to be reused. This aspect of the present invention can be combined with all of the aforementioned details as well as those that follow with the first aspect as described above.

The method of providing a nonwoven fabric may further include applying a pressure differential to at least one of the plurality of openings. This can enhance the above-described effect that the openings have. In particular, when a suction force is applied to further pull the fibers through the plurality of openings, the resulting nonwoven fabric can be provided with sharp contours at the edges of each of the plurality of openings. The pressure difference can also be applied to only one of the plurality of openings. Alternatively, the pressure differential may be applied to two or more of the plurality of orifices, or to all of them. This may include applying a pressure differential to a region including at least one reversible blocked opening. The pressure difference can be uniform across all the openings on which it is applied. Alternatively, the pressure difference can be varied along the surface of the mold. Varying the pressure differential allows a non-uniform shape and / or structure to be produced for a resulting nonwoven fabric. The pressure difference can be kept uniform over time while the nonwoven is being produced. Alternatively, the pressure differential can vary over time during the production of a nonwoven fabric. For example, the pressure differential may be greatest at the moment the nonwoven fibers are applied to the mold, and the pressure differential may decrease as the fibers bind, or vice versa. In this way, a density gradient can be achieved along a cross section of the resulting nonwoven fabric, which allows its performance and feel to be further adjusted.

The reversible at least partially blocking of at least one of the plurality of openings can include introducing a liquid into and / or applying an adhesive tape to at least one opening. These are particularly suitable but reversible options for at least partially blocking at least one of the openings. Also, liquids and tapes can be easily made to follow any shape of substrate into which they are inserted / applied. In other embodiments, other means can be used to reversibly block at least the one opening, for example one or more plugs. An adhesive tape can be applied over or under the one or more openings that are to be reversibly blocked. When applied under the one or more openings, the one or more blocked openings may show up as an additional, slightly different texture in a resulting nonwoven fabric. In particular, the at least partial blocking of at least one of the plurality of openings in this way does not require any additional, special equipment, but is based on common means that are widely available and inexpensive. This can highlight the desired effects of the present invention on production modularity and flexibility while keeping its implementation and operating costs particularly low.

An advantage of using an adhesive tape to block at least one of the plurality of openings is that it forms a border around a desired shape of a nonwoven fabric, the border having a uniform texture. This can be particularly advantageous when fabrics are manufactured for clothing that require additional assembly steps. For example, when two sides of a glove (front and back) are made using the methods described herein, these two sides can be more easily joined together around the edges if such edges are of a uniform texture, for example without dimples or bumps.

Alternatively or additionally, the casting mold can have two or more substrates, a second substrate being at least partially arranged on or below the first substrate in order to at least partially block at least one of the plurality of openings in the first substrate. This can allow one or more openings to be reversibly blocked and uncovered without producing any form of waste, since the substrates can be used several times without significantly wearing out, compared to, for example, an adhesive tape. Such a second substrate can also simply be turned over in order to obtain two mirror-symmetrical parts of nonwovens which can be of significant use in the manufacture of, for example, shoes and gloves. In addition, the use of one or more prefabricated substrates for blocking can accelerate the blocking and / or releasing, and thus make the entire production process faster and thus more efficient. As described above for application of the adhesive tape, if the second substrate is provided below the first substrate, the blocked one or more openings may show up as additional, slightly different textures in a resulting nonwoven fabric. Furthermore, providing the mold in the form of two or more substrates can allow the desired effects of the second aspect to be combined with those of the first aspect of the invention: on the one hand, the substrates can comprise specific shapes in order to obtain the desired overall shape of the resulting composite mold while at the same time they can be adjusted to each other in order to control and adjust the texture effect that the (lack of) airflow through one or more reversibly blocked openings can have. The second substrate may itself include a second plurality of openings to further direct a flow of air. For example, providing a second plurality of openings that partially block but also partially overlap the plurality of openings in the first substrate can result in a slightly angled air flow. Similarly, a suitable arrangement of the second plurality of openings can produce targeted non-laminar and / or turbulent air currents that can have a desired effect on the shape and detail and thus on the performance and feel of a resulting nonwoven fabric.

Alternatively, the second substrate can have no openings. This can allow a particularly tight sealing of the target opening or the multiple target openings. In fact, the properties of a resulting nonwoven fabric can differ even more significantly in regions corresponding to parts of the mold that include unblocked openings and in regions corresponding to parts of the mold that include blocked openings, which in turn results in particularly sharp contours allowed.

Like any mold according to the first aspect of the present invention, a mold comprising one or more substrates, at least one of which comprises a plurality of openings, can be positioned on a conveyor which moves through a shower of nonwoven fibers. This again allows the advantages that are described with reference to the first aspect of the present invention to be utilized in the second aspect as well. Indeed, when the mold is placed on a conveyor that moves through a shower of nonwoven fibers, the advantages of both aspects can be synergistically combined and integrated. In particular, no expensive and complex adjustments to the existing infrastructure are required.

The molds used in both aspects of the present invention as discussed above can be provided by an additive manufacturing step, among other things. This can allow the flexibility of the corresponding production processes to be increased further. In particular, the use of additively produced substrates can allow greater consideration of the individualization. For example, molds can be additively manufactured according to the preferences and / or requirements of customers. In some embodiments, for example, the customer can have his / her foot accurately measured. A corresponding casting mold in the form of a shoe last, or parts thereof, is then produced additively. This mold can then be positioned on a conveyor to the customer to provide a tailor-made shoe in a relatively short period of time, since no special production steps have to be carried out. Rather, the individual casting mold is incorporated into the already optimized and ongoing production process on an industrial scale. In some embodiments, the mold can be provided only partially including an additive manufacturing step. For example, while a pre-fabricated substrate is used for the entire shape of a shoe upper, a second, possibly uppermost, substrate can be additively made according to the requirements and / or preferences of the customer. For example, this allows the texture and thus the wearing comfort of a shoe upper to be individually adjusted without significantly changing the overall shape. Similarly, by providing a suitable second substrate, the customer's initials, for example, can be printed on the resulting nonwoven fabric.

In addition, molds can be positioned, at least in part, using a robotic arm. This can allow the automation and thus the potential further acceleration of the production processes described above. Central control over production can also be made possible. In some embodiments, a robotic arm can provide access to a number of pre-fabricated substrates, e.g. B. plates and / or templates. In response to input from a user - which in some embodiments may be received from remote locations such as stores on other continents - a robotic arm selects a mold and positions it on the conveyor. Alternatively, the robotic arm can select a number of substrates and combine these on a conveying means in such a way that a desired casting mold is positioned there as a result. This may include positioning a second substrate on or under a first substrate to reversibly at least partially block at least one opening therein, as described above. Similarly, the robotic arm can be adapted to introduce a liquid into one or more openings in the first substrate and / or apply an adhesive tape to it. Subsequently, the casting mold obtained moves through a shower of nonwoven fibers, so that the desired nonwoven fabric, which was requested by input from the user, is obtained. All of this can of course be achieved by any type of robot that does not necessarily have to be in the specific shape of a robotic arm.

In another aspect, the present invention relates to nonwovens that have an inhomogeneous and / or three-dimensional shape, which are at least partially obtained by one of the methods described above, as well as clothing or shoes, in particular sports shoes, which comprise such materials. As will be apparent from the foregoing, such nonwovens can be provided on an increasingly individualized basis and in an increasingly rapid, inexpensive, and therefore efficient manner. This is made possible in particular through the use of substrates that can be combined in a modular manner and / or individually manufactured and thus through extensive post-processing steps that are not required any further as far as possible.

Among other things, such nonwovens can comprise regions of more densely or less densely distributed fibers, so that different wearing comfort and different performance characteristics are achieved between these different regions. For example, the density of the fibers can affect the air permeability and the tensile strength of the corresponding region of the nonwoven. In some embodiments, a region comprising more densely arranged fibers may correspond to a portion of the mold that includes at least one blocked opening.

In a further aspect, the present invention relates to casting molds which can be used in any of the methods described above.

In some embodiments, such molds may comprise two or more substrates that are combined to obtain a depression and / or elevation of the corresponding mold. As described above, by modularly combining two or more substrates to obtain the desired mold, the flexibility and efficiency of conventional production processes can be increased significantly; a limited number of substrates can allow a large number of different molds to be molded, which benefits the possibility of customizing the materials obtained. In particular, such casting molds can allow the use of two-dimensional production processes for providing three-dimensionally shaped nonwovens. At the same time, production costs can be reduced since the molds and substrates that are used in them can be reused over and over without experiencing significant wear.

Alternatively or additionally, at least one substrate which is contained in such a casting mold can comprise a multiplicity of openings, of which at least one can be reversibly blocked and released. This allows the selective modification of e.g. the texture of a nonwoven fabric obtained, whereby the flexibility and efficiency of the production processes known in the prior art can be further increased.

Of course, such casting molds can be provided by at least partially using additive manufacturing techniques, which further simplifies the individualization. In some examples, the entire mold can be made including an additive manufacturing step. In other embodiments, only one or more substrates that are used to form the mold can be manufactured in this manner, while at least one other substrate is not provided including an additive manufacturing step.

Figure list

• : Beispielhafte Produktionsstätte, die angepasst ist, die Verfahren gemäß einiger Aspekte der vorliegenden Erfindung auszuführen;
• : Beispielhafte Substrate gemäß einiger Aspekte der vorliegenden Erfindung;
• : Weitere beispielhafte Substrate gemäß einiger Aspekte der vorliegenden Erfindung;
• : Beispielhafte Vliesstoffe gemäß einiger Aspekte der vorliegenden Erfindung.

Possible embodiments of the present invention are described in the following detailed description with reference to the following figures:

• : An exemplary manufacturing facility adapted to carry out the methods according to some aspects of the present invention;
• : Exemplary substrates according to some aspects of the present invention;
• : Further exemplary substrates in accordance with some aspects of the present invention;
• : Exemplary nonwovens according to some aspects of the present invention.

Detailed description of possible embodiments

For the sake of brevity, only a few embodiments are described below. The person skilled in the art understands that the specific features which are described with reference to these embodiments can be changed and combined in various ways and that individual features can also be omitted if they are not essential. The general explanations in the sections above also apply to the following detailed explanations.

shows a grant 30th which went through a shower 10 of fleece fibers 11 (not all marked) moved. The funding moves 30th to the right, as with the arrows 35a and 35b is indicated. shower 10 goes from a fiber transfer device 20th from which above the conveyor 30th is arranged. In some embodiments, the fiber transfer device 20th be a meltblown head. In a meltblown process, melted filaments are created from a spinneret, drawn through a primary air stream and broken into stab fibers by eddy currents. A secondary air flow transfers the fibers onto the substrate. The meltblown process is a very efficient process for producing nonwoven fibers. However, other processes for producing the nonwoven fibers can also be used 11 may be used, such as a spunbond method. In the embodiment of has the shiver 10 a substantially linear cross-section. In other embodiments, it can be any shape. For example, it can have a rectangular, round or elliptical cross section. In some embodiments, the shower may 10 controlled so that it varies over time; it can change its shape and / or even stop for certain periods of time. In a similar manner the number of fibers, ie the density of the shower, can be controlled, all of which depends on the desired shape and / or details of the nonwoven fabric obtained. For example, the shower can 10 can be controlled by user input.

In the embodiment of includes the funding 30th a conveyor belt 31 which by driving tires 32 (not all marked) is operated. The conveyor belt can have a loop structure so that it does not have a beginning and / or an end. In other embodiments, the conveyor belt may not have a loop structure. Instead, a delivery layer can consist of a kind of reservoir at a point above the shower 10 and the fiber transfer device 20th can be rolled out and can be placed on and / or in another reservoir at a point below the shower 10 and the fiber transfer device 20th be rolled up again. Alternatively, the conveyor layer can be thrown away after use. Furthermore, in a further embodiment, a robot, for example a robotic arm, can be used as a conveyor 30th act. In general, the funding can 30th can be moved at constant or variable speed, which can help control the amount of fibers that are on a given section of the conveyor 30th is filed to control.

In the embodiment of positions a robotic arm 50 Casting molds, such as casting molds 100 , 200 , 300 , 400 and 500 , on the conveyor belt 31 . In some embodiments, the robotic arm can 50 Access to a collection of different molds like the molds 100 , 200 , 300 , 400 , 500 and may selectively hold one or more of them or otherwise on the conveyor 30th move. In becomes the robotic arm 50 shown when making casting mold 500 reaches out to this then on the funding 30th to position. In other embodiments, the molds 100 , 200 , 300 , 400 , 500 manually on the conveyor 30th positioned. In further embodiments, the casting molds are automatically transferred to the conveyor by a parallel or otherwise arranged auxiliary conveyor, such as a conveyor belt 30th fed in. In general, any form of automation using can be used some kind of robot can be used to make molds like the molds 100 , 200 , 300 , 400 , 500 on the funding 30th to lay.

Furthermore shows a pressure differential generator 60 who is under the grant 30th is arranged. In other embodiments, the pressure differential generator can be located above the conveying means 30th be arranged. In still other embodiments, the pressure differential generator 60 at least partially adjacent to the funding 30th be arranged. The differential pressure generator 60 can suck in or release air to create a flow of air, preferably through the conveyor 30th . The differential pressure generator 60 can work with any gas or gas mix, not just air. The differential pressure generator 60 may have a different shape and size in other embodiments. It can be adapted to provide a uniform pressure differential, spatially as well as temporally, but it can also be adapted to generate a variable pressure differential. For example, there can be a particularly strong pressure difference below the fiber transfer device 20th generate to nonwoven fibers 11 to suck into the passing conveyor, while having a lower pressure difference below the shower 10 generated.

Mold 100 the is a simple, monolithic, rectangular plate that serves as the first and only substrate 110 serves. In other embodiments, a monolithic mold, such as a mold 100 , or a simple substrate like the substrate 110 but have a non-planar shape. A mold, like a mold 100 , or a simple substrate such as substrate 110 , can, in fact, have any shape, be it essentially two-dimensional or three-dimensional. In particular, such a casting mold can have at least one depression and / or elevation. Depressions and / or elevations can have any shape and / or any size. A casting mold can have only one depression and / or elevation, or several. Depressions and / or elevations can be arranged arbitrarily or at least partially regularly and / or symmetrically. Depressions and / or elevations can be combined, ie an elevation can have one or more depressions and vice versa. A recess can also have the shape of a hole, ie it can break through the casting mold. Depressions and / or elevations can be arranged on any surface of the casting mold. Although preferably on one or more surfaces that at least partially absorb the shower 10 the fleece fibers 11 are exposed, are arranged, they can also be arranged on an opposite side. The elevations can then function as spacers, for example around the corresponding casting mold closer to the fiber transfer device 20th and away from funding 30th to place. As an alternative or in addition, separate spacer elements can be used for this purpose.

In other embodiments, the casting molds may not be monolithic, but rather have at least two substrates, such as the casting mold 200 who have favourited the substrates 210 and 220 includes. Substrate 220 essentially has a cuboid shape and is on the substrate 210 placed which has a substantially planar shape. However, these forms are purely illustrative. As with regard to the mold 100 and the substrate 110 each explained, casting molds can be like the casting mold 100 and 200 as well as substrates such as the substrates 110 , 210 , 220 have any shape, be it substantially two-dimensional or three-dimensional. In particular, casting molds such as the casting mold 100 and 200 as well as substrates such as the substrates 110 , 210 , 220 have a regular or irregular pattern of depressions and / or elevations or a mix thereof. This applies to all molds and substrates that are described here. Also can be a variety of substrates such as substrates 210 and 220 , in particular also a number greater than two, can be combined in order to obtain a casting mold with a three-dimensional shape, for example a casting mold with at least one depression and / or elevation. Substrates like the substrates 210 and 220 can be used one after the other or together, in the same way as monolithic casting molds like the casting mold 100 on the funding 30th to be placed. In particular, a robotic arm, such as the robotic arm 50 can be used for this. But the other approaches described above can also be used.

Mold 300 also includes two substrates 310 and 320 . However, unlike the mold, it includes 200 one of the substrates, ie substrate 310 , a variety of openings. A subset of this plurality of openings is at least partially through the substrate 320 blocked which on the substrate 310 is arranged. Similarly, the molds include 400 and 500 each substrate 410 and 510 , which comprise a plurality of openings, but no further substrates on or under the respective substrates 410 and 510 . Further details, in particular regarding the arrangement of the openings and their reversible blocking, are given below with reference to FIG described. In any case, a pressure differential generator 60 can be used to create a pressure difference along and / or an air flow through at least one of the plurality of openings in substrates 310 , 410 , 510 to generate.

Casting molds 100-500 be through a chill 10 of fleece fibers 11 through the funding 30th emotional. In becomes the mold 400 just covered by fleece fibers, ie it was more than half through the shower 10 emotional. As a result, a non-woven fabric such as non-woven fabric is formed 1000 on the mold 400 - and on all other molds - which has an imprint of the corresponding mold. In this way, a nonwoven fabric having a desired shape and details can be obtained.

show casting molds 600 , 700 , 800 , each comprising a substantially identical first substrate 610 , 710 , 81o . In the embodiments of are the substrates 610 , 710 , 810 essentially planar, meaning they can be described as plates. However, just like the substrates, they can 110 , 210 , 220 , 310 , 320 , 410 , 510 the take some form. In particular, they can comprise at least one depression and / or elevation. Substrates 610 , 710 , 810 each include a plurality of openings 611 , 612 , 711 , 712 , 811 , 812 (not all marked). In the embodiments of are the openings 611 , 612 , 711 , 712 , 811 , 812 etc. arranged regularly and / or symmetrically. However, the openings 611 , 612 , 711 , 712 , 811 , 812 etc. in other embodiments can be arranged arbitrarily, or only partially regularly and / or symmetrically. In various means are used to at least partially block at least one of the openings reversibly.

In is a number of openings in the substrate 610 like the opening 615 blocked at least partially reversibly by the introduction of a liquid. In the embodiment of describe the reversibly blocked openings like the opening 615 roughly a rectangular or # -like shape. Openings like the opening 615 can only be partially filled with a liquid, so that the remaining free space of these openings can appear as an additional texture on a nonwoven fabric to be obtained, such as the nonwoven fabric 1000 the . The liquid can be introduced by hand, for example with the help of a spatula, or automatically, for example by using a robotic arm such as the robotic arm 50 the . The liquid can be sucked out of the openings like the opening 615 be removed again, possibly with the help of a pressure differential generator such as the pressure differential generator 60 the . Alternatively or additionally, the substrate 610 simply from the funding 30th be lifted so that the liquid drains off. Any type of liquid can be used, particularly water or some other widely used liquid. However, specifically selected liquids can be used in other embodiments. For example, such a specifically chosen liquid can remove a nonwoven fabric such as the nonwoven fabric 1000 the from the mold 600 simplify. Again, note that the substrate 610 can in principle have any desired, in particular non-planar, shape in other embodiments.

In is a number of openings in the substrate 710 like the opening 715 at least partially reversibly blocked by a layer of adhesive tape which functions as a second substrate. In the embodiment of is the location of duct tape 720 from a number of adhesive tape strips like the adhesive tape strips 721 , 722 , and 723 (not all marked) composed. The location of duct tape 720 includes the contour of a t-shirt. Of course, the adhesive tape can be used in any desired shape, including any desired contour. In the embodiment of is the location of duct tape 720 on the substrate 710 applied. In other embodiments, the layer may be adhesive tape 720 to the other side of the planar substrate 710 be applied. Then the one or more reversibly blocked openings like the opening 715 prove to be additional, slightly different textures in a resulting nonwoven fabric such as the nonwoven fabric 1000 the demonstrate.

Again, note that the substrate 710 in other embodiments can have any shape, in particular non-planar, and that the layer of adhesive tape 720 can be designed so that it at least partially follows this shape.

In is a number of openings in the substrate 810 like the opening 815 at least partially by a second substrate 820 blocked. Substrate 820 includes a recess 825 that has the same contour as a t-shirt, meaning it can be described as a stencil. It does not include any further depressions and / or openings, although in general it could include such in other embodiments of the present invention. In the embodiment of is just another substrate, i.e. substrate 820 , on the substrate 810 placed. In other embodiments, more than one substrate, such as the substrate 820 , on the substrate 810 be arranged to the desired contour of the recess 825 to obtain. You can also add additional indentations like the indentation 825 be shaped using other substrates. In a similar way, elevations can be formed with the aid of further substrates, or they can already be part of the substrates 810 or 820 form. Also can the substrate 820 - like any other additional substrate - under the substrate 810 be arranged. Then the one or more reversibly blocked openings like the opening 815 prove to be additional, slightly different textures in a resulting nonwoven, such as the nonwoven 1000 the , demonstrate. It is also possible to use additional substrates like the substrate 820 on different sides of the substrate 810 to be arranged in each case. In this way, only a subset of the blocked openings can be used as the opening 815 show up as textures in a resulting nonwoven fabric.

Substrates like the substrates 110 , 210 , 220 , 310 , 320 , 410 , 510 , 610 , 710 , 720 , 810 , 820 can include a variety of materials, such as metal, plastic, acrylic, cardboard, or even paper. In particular, in substrates that are arranged above or below another substrate comprising a plurality of openings, the air permeability of the selected substrate can be taken into account when the corresponding material is selected. The air permeability can affect the density at which the fibers are arranged on the corresponding substrate, in particular when a pressure differential is applied to at least one of the plurality of openings of the other substrate. On the other hand, the recyclability and ease of handling of the material can be taken into account. For example, cardboard and / or paper substrates can be recycled to a large extent and obtained easily and quickly. However, they can just break and wear out. On the other hand, metal substrates can be particularly long-lived, but relatively difficult and expensive to obtain.

Shows in an exemplary manner a number of differently shaped substrates 921 , 922 , 923 , 924 , 925 , 926 made of cardboard or paper and adapted to include at least one of the plurality of openings in a substrate 910 (not shown) similar to substrates 310 , 410 , 510 , 610 , 710 and 810 at least partially block. Substrates 921 , 922 , 923 , 924 , 925 , 926 can also be described as templates. Substrates 921 , 922 , 923 , 924 , 925 , 926 may have been cut from a larger piece of cardboard or paper, for example by hand or by machine. The machine can be programmed to process the substrates 921 , 922 , 923 , 924 , 925 , 926 trims via a received user input.

shows a nonwoven fabric 4000 made by a method according to the present invention. For the production of a nonwoven fabric 4000 can be a mold 900 (not shown) have been used. Mold 900 can be a first substrate 901 and a second substrate 902 include. Substrates 901 and 902 can each have a - possibly identical - rectangular outer shape. To a non-woven fabric 4000 the to get the substrates 901 and 902 for example each formed at least partially from a network. Each net can have a rhombic pattern, similar to wire mesh. The rhombic pattern can be between the mesh for the substrate 901 and the mesh for the substrate 902 vary so that the substrate 901 a different rhombic pattern than the substrate 902 having. In particular, the pattern of the substrate 901 smaller diamonds than the substrate 902 exhibit.

In addition, the mold 900 a third substrate 903 exhibit. Substrate 903 can be made at least partially from paper. Additionally or alternatively, the substrate 903 also have one of the other materials as described above.

Substrate 903 may have a first opening that has the same shape, eg outer contour of the substrate 921 the Has. Additionally or alternatively, the substrate 903 comprise further openings, each having the shape of a parallelogram. These further openings can be arranged next to the first opening, for example between the “legs” of the first opening.

Mold 900 can by arranging the substrates 901 and 902 right next to each other and then placing the substrate 903 on the substrates 901 and 902 can be obtained. For example, the substrate can 903 centered on the substrates 901 and 902 be arranged so that its first opening is symmetrical over the substrates 901 and 902 extends.

For the production of the non-woven fabric 4000 the mold can be placed on a conveyor such as the conveyor 30th the have been placed. In addition, a pressure differential generator such as the pressure differential generator 60 the an air flow through the mold 90 have generated. In particular, an air flow can have been generated in such a way that air comes from above the casting mold 900 to below the mold 900 raft. For example, air can flow towards the conveyor such as the conveyor 30th the have been drawn. For the manufacture of the nonwoven 4000 the pressure difference, e.g. suction, may have been uniform.

Mold 900 can then through a shower of fleece fibers like the shower 10 the have been moved to the nonwoven fabric 4000 to obtain. As a result, the nonwoven fabric contains 4000 a textured region 4921 whose contours are those of the first opening of the substrate 903 can correspond. The textured region 4921 includes the part 4921a (on the left of the shown) and part 4921b (on the right side of the shown). Parts 4921a and 4921b are essentially mirror-symmetrical to one another. The dashed line 4921c , in the is shown reflects the corresponding axis of symmetry. More textured regions 4927a-4927f can the further parallelogram-shaped openings of the substrate 903 correspond.

As in shown include all textured regions 4921 , 4927a-4927f rhombic pattern. These patterns can include depressions. In particular, include the textured regions 4927a-4927c as well as part 4921a the textured region 4921 a different rhombic pattern than the textured regions 4927d-4927f as well as part 4921b the textured region 4921 . That is, the rhombuses in the pattern of the textured regions 4927a-4927e as well as part 4921a the textured region 4921 are smaller than those in the pattern of the textured regions 4927d-4927f as well as part 4921b the textured region 4921 are. These different rhombic patterns can each correspond to the rhombic patterns of the substrates 901 and 902 correspond. For example, the pattern of the substrates 901 and 902 on the textured regions 4921 , 4927a-4927f may have been imprinted as the fleece fibers that are on the mold 900 were transferred, at least partially through the openings in the respective network of substrates 901 and 902 were sucked in. Accordingly, the dashed line 49210 furthermore with the location of the contact area between the substrates 901 and 902 be associated.

Non-woven fabric 4000 also includes a non-textured region 4500 showing the remaining fraction of the part of the nonwoven fabric 4000 , the Indian is visible. The non-textured region 4500 does not include textures like the textured regions 4921 , 4927a-4927f because they are the parts of the mold 900 may correspond to where the substrates 901 and 902 through the substrate 903 were covered so that the nonwoven fibers do not at least partially through the openings in the network of the respective substrates 901 and 902 were sucked in.

In the textured regions 4921 , 4927a-4927f the fleece fibers can be arranged less densely. Conversely, the non-woven fibers in the non-textured region 4500 be arranged more densely.

The production of a nonwoven fabric 4000 with non-textured region 4500 as described above presented textured regions 4921 , 4927a-4927f ready with sharp contours. Such sharp contours can benefit the production accuracy, for example when the textured regions 4921 , 4927a-4927f from the non-woven fabric 4000 should be cut out in order to be applied to another object or for further processing. Alternatively or additionally, at least parts of the non-textured region 4500 of the nonwoven 4000 at the textured regions 4921 , 4927a-4927f remain attached when the latter are cut out. These excess parts can then be used to make the textured regions 4921 , 4927a-4927f to be attached to another object or to each other. For example, the textured regions 4921 , 4927a-4927f are sewn together over these excess pieces, giving the properties of the textured regions 4921 , 4927a-4927f as such are not affected by the attachment.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• EP 2397594 [0004]
• DE 102016223571 [0005]
• US 9732454 [0006]
• US 2013/0285294 [0006]

Claims (19)

A method for providing a nonwoven fabric (1000; 4000), comprising reversible positioning of a casting mold (100, 200, 300, 400, 500; 600; 700; 800) on a conveyor (30) which is spread through a shower (10) from Fleece fibers (11) moved. Procedure according to Claim 1 , wherein the casting mold (100, 200, 300, 400, 500; 600; 700; 800) has at least one depression and / or elevation. Method according to one of the Claims 1 or 2 , wherein the casting mold (100, 200, 300, 400, 500; 600; 700; 800) by combining two or more substrates (110, 210, 220, 310, 320, 410, 510; 610; 710, 720; 810 , 820; 921, 922, 923, 924, 925, 926) is obtained such that they at least partially overlap. A method of providing a nonwoven fabric comprising: a. Providing a casting mold (100, 200, 300, 400, 500; 600; 700; 800) comprising one or more substrates (110, 210, 220, 310, 320, 410, 510; 610; 710, 720; 810, 820; 921, 922, 923, 924, 925, 926), wherein at least one first substrate (310, 410, 510; 610; 710; 810) comprises a plurality of openings (611, 612; 711, 712; 811, 812); b. Reversibly blocking at least one of the plurality of openings (611, 612; 711, 712; 811, 812) at least partially; and c. Transferring a plurality of nonwoven fibers (11) to the one or more substrates (110, 210, 220, 310, 320, 410, 510; 610; 710, 720; 810, 820; 921, 922, 923, 924, 925, 926) comprising the at least one reversibly blocked opening. Procedure according to Claim 4 further comprising applying a pressure differential to at least one of the plurality of openings (611, 612; 711, 712; 811, 812). Method according to one of the Claims 4 or 5 wherein the reversible blocking of at least one of the plurality of openings (611, 612; 711, 712; 811, 812) comprises at least partially introducing a liquid into and / or applying an adhesive tape to at least one opening. Method according to one of the Claims 4 - 6th wherein the mold (100, 200, 300, 400, 500; 600; 700; 800) has two or more substrates (110, 210, 220, 310, 320, 410, 510; 610; 710, 720; 810, 820; 921, 922, 923, 924, 925, 926) and wherein a second substrate (320; 720; 820; 921, 922, 923, 924, 925, 926) at least partially on or below the first substrate (310, 410, 510; 610; 710; 810) is arranged to be at least partially reversible by at least one of the plurality of openings (611, 612; 711, 712; 811, 812) of the first substrate (310, 410, 510; 610; 710; 810) to block. Procedure according to Claim 7 wherein the second substrate (320; 720; 820; 921, 922, 923, 924, 925, 926) does not include openings. Method according to one of the Claims 4 - 8th , further comprising positioning the casting mold (100, 200, 300, 400, 500; 600; 700; 800) on a conveyor (30) which moves through a shower (10) of nonwoven fibers (11). Method according to one of the Claims 1 - 9 , wherein the casting mold (100, 200, 300, 400, 500; 600; 700; 800) comprising an additive manufacturing step is provided. Method according to one of the Claims 1 - 10 wherein the mold (100, 200, 300, 400, 500; 600; 700; 800) is positioned at least in part using a robotic arm (50). Nonwoven fabric (1000; 4000) having an inhomogeneous and / or three-dimensional shape, at least partially by a method according to one of the Claims 1 - 11 provided. Nonwoven (1000; 4000) according to Claim 12 wherein the fibers of a first region (4500) are arranged more densely than the fibers of a second region (4921, 4927a-f). Nonwoven (1000; 4000) according to Claim 13 in combination with one of the Claims 4 - 11 wherein the first region (4500) of the fabric corresponds to a region on the mold (100, 200, 300, 400, 500; 600; 700; 800) comprising the at least one blocked opening. Garment or footwear comprising a nonwoven fabric (1000; 4000) according to one of Claims 12 - 14th . Casting mold (100, 200, 300, 400, 500; 600; 700; 800) for use in a method for providing a nonwoven fabric, comprising two or more substrates (110, 210, 220, 310, 320, 410, 510; 610; 710 , 720; 810, 820; 921, 922, 923, 924, 925, 926), which are combined to obtain a depression and / or elevation of the casting mold. Casting mold (100, 200, 300, 400, 500; 600; 700; 800) for use in methods of providing a nonwoven fabric, comprising one or more substrates (110, 210, 220, 310, 320, 410, 510; 610; 710 , 720; 810, 820; 921, 922, 923, 924, 925, 926), at least one first substrate (310, 410, 510; 610; 710; 810) having a plurality of openings (611, 612; 711, 712; 811, 812), at least one of which can be reversibly blocked and released. Casting mold (100, 200, 300, 400, 500; 600; 700; 800) according to Claim 16 or 17th , wherein at least one substrate (110, 210, 220, 310, 320, 410, 510; 610; 710, 720; 810, 820; 921, 922, 923, 924, 925, 926) comprising an additive manufacturing step is provided. Casting mold (100, 200, 300, 400, 500; 600; 700; 800) according to one of the Claims 16 - 18th , suitable for use in a method according to any one of Claims 1 - 11 .

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