WO2020240251A1 - Procédé de formation d'un article unitaire en duvet à différentes sections de densité - Google Patents

Procédé de formation d'un article unitaire en duvet à différentes sections de densité Download PDF

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Publication number
WO2020240251A1
WO2020240251A1 PCT/IB2019/054389 IB2019054389W WO2020240251A1 WO 2020240251 A1 WO2020240251 A1 WO 2020240251A1 IB 2019054389 W IB2019054389 W IB 2019054389W WO 2020240251 A1 WO2020240251 A1 WO 2020240251A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
down feather
article
mixture
cavity
Prior art date
Application number
PCT/IB2019/054389
Other languages
English (en)
Inventor
Ronie Reuben
Original Assignee
Ronie Reuben
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ronie Reuben filed Critical Ronie Reuben
Priority to PCT/IB2019/054389 priority Critical patent/WO2020240251A1/fr
Priority to CA3142107A priority patent/CA3142107A1/fr
Publication of WO2020240251A1 publication Critical patent/WO2020240251A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/02—Moulding by agglomerating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0097—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts

Definitions

  • the present invention relates to a method of forming a unitary, shaped, down feather article having different density sections to provide different thermal insulation values at specific locations therein and in a product containing the down feather article.
  • down is the most efficient natural product that provides maximum warmth with minimal weight.
  • Down is a fluffy material formed of clusters that trap air molecules in small pockets which create a thermal barrier.
  • the clusters have tiny hairs that criss-cross in all directions, up to two million filaments for every ounce of down, and this structure can be compressed to be packed into very small spaces and then released to assume its natural loft.
  • Down insulating material can breathed due to the air captured therein by the clusters.
  • Duck, geese or swan are the only birds that can live in the r and tropics and its down provides heat in the winter time and coolness in the summer time.
  • down has some drawbacks when used in free form and this has been addressed in my earlier US Patent No. 6,025,041 where I describe converting the loose down into sheet form to overcome prior problems associated with the use of down.
  • down can also provide sound insulation. It is also a product that is bio-degradable. The use of down in manufactured articles also supports the farming communities.
  • waste material is caused during the stuffing processes or cutting processes when using down in sheet material form, as described in my above referenced patent, and when cutting pattern pieces within the down sheets. This also causes some of the tiny clusters, as described above, to be release in the air causing a health hazard to the working person. Therefore, it is important when working with down to assure that it is always maintained in a captive manner.
  • the stuffing method by forming pockets of different size by stitching fabric pieces together and inserting loose down in the pockets is a solution which has many disadvantages which have been addressed in the past.
  • the article is an article of apparel, such as a jacket, it provides bulging parts which is not eye pleasing and which provide many disadvantages when the article is washed and ages when the down material forms clumps.
  • the use of down sheet material of my patent overcomes this problem of having to quilt fabric pieces to retain down therebetween.
  • the down feather sheets are formed by depositing down cluster mixed with a binder material and heating the mixture to fuse the binder to produce a sheet of substantially constant thickness and constant thermal insulating value.
  • down insulation may find other commercial applications if it could be produced as a panel with component parts having different insulation values, such as is required in door panels of vehicles or wall panels of aircrafts, as examples only.
  • Another feature of the present invention is to provide a method of forming a single shaped, down feather article piece, having different density sections with substantially no waste of down material which results in savings on labor cost.
  • the molded down product of the present invention is ready for use and provides the proper insulation values where it is needed to isolate cold spots and provide comfort where needed.
  • a further feature of the present invention is to provide molded thermally insulating articles, such as insulating panels, shaped to a desired form for use in the manufacture of specific products using such articles or panel to provide different insulation values within specific parts of the product.
  • the present invention provides a method of forming a single piece, shaped, down feather or down mixture article having different density sections, said method comprising the steps of:
  • FIG. 1 is a schematic diagram illustrating the molding process of forming a down feather article having different density parts and a specific shape
  • Figure 2 is a perspective view showing a closed mold in which down feathers and a binder product has been injected and illustrating a cooling process after the mold has been heated to fuse the binder material within the mixture;
  • Figure 3 is a block diagram illustrating the different steps in the process of forming a down feather article having different density parts and a specific shape
  • Figure 4A is a top view of a cavity formed in a mold part to mold an insultation panel for an article of apparel;
  • Figure 4B is a perspective view of the molded panel formed b the mold of Figure 4A;
  • Figure 5A is a top view of a cavity formed in a mold part and wherein the cavity defines a section having a different shape and depth;
  • Figure 5B is a perspective view illustrating a down feather article molded with a specific shape and having an internal section thereof formed with a material thickness greater than the surrounding material;
  • Figure 6 is a sectional view of a mold wherein one of the mold part is
  • Figure 7 is a section view of a mold formed of plastic material and wherein one of the parts of the mold is formed of clear plastic material and
  • Figure 8 is a schematic illustration of a continuous molding conveyor system to carry out the method of the present invention.
  • FIG. 10 there is shown generally at 10 an example of a mold in which is formed a cavity 1 1 of irregular shape to define the shape of a single piece down feather article to be formed thereby.
  • the shape of the cavity 1 1 is that of a pillow core wherein the core has different density sections due to its non-uniform shape.
  • the mold has an injection port 13 through which a mixture 12 of down feather clusters 14 mixed with a heat reacting binding material, herein bi-component fibers 15, which are polymeric fibers coated with a binding agent when subjected to heat within a predetermined temperature range, is injected, herein blown into the cavity 1 1 .
  • the binding material can also be in the form of heat settable glue particles, other forms of binding synthetic fibers, such as crimp bonding polymeric fibers, stretchable polymer fibers and combinations thereof.
  • the fibers also provide elasticity to the molded article to permit compressing and stretching of the molded article with the molded mixture recovering its shape after such
  • the mixture comprises 65% to 90% of down clusters and 10% to 35% of the binder material.
  • a predetermined quantity of synthetic thermally insulating material in fiber form can also be mixed with the down to reduce cost while maintaining loft.
  • An anti-microbial agent may also be introduced in the mixture depending on the intended use of the article being molded. Still further, depending on the material used to construct the mold, it may be necessary to coat the inner surfaces of the cavity with a non-stick material such as TEFLON, registered trademark, or the like coating material.
  • a plug seals the injection port 13 and projects to the interior surface 16 of the cavity 1 1 to seal the cavity and provide a uniform molded surface at the area of injection.
  • the down feather clusters 14 and the binding material 15 are fed to a hopper 17 where air jets 18 and rotating blades 19 cause a mixing action with the mixture discharging at the bottom of the hopper where a substantially uniform mixture is fed to an injection pump supply chamber 20 to which is connected a conduit 21 having a nozzle 22 at an end thereof adapted to be connected to a connector 23 of the injection port 13.
  • a controller 24 operates a blower device 25 to inject into the mold cavity 1 1 a predetermined quantity of the mixture to form the molded article, herein a pillow core 26.
  • the method comprises different steps after the mold 10 has been filled with the mixture in order to form the molded article, herein the pillow core 26.
  • the mold is conveyed to a heat treatment wherein the mold is heated to a temperature sufficient to cause the binder, herein the bicomponent fibers 15, to soften and fuse together at their crossings and with the down feathers to fuse with the mixture to form a homogeneous product.
  • the binding agent dependent on the type thereof, usually fuses within a temperature range of between 160 degrees to 350 degrees Fahrenheit.
  • the mold 10 is constructed of metal and is provided with conduits 30 extending in both mold sections 10’ and 10” and interconnected together when the mold sections are closed. Connectors 31 are secured to opposed ends of the conduits 30 and to which hoses 32 are connected to circulate a pressurised cooling liquid, herein water, through the mold sections for quick cooling of the mold sections. Thereafter, the molded article, herein the pillow core 26 is removed and the mold is recycled for filing again with the mixture.
  • a pressurised cooling liquid herein water
  • Figure 4A is a top view of the bottom mold sectionl O’ showing a cavity 26 having a pattern shaped contour 27 having straight sections 27’ and curved shaped sections 27”. Also, the depth of the cavity 27 increases gradually from the bottom edge 28 to the top edge 28’ whereby to mold a thermally insulating panel 29 as illustrated in Figure 4B wherein the thermal insulation value increases from its bottom edge 29’ to its top edge 29”.
  • a thermally insulating panel 29 as illustrated in Figure 4B wherein the thermal insulation value increases from its bottom edge 29’ to its top edge 29”.
  • Such panel is for example used in the fabrication of the back section of a jacket where more warmth is desired in the upper back part o the jacket.
  • Figure 5A is a top view of a bottom mold section 10’ in which a cavity 35 is formed and herein delineated by a rectangular contour 36 and having a predetermined depth.
  • a further cavity 36 is formed in the bottom surface 37 of the rectangular cavity 35 and spaced from the rectangular contour 36 of the cavity 35 whereby to form a section of the article, herein a thermally insulating panel 38, as shown in Figure 5B, with a greater density part, that is to say, with a section which is thicker than the surrounding sections of the article 38.
  • the molded panel 38 has a large flat section 38’ of constant thickness and a shaped, internal sections 38”, which is thicker to provide to the panel an area which has more thermal insulation.
  • FIG. 6 there is illustrated another example of a mold structure wherein the bottom mold section 10’ defines a cavity 40 having vertical side walls 41 wherein to receive a top mold section 10” which is displaceable vertically into the cavity 40 by a cylinder rod 42 to compress the mixture 12 injected into the cavity through the injection port 43.
  • a plug 44 seals the port in the manner described above.
  • the cavity 40 is shaped to define a variety of shapes and down densities, such as when used in commercial articles , such as aircraft wall panels, car door panes, etc...
  • the mold cavity 40 can be machined automatically following instructions from a computer having a model programmed therein, as well known in the art of mold machining.
  • FIG. 7 illustrates another example of a mold structure to implement the present invention.
  • the mold 50 is formed of plastic material capable of retaining its shape when subjected to heat at temperatures sufficient to fuse the binding material of the mixture 12.
  • the heat source can comprise sources other than radiant heat, such a microwave radiation, induction heating, or other suitable heat sources capable of causing the binder to fuse
  • using a plastic mold is a less expensive method of molding.
  • the mold section 10 may be formed of clear plastic material whereby to visually inspect the distribution of the mixture12 injected in the cavity 51 of the mold through the injection port 52 which is sealed off with a plug 53.
  • the mold inner surfaces may also be coated with TEFLON TM, registered trademark, or similar coating material to prevent the mixture to stick to the cavity walls during the fusing step..
  • the mold sections 10’ and 10” are interconnected together by suitable clamp means 54.
  • Figure 8 illustrates a molding assembly to carry out the method of the present invention and many other assemblies are possible and within the scope of the present invention.
  • molds can be secured to a turret arrangement to displace the mold to different stations of the process.
  • a plurality of molds 10, of identical construction are pivotally secure by a pivot connection 55 to an endless belt 56 of a conveyor 57.
  • the mold 10 is filled with the mixture 12 at station 58 and displaced along the conveyor through a radiant heat chamber 59 of sufficient length to heat the mold to fuse the binder. It continues along the conveyor through a cooling chamber 60 to sufficiently cool the mold when it reaches the article extraction station 61 where the mold is opened and the molded article 26 removed.
  • the mold is then displaced to its filing station 58 and the process continues which each mold being recycled.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un procédé de formation d'un article d'isolation thermique, en duvet, façonné et en une seule pièce qui présente différentes sections d'isolation thermique. Un moule est pourvu d'une cavité délimitant une forme prescrite non uniforme et présentant des sections de différentes formes et profondeurs. Des groupes de duvet ou un mélange de ces derniers sont mélangés avec un matériau de liaison et sont injectés dans le moule, ce dernier étant ensuite chauffé au moyen d'une source de chaleur appropriée en vue d'amener le matériau de liaison à ramollir et de fusionner le mélange. Après refroidissement du moule, un article en duvet, façonné et en une seule pièce est formé, tout en étant constitué de sections présentant différentes valeurs d'isolation thermique, afin d'être utilisées dans un produit dans lequel des parties du produit fournissent différentes propriétés d'isolation thermique.
PCT/IB2019/054389 2019-05-27 2019-05-27 Procédé de formation d'un article unitaire en duvet à différentes sections de densité WO2020240251A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/IB2019/054389 WO2020240251A1 (fr) 2019-05-27 2019-05-27 Procédé de formation d'un article unitaire en duvet à différentes sections de densité
CA3142107A CA3142107A1 (fr) 2019-05-27 2019-05-27 Procede de formation d'un article unitaire en duvet a differentes sections de densite

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2019/054389 WO2020240251A1 (fr) 2019-05-27 2019-05-27 Procédé de formation d'un article unitaire en duvet à différentes sections de densité

Publications (1)

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WO2020240251A1 true WO2020240251A1 (fr) 2020-12-03

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PCT/IB2019/054389 WO2020240251A1 (fr) 2019-05-27 2019-05-27 Procédé de formation d'un article unitaire en duvet à différentes sections de densité

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CA (1) CA3142107A1 (fr)
WO (1) WO2020240251A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5269992A (en) * 1991-10-18 1993-12-14 Ikeda Bussan Co., Ltd. Method of making a feather containing resilient body
US5824249A (en) * 1996-02-28 1998-10-20 Dow-Ut Composite Products, Inc. Modular molding method and associated mold
CA2136702C (fr) * 1993-11-29 2002-10-08 Bernhard Eder Piece formee constituee de focons de mousse plastique
US9380893B2 (en) * 2014-01-13 2016-07-05 Ronie Reuben Thermally insulating stretchable down feather sheet and method of fabrication
US20160362547A1 (en) * 2015-06-10 2016-12-15 Ronie Reuben Down and polymer mixture thermal insulating sheet

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5269992A (en) * 1991-10-18 1993-12-14 Ikeda Bussan Co., Ltd. Method of making a feather containing resilient body
CA2136702C (fr) * 1993-11-29 2002-10-08 Bernhard Eder Piece formee constituee de focons de mousse plastique
US5824249A (en) * 1996-02-28 1998-10-20 Dow-Ut Composite Products, Inc. Modular molding method and associated mold
US9380893B2 (en) * 2014-01-13 2016-07-05 Ronie Reuben Thermally insulating stretchable down feather sheet and method of fabrication
US20160362547A1 (en) * 2015-06-10 2016-12-15 Ronie Reuben Down and polymer mixture thermal insulating sheet

Also Published As

Publication number Publication date
CA3142107A1 (fr) 2020-12-03

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