US 12,528,282 B2 · Methods and systems for manufacturing a composite textile

Abstract

This disclosure relates to a composite textile that can be sustainable, as well as methods and systems for constructing the composite textile and recollecting and harvesting excess material (e.g., remnants). In at least some examples, a first pattern piece is cut from a first material layer, and a second pattern piece is cut from a second material layer. In addition, the first pattern piece can be separated from the first material layer, which can leave a first remnant, and the second pattern piece can be separated from the second material layer, which can leave a second remnant. Once separated, the first pattern piece can be stacked atop the second pattern piece, and the stacked pattern pieces can be entangled to form a composite pattern piece. The remnant associated with the first material layer can be separated from the remnant associated with the second material layer and reused.

Claims20

Dependent claims

A method comprising:

stacking a fiber web adjacent to a material layer;
cutting, in a shape associated with a pattern, the fiber web and the material layer;
separating the fiber web into a fiber-web pattern piece, which comprises the shape associated with the pattern, and a fiber-web remnant;
separating, concurrently with separating the fiber web, the material layer into a material-layer pattern piece, which comprises the shape associated with the pattern, and a material-layer remnant;
and
peeling the fiber-web remnant apart from the material-layer remnant.

3 more elements

A method comprising:

positioning a first fiber web on top of a second fiber web to form a stack, wherein:
the first fiber web comprises a first property and the second fiber web comprises a second property, which corresponds with the first property and is different from the first property;
and
the first property and the second property include at least one of chemical composition of fibers, average denier of fibers, average diameter of fibers, average length of fibers, surface coating applied to a respective web, and fiber color;
cutting the stack to form a first part and a remnant, wherein:
the first part comprises a first delineated portion of the first fiber web and a second delineated portion of said second fiber web, and
the remnant comprises a first remnant portion of the first fiber web and a second remnant portion of the second fiber web;
separating the first part from the remnant;
entangling the first delineated portion of the first fiber web with the second delineated portion of the second fiber web;
removing the second remnant portion from the first remnant portion, wherein, after the removing, the first remnant portion comprises less than 10% by weight of fibers from the second remnant portion;
and
recycling at least one of the first remnant portion and the second remnant portion.

9 more elements

Dependencies are inferred from the claim text.

Methods and systems for manufacturing a composite textile

Life of this patent

Methods and systems for manufacturing a composite textile

Life of this patent

Abstract

Claims20