Patents by Inventor Andrea Piana
Andrea Piana has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20230398749Abstract: 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.Type: ApplicationFiled: August 24, 2023Publication date: December 14, 2023Inventors: Andy HOLLIS, Michael Stephen DEFRANKS, Eric MCCANN, Mehran JAFARI, Helias ANDRIESSEN, Sang-hoon LIM, Andrea PIANA, Alfio BORGATTI
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Publication number: 20230398421Abstract: 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.Type: ApplicationFiled: August 29, 2023Publication date: December 14, 2023Inventors: Andrea PIANA, Michael Stephen DEFRANKS, Eric MCCANN, Andy HOLLIS, Sang-hoon LIM, Mehran JAFARI
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Patent number: 11780177Abstract: 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.Type: GrantFiled: March 16, 2020Date of Patent: October 10, 2023Assignee: PIANA NONWOVENS, LLCInventors: Andy Hollis, Michael Stephen Defranks, Eric McCann, Mehran Jafari, Helias Andriessen, Sang-hoon Lim, Andrea Piana, Alfio Borgatti
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Patent number: 11771971Abstract: 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.Type: GrantFiled: April 8, 2020Date of Patent: October 3, 2023Assignee: PIANA NONWOVENSInventors: Andrea Piana, Michael Stephen DeFranks, Eric McCann, Andy Hollis, Sang-hoon Lim, Helias Andriessen, Mehran Jafari
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Patent number: 11718952Abstract: Nonwovens having low-density and resilience have a chemical formulation applied on one surface (e.g., a top surface) by any of various application methods. Then, the chemical formulation is forced to move toward the opposite surface of the nonwoven (e.g., move downward through the nonwoven from top to bottom). The chemical-treated nonwoven is dried to fix the chemical on the nonwovens. Movement through the nonwoven is performed in a controlled fashion so that after drying the distribution of a chemical formulation throughout the nonwoven (e.g., from the top surface to the bottom surface of a nonwoven) is controlled.Type: GrantFiled: May 21, 2020Date of Patent: August 8, 2023Assignee: Tintoria Piana, US Inc.Inventors: Sang-hoon Lim, Andrea Piana
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Publication number: 20230210271Abstract: Vertically lapped nonwoven material is used without cross lapped nonwoven to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.Type: ApplicationFiled: March 10, 2023Publication date: July 6, 2023Inventors: Sang-hoon Lim, Andrea Piana
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Patent number: 11684121Abstract: Footwear with vertically lapped nonwoven layers in upper and sole structures for enhanced breathability and moisture wicking is disclosed. Exemplary vertically lapped nonwoven dual layers comprise one or more hydrophobic layers and one or more hydrophilic layers that are adhered to each other by a plurality of methods and are further integrated into the inside of the upper and sole of the footwear so that the hydrophilic layer is in direct contact with the feet. The hydrophilic part of the dual layer wicks sweat or bodily fluid from the wearer into the nonwoven and transports the moisture to the hydrophobic layer for fast evaporation, thus keeping the feet dry. The nonwoven footwear is environmentally friendly as the nonwoven layers can be made of recycled materials and may be fully recyclable.Type: GrantFiled: March 9, 2021Date of Patent: June 27, 2023Assignee: Piana Nonwovens, LLC.Inventors: Andy Hollis, Michael Stephen DeFranks, Eric McCann, Andrea Piana
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Patent number: 11627812Abstract: Vertically lapped nonwoven material is used to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.Type: GrantFiled: October 27, 2021Date of Patent: April 18, 2023Assignee: TINTORIA PIANA US, INC.Inventors: Sang-hoon Lim, Andrea Piana
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Patent number: 11627811Abstract: Vertically lapped nonwoven material is used without cross lapped nonwoven to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.Type: GrantFiled: February 9, 2021Date of Patent: April 18, 2023Assignee: TINTORIA PIANA US, INC.Inventors: Sang-hoon Lim, Andrea Piana
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Publication number: 20230115100Abstract: Consumer products such as pillows for bedding or furniture, sack-like furniture, toppers for car seats, office seats, or household seats, and pet mattresses, are constructed from an outer casing, such as a woven or knitted fabric or a quilted fabric which may include a cushioning layer and a plurality of cut pieces of vertically lapped nonwoven material. The outer casing may be sewn closed but preferably includes a zippered opening or other opening which can be selectively opened and closed to allow the consumer to add or subtract cut pieces of vertically lapped nonwoven material from the interior volume of the outer casing. A zippered inner layer may neatly hold all of the cut pieces of vertically lapped nonwoven material together while the outer casing is changed or cleaned.Type: ApplicationFiled: September 27, 2022Publication date: April 13, 2023Inventors: Sang-hoon Lim, Yang Yu, Eric McCann, Ariel Guerra, Andrea Piana
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Publication number: 20230104609Abstract: Provided are a diagnostic system and methods for detecting the presence or absence of one or more targets that represent virus infection, inflammatory diseases and/or respiratory disorders by optically and noninvasively observing changing in color of the diagnostic system upon binding of the antigen of interest. Exemplary diagnostic systems and methods include detection of SARS-CoV-2 virus S protein or receptor of advanced glycation end products (RAGE) for diagnosis of COVID-19 infection or inflammatory/respiratory diseases.Type: ApplicationFiled: October 3, 2022Publication date: April 6, 2023Inventors: Andrea Piana, Michael Stephen DeFranks, Sang-hoon Lim, Andy Hollis, Matteo Cocuzza, Valentina Sinisi, Andrea Zappettini, Natalia Malara, Marialaura Coluccio
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Patent number: 11554699Abstract: A cushion having a fibrous foam architecture. The cushion has a trim cover and a number of fibrous layers attached to the trim cover. One or more structural properties of a fibrous layer can be controlled to differ from that of other layers.Type: GrantFiled: May 7, 2019Date of Patent: January 17, 2023Assignees: Tesla, Inc., PIANA NONWOVENS. LLCInventors: Forrest Wen Liau, Stefan Kuzmanovski, Jorge C. Fialho, Andrea Piana, Eric McCann, Mehran Jafari, Andy Hollis, Helias Andriessen
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Publication number: 20220363018Abstract: 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.Type: ApplicationFiled: July 25, 2022Publication date: November 17, 2022Inventors: Andrea Piana, Andy Hollis, Mehran Jafari, Helias Andriessen, Sang-hoon Lim, Eric McCann
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Publication number: 20220339888Abstract: 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.Type: ApplicationFiled: March 16, 2020Publication date: October 27, 2022Inventors: Andy HOLLIS, Michael Stephen DEFRANKS, Eric MCCANN, Mehran JAFARI, Helias ANDRIESSEN, Sang-hoon LIM, Andrea PIANA, Alfio BORGATTI
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Patent number: 11472132Abstract: 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.Type: GrantFiled: October 7, 2019Date of Patent: October 18, 2022Inventors: Andrea Piana, Andy Hollis, Mehran Jafari, Helias Andriessen, Sang-hoon Lim, Eric McCann
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Patent number: 11450246Abstract: A mobile product manufacturing demonstration, apparatus and method is intended to cut through the clutter and rise above the noise of typical marketing language and tactics, replacing the same with demonstrable, real-world demonstrations of how a producer is making a difference in terms of environmentally conscious manufacturing and good environmental stewardship. The mobile product manufacturing demonstration, apparatus and method includes a vehicle for transportation between rural townships and urban centers which itself is preferably battery powered, hydrogen powered, or powered by some other environmentally friendly mechanism. On board is a plurality of display stations which allow the public to interact with and/or manipulate materials used in the recycling and/or manufacturing process. Thus, the consumers will be able to see, hear, and feel (through touch and/or manipulation) how the products are made from recycled or recyclable materials.Type: GrantFiled: January 29, 2021Date of Patent: September 20, 2022Assignee: PIANA NONWOVENS, LLC.Inventors: Andrea Piana, Michael Stephen DeFranks, Andy Dean Hollis
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Publication number: 20220098770Abstract: 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.Type: ApplicationFiled: September 10, 2021Publication date: March 31, 2022Inventors: Mehran Jafari, Sang-hoon Lim, Andy Hollis, Andrea Piana, Eric McCann, Helias Andriessen
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Publication number: 20220047090Abstract: Vertically lapped nonwoven material is used to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.Type: ApplicationFiled: October 27, 2021Publication date: February 17, 2022Inventors: Sang-hoon Lim, Andrea Piana
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Patent number: 11185171Abstract: Vertically lapped nonwoven material is used to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.Type: GrantFiled: March 28, 2019Date of Patent: November 30, 2021Assignee: Tiritona Piana US, Inc.Inventors: Sang-hoon Lim, Andrea Piana
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Patent number: 11186063Abstract: 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.Type: GrantFiled: January 15, 2019Date of Patent: November 30, 2021Assignee: PIANA NONWOVENSInventors: Andrea Piana, Mehran Jafari, Eric McCann, Sam Lim, Andy Hollis, Helias Andriessen