EP1851373A1

EP1851373A1 - Machine comprising at least a felting table, felting means and soaking means

Info

Publication number: EP1851373A1
Application number: EP06716727A
Authority: EP
Inventors: Arne H. Hveding
Original assignee: Hauge Lise Andrine
Current assignee: Hauge Lise Andrine
Priority date: 2005-02-18
Filing date: 2006-02-08
Publication date: 2007-11-07
Also published as: NO20050889A; NO20050889D0; WO2006093414A1; NO321929B1

Abstract

Machine comprising at the least a felting table (1), a felting means and a soaking means. The felting table comprises a felting plate (2), an underlying chamber (3) for holding a hot medium, and water gutters (4) surrounding the felting plate. The felting means is arranged above the felting table (1), and comprises one or more rotatable rolls (9) having a rough surface, the rolls being fastened to a movable unit in such a way that, by frictional force they rotate when they contact a subject on felting plate (2) at the same time as the unit is moving over the felting table (1). The felting means further comprises a water pipe (12) for adding water evenly to the length of the roll. The soaking means comprises a soaking plate (13) having holes (14) there through and devices (16) for lifting and lowering the soaking plate (13) down onto the felting plate (2).

Description

Machine comprising at least a felting table, felting means and soaking means

The present invention relates to a machine for felting wool and the like, according to the preamble of the independent claims.

Background

The simplest kind of felted wool product is a one-coloured, plain felt, which may be cut and put together to create specific products, but the felting technique may also be used to create decorations, pictures and artistic expressions. Often coloured wool is used in the outermost layer of wool, which gives the visual impression after the felting.

At present, the felting process is manual, and consists of many and work demanding steps. First, of course, the wool must be washed, centrifuged, dried and carded. Then it must be placed in layers on a work table, and if the finished felt is to have a pattern, this must, of course, be laid when the wool is put in place. To achieve a normal thickness of the finished felted product, the carded wool must be placed in a height of 15-20 cm. Between the wool and the work table there is generally placed a curtain of fibrous material and a fine gauze, wherein the fibrous material is closest to the table and the gauze closest to the wool.

When the wool is put in place, it is soaked with soapy water having a temperature of 40- 6O⁰C. To ensure that the wool is not moved during the soaking, the soaking must in the beginning be carried out very carefully, and often a cup, mug or the like is used. It is not possible to use a shower directly onto the wool, as this might cause displacement of the wool, and in addition give "wave-effects" in the pattern. The height of the wool will be substantially reduced during the soaking.

When the wool is soaking wet, it is rolled together to a cylinder, with the bast curtain as the outermost layer. The cylinder is then rolled backwards and forwards a number of times, so that the wool fibres are moved in relation to each other, and in this way they get entangled. During this process it will be necessary to unroll the material, in order to ensure that the material has not been displaced, and roll it up again in the opposite direction. More hot soapy water should also be added during the process. The longer time the rolling proceeds, the more compact the finished material will be, so that the felting must be ended when the product has the desired compactness. When the felting process itself is finished, the product is washed in tepid water and placed aside for runoff and centrifugation.

Accordingly, the felting process of today is physically demanding and time consuming, and it is characterized by repeated rolling up and rolling out from different ends of the material, and manually soaking with hot water. By using soap the time is shortened, and some types of wool would in practice, be very hard to felt without using soap. The temperature of the water also effects how fast the wool felts, as hotter water, shortens the time. With the manufacturing methods of today, how hot the water can be is limited to ensure the user does not scald his/her hands. Besides, the material gets chilled very fast during the felting- process.

If mechanical felting is used, the temperature may be 80-95 ⁰C, which gives a much faster felting. There are some machines developed for felting, among others as described in DE 618640 and DE 2464575. However, all known machines are large industral machines demanding a lot of place and are designed to produce goods by the yard. Besides, they are designed in such a way that the wool should be moved, and the machine should not. This is not very desirable if the felted material is to have a pattern or picture, as it can not be controlled how the pattern is moved during the felting process.

Moreover, different types of wool demands different treatment, and wild sheep wool demands an especially long processing period to make the wool fibre entangle. Wild sheep wool is little utilized today, both in felting and in other processing-processes for wool, and it is not likely that the known machines can felt this kind of wool with a satisfactory result, because it demands more processing that these are designed to give.

Object

The main object of the present invention is to develop a machine which is able to perform the felting process easier and faster than the manual method of today, and that eventual patterns or pictures in the wool should not be displaced during the felting. It is another object that the machine should be able to felt "difficult raw materials" such as wild sheep wool. Finally it is an object that the machine should be time and cost efficient both when purchased and in use. The invention

The object is achieved with a machine according to the characterizing part of patent claim 1. Further advantageous features are stated in the dependent claims.

In the following the machine will be described with reference to felting of wool, but it may, for example, also be used to manufacture paper from recycled paper, and similar materials that may be treated in a corresponding way. Upon other use than felting of wool, the "subject" as stated in patent claim 1, should refer to the material to be processed.

The machine according to the present invention comprises several main parts, a felting table, a felting means and a soaking means.

The felting table comprises principally a felting plate, underlying heating chamber(s), and water gutters for collecting superfluous water. The felting plate is a plane plate where the wool to be felted is placed in layers, and where an eventual pattern is placed in the top layer. The felting plate is preferably provided with holes there through, so that superfluous water can flow off through the wool, instead of moving towards the edge of the plate. Horizontal water flows will displace the wool and reduce both quality and look of the finished product. Further, it is an advantage if the surface of the felting plate is not smooth. A rough surface will positively contribute to the felting of the wool, and the wool will not be so easily displaced during the felting process.

Underneath the felting plate there are heating chambers. The chambers are preferably designed to hold a hot medium, preferably a hot liquid, which would be the most appropriate, but of course, there might be other designs wherein the heating chambers are heating elements. During the felting process a relatively large amount of water is used, and in case of heating elements being used, these must, of course, be protected from the water. In the preferred embodiment, the heating chambers are designed to hold hot water, and the water used during the felting is also directed into the heating chambers, so that the felting plate above is kept warm.

Water gutters are arranged around the felting plate, to collect superfluous water from the felting process. In most cases it will be an advantage to circulate this water instead of adding new water. The water removed from the felting plate will be hotter than new water, and thus less energy needs to be added to heat this to the temperature of the process. It is especially preferably to circulate the water when using soapy water, because the soap consumption will be reduced. With a circulation system the water gutters surrounding the felting plate will be connected to collection pipes leading the water out of the gutters to a tank with heating. From the tank are arranged supply pipes to direct the water back to the process. It would be an advantage to place a filter upstream of the tank, to remove eventual wool detached from the felting plate and flowing with the water.

Above the felting table is arranged a felting means which comprises one or more felting rolls. These are fastened to a movable unit running along the edge of the felting table so that the rolls may be moved above the whole of the felting plate, preferably in a longitudinal direction. The felting rolls should have a length corresponding to the width of the felting plate, and the unit should be movable along the whole of the felting plate, in such a way that the rolls move over the whole of the plate when the unit is moved backwards and forwards. Eventually, the rolls may be designed in such a way that the length corresponds with the length of the table, and that the unit is moveable crosswise of the table. Further, the felting rolls should be height adjustable, in such a way that the pressure from the rolls onto the wool can be adjusted. When the rolls are touching the wool, and the unit is moved along the table, the friction between the wool and the rolls makes the rolls rotate, and in this way the underlying wool gets felted.

The roll or rolls are provided with a rough surface, for instance with longitudinal and/or circumferential grooves. These ensures that both the felting process is faster and that one achieves a better result, at the same time as the wool is less likely to get stuck on rolls having grooves than on smooth rolls.

During the felting process, hot water, above 40°C, is added when required, and thus a water pipe with nozzles or outlets is placed above the roll or rolls, in such a way that hot water can come down onto the wool during the felting process. Further, it is an advantage to place two rolls side by side, one after the other, in such a way that both are in contact with the wool when the unit is moved forwards and backwards over the material. When two ore more rolls are used in this way, they should have different patterns, so that the wool fibres are alternatingly affected to arrange in relation to longitudinal and circumference ribs. Desirable movements of the wool fibres contributing to a faster felting process are thus achieved.

Above the felting table there is a soaking unit comprising a soaking plate, lift/sink device and preferably a vibrator. The soaking plate is a planar plate with holes there through. These holes must have a given size and be at a given distance from each other. If the holes are too small, the surfacefilm of the water will prevent the water from oozing through the holes, or the water will ooze so slowly that the process becomes unnecessarily time consuming. If the holes are too large, the wool fibres facing the holes will not be exposed to pressure, and initial felting will not be achieved. Further, the distance between the holes must not be so large that the wool between the holes does not get sufficiently soaked during an acceptable period. Moreover, the material of the soaking plate must be smooth so that the wool does not become fastened to it. It is another advantage that the soaking plate is of a durable material so that different chemical compounds, for instance as used in coloured wool, does not destroy the soaking plate when hot water and soap is added.

When the wool is placed on the felting plate, it should be soaked without displacing the pattern. This is done by lowering the soaking plate onto the wool, and adding water to the upper side of the soaking plate. The water will ooze through the holes, and thereby soak the wool. During this process the height of the wool will be reduced, and thus the soaking plate must be lowered continuously during the soaking. When the wool is sufficiently soaked, the soaking plate is lifted again, and the felting rolls may be moved across the wool. Further, it is an advantage that the soaking plate presses the wool, either in that the lifting/lowering device is designed in such a way that the plate can be pressed onto the wool, or that the plate has a specific weight. The lifting/lowering device may be of any design satisfying the given requirements.

It is very advantageous if the soaking plate can be vibrated before it is lifted to the start position. The vibration will start the felting, and thus the wool will let go of the plate more easily. To ensure that the pattern is not moved, the vibration must be vertical, as horizontal vibrations may displace the pattern.

Example In the following a particularly preferred embodiment of the present invention will be described, with reference to the enclosed drawings, where

Figure 1 shows a longitudinal section of the machine,

Figure 2 shows one of the felting rolls in detail, and Figure 3 shows the soaking plate from above.

In the embodiment shown in Figure 1 , the felting table 1 comprises a felting plate 2, a heating chamber 3 for holding hot water, and water gutters 4 surrounding the felting plate 2. In order to avoid the felting plate 2 getting too hot, i.e. such that it becomes deformed, the felting plate 2 is placed at a distance from the heating chamber 3, in such a way that an airspace 5 is created between the chamber and the plate. The felting plate is made of aluminium, which material conducts heat well, and has sufficient resistance to deformation at the temperatures used. Further, the felting plate 2 has a rough surface and a number of drain-holes 6 there through being connected to the water gutters 4. The holes 6 have a diameter of ca 1 ,5 cm and are placed in rows with an internal distance in the row of ca 7 cm, and the rows are placed ca 21 cm from each other.

The heating chamber 3 is, as said, designed to hold hot water, and the water of the chamber is the same as the water used elsewhere in the process. The heating chamber 3 is further provided with spillways (not shown) leading to the water gutters 4 around the table. These spillways may also be used for emptying and cleaning of the chamber. In the illustrated embodiment, the chamber might either be filled with hot water being swapped at given times, or it might be pumped hot water continuously. If it is pumped continuously, it will be a constant water flow through the spillways and down into the water gutters. Underneath the heating chamber there is placed a layer of insulating material 18, so that all heat goes up towards the felting plate 2.

On the outside of the water gutters 4 surrounding the felting plate 2, a frame 7 is fastened around the felting table, to prevent water flowing onto the foundation. The upper edge of the frame is ca 5 cm above the felting plate and creates an upwardly facing horizontal surface 8. In the water gutters drain holes (not shown) are arranged to take care of superfluous water. The illustrated embodiment is provided with a water circulation system, and as described above, the water in the water gutters will be a part of the circulation system and be filtered, heated and directed back to the system. Above the felting table 1 felting rolls 9 are arranged which extend across the felting plate 2, these are supported in a rotating casing (not shown). The casing is fastened to linear mechanical trolleys (not shown) running along the horizontal surface 8 of the frame 7 outside of the water gutters 4. The trolleys, and thereby the casing and the rolls 9, are driven linearly forward and backward along the felting table when felting is in progress, by means of a drive unit, such as a speed regulated electrical motor (not shown). The distance between the rolls 9 and the wool, or the pressure from the rolls onto the wool is adjustable, but the pressure must always be such that the rolls rotate when they are moved along the wool. The working length of the felting means (meaning the rolls, casing and trolleys) may be adjusted according to the size of the workpiece, and the resting position may be adjusted in such a way that the finished felted material may be removed, and new wool can be placed on the felting plate.

As shown in Figure 2, the rolls are made by treading a sleeve 10 of polyurethane on the outside of aluminium pipes 11. It is an advantage if the sleeves 10 have a standardized length, and that they are substantially shorter than the length of the rolls 9. In this way one roll can be put together of several sleeves 10, and these must not necessarily have the same pattern. It will be much easier to replace the whole or parts of the sleeve, for instance because it is worn, instead of replacing the whole roll. The pattern of the sleeve 10 and the roughness of the pattern influence the felting process, in that hard wool requires a coarser pattern to achieve the same felting effect on the same time. With such sleeves it is simple to change from a shallow to a rough pattern, and in practice, both pattern and roughness should be adjusted according to the type of wool and product.

In the embodiment shown in Figure 1, three rolls 9 are shown above the felting plate, where two rolls are closer to the plate. This is an advantageous embodiment as the casing may be rotated, and thus it can be varied which two of the three rolls are touching the wool and contributing to the felting process. The rolls have different pattern on the outside, so that the two rolls contributing to the felting always have different patterns.

Above the rolls, and in the full length of the rolls, there is arranged a water pipe 12 with holes, the holes being in a row on the underside of the pipe. When felting, hot water is pumped to this pipe 12 when required, the water flowing out through the holes, down on the rolls 9, and further down on the wool sheet. The water not absorbed by the wool sheet flows into the water gutters 4 through the drain holes 6 of the felting table. The purpose of this is to maintain the temperature of the wool sheet as high as possible during the felting, and simultaneously resolving the fibre structure of the wool, in order to increase the movement between the wool fibres of the wool sheet.

The soaking unit is shown in detail in Figure 3, and comprises a plane soaking plate 13 with holes 14 there through. These holes have a diameter of 1,5 cm, and are placed at a distance of 1,5 cm. Along the outer edge of the plate, there is fastened a frame 15, ca 3 cm high, preventing added water from flowing off the plate and straight into the water gutters of the felting table. This frame also provides a stiffening function, and is therefore also placed diagonally across the plate. This will also contribute to the weight of the soaking unit to exert pressure on the wool, when the soaking unit is filled with water. In the embodiment shown, the lifting/lowering device comprises only wires 16 at each corner of the plate and a winch (not shown).

About the middle of the soaking plate there is fastened a vibrator 17. This can be of any kind giving vertical vibration.

Wool fibres are placed in layers on the felting plate 2, in desired pattern, size and thickness. When the wool is placed, it should be soaked, and that is performed in the following way: The soaking unit is lowered onto the wool until it rests against it. Then, soapy water 40- 95°C, preferably 40-70°C, is added to the upper side of the soaking plate 13, so that water oozes down through the holes 14. Gradually the wool will gets soaked and subsides. Accordingly, the soaking unit must, if necessary, be lowered in such a way that it is always resting on the wool and not hanging in the wires. Some of the water will be superfluous and some water will flow through the wool and the drain holes 6 of the felting plate 2. This water will flow out into the water gutters 4 surrounding the felting plate, and enter the circulation. When the wool is soaked and no longer subsides, the water supply is cut. When the water has oozed through the holes 14 of the soaking plate 13, the vibrator 17 is started, and the plate 13 is vibrated above the wool. This finishes the soaking process and the soaking unit is lifted. When the wool is soaked, the actual felting process begins. The casing, on which the felting rolls 9 are supported, is rotated in such a way that the desired rolls 9 are facing the wool, and the desired distance/pressure between the rolls and the wool is adjusted. It is an advantage if the pressure introduced is as small as possible, but sufficient to make the rolls rotate. The pressure may advantageously be increased gradually. The drive unit is started and the rolls are moved across the felting plate 2 and the wool. Accordingly, the wool lays still on the felting plate 2, while the rolls 9 are moved across. When the rolls are moving across the wool material, the wool fibres will be deformed by the pattern of the rolls, and when two rolls having different patterns are placed after each other, the wool fibres will alternately, repeated times, be folded one way and then the other. This creates movement between the wool fibres of the wool sheet, and thus contributes to the felting of the wool.

In addition to the illustrated and above mentioned parts, the machine comprises an electrical water heater being specially suited for heating water, preferably soapy water to the felting work, to a temperature of 80-95°C. The circulation system further comprises pumps to pump water from the heater to the felting table, and for returning water flowing off the felting work during the felting process. Run off water is filtered before it flows back into the heater. In a specially preferred embodiment, the operation of the felting process may be controlled electronically, in such a way that one may choose water temperature, roll-pressure, felting time etc., depending on the product and quality of wool.

Claims

Patent claims

1. Machine comprising at least a felting table (1), a felting means and a soaking means, characterized in that the felting table comprises a felting plate (2), an underlying chamber (3) for holding a hot medium, and water gutters (4) surrounding the felting plate, the felting means is arranged above the felting table (1), and comprises one or more rotatable rolls (9) having a rough surface, the rolls are fastened to a movable unit in such a way that, by frictional force they rotate when in contact with the felting plate (2) at the same time as the unit is moved along the felting table (1), and that the felting means further comprises a water pipe (12) adding water evenly to the length of the roll, and that the soaking means comprises a soaking plate (13) having holes (14) there through, and devices (16) for lifting and lowering the soaking plate (13) down onto the felting plate (2).

2. Machine according to claim 1, characterized in that the rolls (9) extend across the whole of the felting plate (2), and that the moveable unit can be moved over the whole of the felting plate (2).

3. Machine according to claim 1 or 2, characterized in that two rolls (9) having different surface are placed after each other in the felting means, in such a way that both are moved across the felting plate (2).

4. Machine according to any one of the proceeding claims, characterized in that the felting means comprises three rolls (9) supported by a rotating casing in such a way that two rolls (9) face down towards the felting plate (2).

5. Machine according to any one of the proceeding claims, characterized in that the rolls (9) comprise an inner metal pipe (11) and an outer sleeve (10) having a pattern, wherein the sleeves can be replaced.

6. Machine according to any one of the proceeding claims, characterized in that the distance between the rolls (9) and the felting plate (2) can be adjusted.

7. Machine according to any one of the proceeding claims, characterized in that the felting plate (2) is placed at a distance from the heating chambers (3).

8. Machine according to any one of the proceeding claims, characterized in that the felting plate (2) has a rough surface.

9. Machine according to any one of the proceeding claims, characterized in that the soaking plate (13) has a frame (15) at its outer edges.

10. Machine according to any one of the proceeding claims, characterized in that the soaking means further comprises a vibrator (17).