US1642509A - Cotton batting and process of making the same - Google Patents

Description

1,642,509 p 1927 A. ROGERS COTTON BATTING AND PROCESS OF MAKING THE SAME Filed Nov. 11, 1924 s sheets-sheet -1 INVENTOR AZWARD ALBERT ROGERS A ORNEYS 13 19 7. Sept 2 E. A. ROGERS COTTON BATTING AND PROCESS OF MAKING THE SAME Filed Nov. 11, 1924 v 3 Sheets-Sheet 2 INVENTOR fow/wa ALBERT Ros/ms A ORNEYS 13 1927. Sept E. A. ROGERS COTTON BATTING ANDfROCESS OF MAKING THE SAME 3 RWU m 9 mi N e mm m w? m r A MW m h s my 3 AB Filed Nov. 11, 1924 Patented Sept. 13, 1927.

UNITED STATES PATENT OFFICE.-

EDWARD ALBERT ROGERS, OF LOCKPORT, NEW YORK, ASSIGNOR TO LOCKPORT COTTON BATTING CO., OF LOCKPORT, NEW YORK, A CORPORATION OF NEW YORK.

COTTON BATTING AND PROCESS OF MAKING THE SAME.

Application filed Novemberll, 1924. SerialNo. 749,269.

This invention relates to cotton batting and to processes of making cotton batting, and has for its general object so to form or to construct cotton bats, without mate- 3 rially increasing their cost, as to facilitate their handling in the production of certain articles for which suchbats are commonly used, such, for example, as comforters, and also so to construct the bats as to insure preservation of the original bat structures so far as possible in the subsequent use and treatment of the comforters or other articles for which the bats have been used.

.The inherent .strength or resistance to disruption of cotton batting varies somewhat, of course, with'the length of the staple used in' the production of the batting, and also with the compactness of the batting. For many uses for which the batting is intended, and particularly for use in making comforters, it is important, however, that the cotton have considerable fiuifiness. Attempts heretofore made to reinforce or strengthen cotton batting and to hold the cotton against lateral displacement and wadding when used in comforters, have usually resulted in a considerable loss of the fluffiness and other qualities particularly desirable in the making ofcomforters. This is particularly true where reliance has been placed principally upon stitching of the bat. Too much stitching of the bat tends to compact it and to destroy a considerable part of its fiuffiness.

' as Other attempts to reinforce cotton batting by laying threads in the batting in the course of manufacture have proved ineffective for two reasons: In the first place, if the threads are to be carried across the bat in the course 40 of the manufacture thereof by a reciprocating carrier, it is necessary to slow up very much the formation of the bat if the threads are to lie in suflicient approximation to a crosswise position in the bat to be effective for crosswise reinforcement. In'the second place, such threads not positioned in lines substantially normal to the length of the bat and not relatively close together are substantially useless for reinforcement of the bat against the disrupting strains to which it is subjected in ordinary use.

One object of the present invention is to secure reinforcement of the bat against both lateral and longitudinal disrupting strains which will be more effective than methods embodying the present invention and the heretofore employed, which can be effected at low cost and which does not materially interfere with the speed of manufacture of the bats, the reenforcement being so effected as to lend itself to continuous operation.

The invention also aims so to reinforce cotton batting that the reinforcing means will remain in position, will tend to prevent lumping and wadding of the cotton when used, for example, in comforters, and will not materially reduce the flufiiness of the cotton so desirable for such uses.

The invention aims also so to reinforce cotton batting as to give the batting substantially uniform strength both longitudinally and laterally, and to do this without affecting the utility of the batting for any of (ghe purposes for which it is ordinarily use Other objects and important features of the invention will appear from the following description andclaims when considered in connection with the accompanying drawings in which is illustrated both a novel bat novel process of producing this bat. I

Fig. 1 is a diagrammatic plan view illustrating the process of forming the novel hat of the present invention;

Fig. 2 is a diagrammatic side elevation of the arrangement shown in plan in Fig. 1;

Fig. 3 is a detail plan view partly broken away illustrating the steps of providing reinforcement for the novel hat of the present invention;

Fig. 4 is a side elevation of the arrangement illustrated in Fig. 3 in about the same detail;

Fig. 5 is a diagrammatic side elevation of a carding machine used to form one of the webs that go into the bat and showing its relation to the forming apron illustrated in section at the left of this view; and

Fig. 6 is a perspective view of a finished bat with a portion of the reinforcing web-' 1 bing uncovered to show its position in the bat with relation to the lines of reinforcing stitching and also in relation to the layers of cotton.

In the manufacture .of cotton batting, it 10 has long been customary to lay down upon a continuously traveling apron 2 upon which the bat is formed, successive webs 4, 6, 8,

10, 12, 14, of cotton formed in cardin or garnetingmachines 16. These webs are aid 1 upon the forming apron by delivering mechanisms 18 associated with the respective carding machines, which delivering mechanisms reciprocate across the forming apron 2 and lay the web upon the apron as said apron is traveling at right angles to the path of reciprocation of the delivering mechanisms, the carding or garneting Inachines 16 being arranged at intervals along the path of travel of the forming apron as shown diagrammatically in Figs. 1 and 2. The succeeding layers or webs of cotton are therefore laid upon the preceding ones in a zigzag or criss-cross form or arrangement, as shown in Fig. 1, which causes considerable overlappin of the webs upon themselves and crosslng and interlockmg of the fibres of the cotton, whereby an effective felting of the cotton is attained.

In producing the novel batting of the present invention by the process hereinafter escribed, the introduction of the reinforcing loosely-woven fabric or webbing has been so arranged that the webbing enters into and forms a constituent part of the bat, is thoroughly interlocked with the cotton in the formation of the bat and does not materially interfere with the speed of formation of the bat. As herein illustrated, the webbing 20 is arran ed to be unwound from a roll 22 and lai upon the cotton on the forming apron before all of the webs or layers which go to make up a complete but have been laid upon the apron. Thus, for example, when, as herein shown, a bat is to be formed of six webs or layers of cotton delivered from six carding or garneting machines arranged at intervals along the line of travel of the forming apron, the roll 22 of loosely-woven fabric or webbing from which the reinforcing webbing is to be unwound upon an intermediate layer of the bat is preferably arranged at a point in the line of travel of the forming apron 2 where it will deliver the webbing 20 to the forming a rgn so that it will be laid upon the first tiree, 4 6 and 8, of the webs or layers which go into the make-up of the bat, thus permitting the other three layers, 10, 12 and 14, to be laid over the webbing, thereby having the webbing or reinforcement midwa of the thickness of the bat.

y introducing the reinforcing webbing 20 into the batting in the manner hereinbefore set fort-h during the formation of the bat, the webbing, as herein shown, being of relatively wide mesh, the cotton interlocks itself through the interstices of the mesh and the webbing is thus incorporated in the battin and is not a distinct and separate layer.

To insure the maximum reinforcing e ect of the webbing, it is essential that the threads lie substantially straight, both those that extend len thwise of the batting and those that eaten crosswise; To insure such wan on location and condition of the threads of the webbing in the batting, the lengthwise threads of the webbing are kept under tension during the laying of the webbing upon the batting and lateral tension is also put upon the webbing so that the crosswise threads are also stretched into substantially straight condition, this being further important to insure that the webbing extend to the full width of the batting. Such stretching may be effected in any suitable way as, for example, over the arched stretcher bar 24: herein illustrated.

As shown in Figs. 3 and 4 of the drawings, the webbing 20, after passing over the arched stretcher bar 24, passes beneath a roller 25 which spreads it evenly over the bat and insures its embedding therein in its laterally and longitudinally stretched open mesh condition.

The loosely-woven fabric or webbing having been positioned in and interlocked with the batting and the batting having passed under the usual pressure roller 26 to even out its surface and insure a substantial. uniformity of its internal structure, the batting thus formed and reinforced is preferably further reinforced and the webbing secured in position by longitudinal lines of stitching 28 so spaced laterally as not to in terfere substantially with the fluiiincss of the batting but yet sufliciently numerous to serve to tack the webbing in position in the batting and to tack the batting to the webbing, thus producing a batting-structure having substantially all the desirable characteristics of the unreinfn'ced bat, but many fold its resistance to disruption and relative displacement of its parts.

The insertion of the reinforcing lines of stitches is illustrated diagrammaticall in Fig. 4c of the drawings where a stitcling machine 30 having as many needles 32 as there are rows of stitches to be inserted in the bat is shown as arranged in the path of travel of the bat to a cutting machine 3% where the continuous bat formed upon the apron 2 is cut into lengths suitable for the particular uses for which such bats are intended. For example, a bat formed upon the apron 2, 72 inches wide, is provided with a reinforcing webbing of the same width and, if the lines of reinforcing stitches are s aced 4 apart, would have across its widt 17 of such lines. This bat, as intended for use in the making of comforters, would ordinarily be cut in lengths of by the cutting machine 34.

By reason of the reinforcing hereinabove described, bats made in these relatively lar 'e dimensions can readily be handled without danger of being torn apart.

From the foregoing description it will be seen that the process of making the improved batting of the present invention results in lit) the production of batting, or of individual bats, in which the reinforcing loosely-woven fabric or webbing is so incorporated in the bat that it forms a part of the unitary structure of the bat and not a distinct layer, the webbing being laid and interlocked with the cotton while both its warp threads and its weft threads are so stretched as to'insure the relatively wide mesh being open at the time the webbing is laid upon the cotton and embedded therein, whereby the-fibres of the cotton extending through the interstices of the Webbing and being further interlocked with the fibres of the cotton superposed upon the webbing, and pressed into interlocking relation, permanently position the warp and weft threads of the webbing in substantially their extendedbr straight condition so that they are immediately in position to resist rupturing strains exerted along the rectangular dimensions of the bat. Moreover, the laying of the webs of cotton with the run of the fibres oblique to the travel of the apron causes these fibres to be located in the bat on the diagonals of the rectangu-' lar mesh of the webbing and therefore further reinforces the bat in that they form truss-like structures with the threads of the structure to rupture over localareas in that,' as shown in the illustrated embodiment of webbing.

The further securing of the parts of the bat in the relations to each other just described by relatively Widely spaced lines of stitching'extending along one rectangular dimension only of the'bat serves, among other things, to reinforce the resistance of the the invention, these lines of stitching tack the weft threads at intermediate pointsalong their lengths sothat they are secured in more localized areas and thus offer greater resistance, particularly to rupturing strains transverse to the plane of the bat. This tacking of the parts to increase the local resistance to rupturingstrains does not, however, because of the relatively wide mesh of the fabric and thetrelatively wide spacing of the lines of stitches, affect the flufiiness and elasticity of-the bat structure as a whole.

What is claimed as new is:

1 As a new article of manufacture, a cotton bat suitable for use in comforters, said bat comprising webs of cotton and a web of loosely-woven fabric of such open rectangular mesh as to permit interlocking of the fibres of the Webs of cotton therethrough, said web of fabric being situated between said webs of cotton and embedded therein with both its warpi and its weft threads in substantially straight condition, the webs of cotton bein through the interstices of said loosely-woven fabric.- M .Q

2. As a new article of manufacture, a cotton bat suitable for use in comforters, said interlocked with each other bat comprising webs of cotton and-a web of loosely-woven fabric of such open rectangular mesh as to permit interlocking of the fibres of the webs of cotton therethrough, said web of fabric being situated between said webs of cotton and embedded therein with both its warp and its weft threads in substantially straight condition, the Webs of cotton being interlocked with each other through the interstices of said loosely-woven fabric, said webs of cotton and said web of loosely-woven fabric being tacked, to prevent relative displacement and to reinforce their resistance to rupture over local areas, by relatively widely spaced lines of stitching extending across the bat in one dimension onl As a new'article of manufacture,-a cotton bat suitable for use in comforters, said bat comprising webs of cotton having the run of the fibres oblique to the length of the bat and an interposed web of loosely-woven fabric of such open mesh as to permit the interlocking of the fibres of thewebs of cotton therethrough, the webs of cotton being interlocked through the interstices of said fabric and the warp and weft threads of the fabric'being embedded in the bat in substantially straight condition and substantiallyparallel to the rectangular dimensions .of

the bat.

4. As a new article ofmanufacture, a cot- I ton bat suitable for use in comforters,said bat being formed of webs of ,cotton having 7 interposed therebetween and I interlocked therewith a'webbing of such open rectangular mesh as to permit interlocking of the I fibers of the opposedwebs of cotton therethrough, the warp'threads of said webbing extending in substantially straight condition throughout the length of the bat, and the weft threads extending in substantially straight condition across the bat, and lines of stitching tacking said webbing in position in the bat.

5. As a new article of manufacture, acotton bat suitable for use, in comforters and comprising webs of cotton, said bat having embedded therein intermediate between its faces a webbing of such open rectangular mesh as to permit interlocking of the fibres of the webs of cotton therethrough, said webbing being in both its laterally and its longitudinally extended-condition, said webs of cotton being interlocked through the interstices thereof and the parts being secured in 'suchirelation by lines of stitchin along one dimension only and substantia y uniformly spaced across said bat.

6. As-a new article of manufacture, a cotton bat suitable for use in comforters and comprising superposed webs of cotton, said bat having intermediate between its faces a webbing of such open rectangular mesh as to permit interlocking of the fibres of the ing to tack them in the bat.

7. As a new article of manufacture, a cotton bat suitable for use in comforters and comprising webs of cotton arranged obliquely to the length of the bat in cries-cross arrangement, said but having intermediate between its faces a loosely-wovenfabric of such open rectangular mesh as to permit interlocking of the cotton fibres therethrough, the warp threads of said fabric extending in substantially straight lines along one rec.- tangular dimension of said bat and the weft threads extending in substantially straight lines along the other rectangular dimension of the bat and the cotton being interlocked through the open mesh of the fabric to maintain the relative positions of the warp and weft threads of the fabric, and relatively widely spaced lines of stitching serving to reinforce the resistance of said structure to rupture over local areas.

8. As a new article of manufacture, a cotton bat suitable for use in comforters and comprising webs of cotton having the run of the fibres oblique to the length of the bat, said bat having incorporated therein intermediate between its faces a web of loosely woven fabric of such open rectangular mesh as to ermit interlocking of the fibres of the we 5 of cotton therethrough, the war threads of said fabric extending longitudinally of the bat in substantially straight condition and the weft threads extendin crosswise of the bat in substantially straig 1t condition and the cotton webs being interlocked through the interstices of said fabric, whereby the resultant bat is reinforced both longitudinally, transversely and dia onally.

9. As a new article of menu acture, a cotton bat suitable for use in comforters and comprising webs of cotton having the run of the fibres oblique to the length of the bat, said bat having incorporated therein intermediate between its faces a web of looselywoven fabric of such open rectangular mesh as to permit interlocking of the fibres of the webs of cotton therethrough, the war threads of said fabric extending longitudinally of the bat in substantially straight condition and the weft threads extending crosswise of the bat in substantially straight condition and the cotton webs bein interlooked through the interstices of said fabric, whereby the resultant bat is reinforced both longitudinally, transversely and diagonally, and relatively widely spaced lines of stitcheagues ing tacking said parts in their relative positions and thereby serving to reinforce the resistance of said structure to rupture over local areas.

10. The process of forming reinforced cotof such open rectangular mesh as to permit the ready interlocking of the fibres of webs of cotton on opposite sides thereof through the interstices thereof, and, durin the laying operation, stretching said web ing both longitudinally and laterally so that the warp threads of said webbing extend in substantially straight lines lengthwise of the batting and the weftthreads extend in substantially straight lines crosswise of the batting, then laying another web or webs of cotton over the webbing and forcing t parts into interlocked relation to each other and tacking the whole together by stitching.

11. The process of forming reinforced cotton battingsuitable for use in comforters, which consists in laying down on the forming apron one or more zigzag la ers of cotton with the run of the fibres ob ique to the travel of the apron, then layin upon the cotton a loosely-woven webbing 0 such open rectangular mesh as to permit the interlock ing therethrough of the fibres of layers of cotton on the opposite faces thereof and, during the laying operation, stretching said webbing both longitudinally and laterally so that the warp threads of said webbin extend in substantially straight lines lengt wise of the battin and the weft threads extend in substantia y straight lines across the batting, then layin one or more zigzag layers of cotton over the webbing with the run of the fibres oblique to the travel of the apron,

ressing the cotton of the upper and lower ayers into interlocked relation throu h the interstices of the webbing while the '0 reads of the webbing are still in their initially laid relation, and, while the parts of the batting are thus in their predetermined relations to each other, tacking the parts of the batting together by relatively widely spaced lines of stitching.

12. The process of forming reinforced cotton batting suitable for use in comforters, which consists in laying down on the forming apron one or more zigzag layers of cotton with the run of the fi res oblique to the travel of the apron, then laying upon the cotton a loosely-woven webbing having a mesh of such dnnensions as to ermit interlocking of the fibres of layers of cotton upon opposite faces of the webbing through the interstices thereof and, during the laying operation, so stretching said webbing both 1on webbing to extend in substantially straight lines lengthwise of the batting and the weft threads to extend in substantially straight lines across the batting, pressing the webbing in its open condition into the cotton, then laying one or more zigzag layers of cotton over the webbing with the run of the fibres oblique to the travel of the apron, pressing the cotton of the upper and lower layers into interlocked relation through the interstices of the webbing, while the mesh is still in its open condition and the threads of the webbing are still in their initially laid relation to the bat, and, while the parts of the batting are thus in their predetermined relations to each other, tacking the parts of the batting together by lines of stitchin serving to reinforce the resistance of sai structure to rupture over local areas.

13. The process of formmg remforced cotton batting suitable for use in comforters,

which consists in laying down on the forming apron one or more layers of cotton having the fibres in crisscross relation and oblique to the travel of the apron, then laying upon and partly embedding in the cotton a loosely woven webbin of such open rectangular mesh as to permit the interlocking therethrou-gh of the fibres of layers of cotton on opposite faces thereof and, durin the laying operation, putting the warp an. Weft-threads of said webbing under tension so that the threads of one group extend in substantially straight lines lengthwise of the batting and the threads of another group extend in substantially straight lines across the batting and while the webbing is thus partly embedded in its laid condition in the batting laying similar layers of cotton over the webbing and pressing the cotton of the upper and lower. layers into interlocked relation through the interstices of the webbin Signed at Lockport, N. Y., this 7th day of November, 1924.

EDWARD ALBERT ROGERS.

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