Method and Apparatus for Felting Three Dimensional Objects

Abstract

A method and apparatus for felting three-dimensional objects is disclosed. The method involves wrapping a three-dimensional object with wool, and agitating the encased object within a drum in the presence of heated alkaline solution. The process may be repeated to achieve the desired felt consistency. An apparatus is provided for use with the method. Products produced in accordance with the invention have consistent texture, resiliency, and density throughout, with no visible seams or rough edges.

Description

FIELD OF THE INVENTION[0001]The present invention relates generally to felting. More particularly, the present invention relates to an apparatus and method for felting three-dimensional objects.BACKGROUND OF THE INVENTION[0002]Wool batting, the fleecy coat sheared from sheep, when combined with an alkaline solution, heat and agitation, has the unique ability to compress and interlock into a dense material called felt. The process of felting wool is 2,000 years old, originating in the highlands of northern Asia; it has since been embraced by cold weather cultures around the world. Felting has traditionally produced flat objects such as rugs, wall hangings, and fabric for clothing.[0003]There are many qualities associated with felted wool. Aesthetically it is pleasing to touch, holds colour beautifully, and is warm and comfortable. Physically, it has a consistent nape; cuts without unravelling; is durable and protective; insulates against temperature, sound waves, and vibration; wicks...

AI Technical Summary

Benefits of technology

[0059]In comparison to existing industrial felting processes, the method and apparatus of the invention may be used to produce a denser, smoother and more resilient felt than the needle-felt method. Felted wool currently produced using industrial methods (steam process and needle-felting) is not suitable to applications in fashion due to coarseness of texture, instability of felt, and aesthetically unsuitable (as in needle felting), or stiffness of felt (as with steam process). In relation to the existing wet-felt methods that produce flat sheets of felt, the benefit of the present method includes quality comparable or more favourable than any felt produced by hand or by industrial process, but in-the-round. Therefore, the production of three-dimensional forms is more direct and efficient with the methods of the present invention, eliminating the need for die-cutting, scoring, folding and gluing or sewing felt pieces into the desired form. The method of the present invention produces felt forms directly from wool by utilizing the natural ability of wool fibres to interlock and matte into a single, cohesive substance that is capable or retaining its shape without the need for stiffeners.

[0060]In comparison to existing hand felting processes, the apparatus of the present invention removes the dependency of the process on the human-element as providing the primary source of energy in the creation of agitation and automates this task. A three-dimensional object is created in the round that has a consistent appearance in surface texture, wall thickness and density. Research and testing has shown that these characteristics have rarely been attempted or achieved using traditional hand-felting methods.

[0061]The quality of felt produced by the present process has a remarkably smooth surface texture that makes it aesthetically suitable for products on-view to consumers. It also has a consistent fibre matrix that provides structural integrity, providing excellent surface wear and a resistance to further shrinkage, and it can be moulded to take on the form of any concave or convex form.

[0062]The potential advantages for the consumer include an aesthetically pleasing material that expresses the warmth; comfort and ease of wear associated with wool. The felted wool produced by the present method and apparatus has exemplary structural integrity, providing stability and resistance to surface wear, while retaining these aesthetic qualities desired by the consumer. Other advantages include the renewability of wool as a natural resource that is non-toxic, and eco friendly.

[0063]Applying the technology to the production of existing products made using existing methods will generate significant improvements in quality and design. For example, wool liners in ski boots may be made seamless, improving comfort. In addition, the technology lends itself to mass-manufacturing methods, complementing existing methods and machinery utilized by manufacturers, making for easy integration into existing systems.

Problems solved by technology

Currently, three-dimensional forms can only be created by indirect methods involving a number of manual steps between raw materials and finished product.

Some shrinking occurs, but the primary result is the softening of the surface appearance.

This method is limited to small-scale objects, in the round, approximately six inches in diameter, that will fit between the agitator and wall of the drum.Drawbacks in the use of a washing machine for felting include the excessive amount of water contained in the drum and the indirect agitation of the beater (in a top-loading model) or the rotation of the drum (in a front-loading model), which impede the felting process by preventing the fibres from matting.

For these reasons, the washing machine is appropriate for use by hobbyists, but unsuitable and ineffective for use by artisans or industry when a predictable method of manufacture providing consistent, quality products is required.Hand-held Palm Sander—Used for flat felting, the resulting felt may be cut and sewn into a three-dimensional form.

This causes the fibres to tangle and knot together.

This process produces a low quality of felt with a weak fibre matrix.

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