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Method and Apparatus for Felting Three Dimensional Objects

a three-dimensional object and apparatus technology, applied in the field of felting, can solve the problems of shrinkage, surface appearance softening, and the creation of three-dimensional forms only by indirect methods, and achieve the effects of smooth surface texture, less shrinkage, and more direct and efficient operation

Inactive Publication Date: 2008-08-14
LOXAM KOHL DEBORAH
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0038]In a further embodiment, the heated alkaline solution is added to the drum prior to agitation in step c), and the drum includes a sealable lid to prevent leakage of the heated alkaline solution during agitation. In an alternate embodiment, the heated alkaline solution is applied as a spray or vapor.
[0067]Insulating panels in automobiles: located in front dash, side doors, overhead, under seats, and trunk liners; die cut from flat felt pieces; protect against sound, vibration and temperature;

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.

Method used

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  • Method and Apparatus for Felting Three Dimensional Objects
  • Method and Apparatus for Felting Three Dimensional Objects
  • Method and Apparatus for Felting Three Dimensional Objects

Examples

Experimental program
Comparison scheme
Effect test

example 1

Felting Method

[0087]With reference to FIG. 1, a method for felting a three-dimensional object is provided in which an apparatus in accordance with the invention is also employed.

Wool Wrapping

[0088]In accordance with the method shown in FIG. 1, the object or blank to be felted is first wrapped with wool batting in step A. Multiple layers of wool batting are built up around the object, with each subsequent layer of wool batting placed upon the previous layer with the wool fibres preferably misaligned between each layer. The object should be wrapped with sufficient batting to result in the desired felt thickness (approximately 1½ to 2 inches of batting will compress down to ¼ to ⅜ inch thick of hard felt). The object that is to be felted may be a solid object such as a ball, or may be an inflated blank having an appropriate shape and size for felting.

Protective Casing

[0089]A protective casing is then applied B to the wrapped object to hold the wool in place, preventing unravelling. In ...

example 2

Apparatus

[0122]An embodiment of a machine for use with the above method is shown in FIGS. 2 through 5.

Motor

[0123]The motor 1 drives the v-belt 5 that in turn drives the pulley 6 attached to the active roller 7a, thereby rotating the drum 15 as it lies horizontally upon rollers 7a, 7b. The motor 1 should be selected so as to provide ample power for the scale of the machine, allowing the machine to function and not labour under the weight of the drum and its contents. A weak motor may overheat and may not be effective in carrying the combined weight of the drum+rubber shot+water+object. This will cause the drum to shuffle between the rollers rather than spinning.

[0124]The motor may include various speed settings for flexibility, allowing different configurations or different sizes of drum to be used. Experimentation has shown that a motor speed of 875 rpm is suitable for small objects felted in a 12-inch diameter cylindrical drum, which results in a drum speed of approximately 33 rpm....

example 3

Apparatus

[0144]With reference to FIG. 7, a further embodiment of the apparatus is shown in which the drum 25 is a six-sided prismatic drum without interior baffles, the drum constructed of a rigid and perforated material such as perforated stainless steel, metal mesh or screening. A door or hatch 26 is present to provide access to the drum interior for placement and removal of the wrapped object along with rubber shot 20. A spray system 30 is present for receiving heated alkaline solution or steam from a reservoir 35 and spraying the solution over the drum 25 and its contents. The heated alkaline solution or steam will penetrate the drum and the wrapped object inside the drum to facilitate felting during agitation. As the heated solution or condensation arising from steam application will drip from the drum during agitation, a bottom tray 36 is present to collect the excess, which may be discarded or heated and recycled back to the reservoir 35.

[0145]The drum 25 may be driven direct...

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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...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D04H1/22
CPCD04H1/22D06M23/14D06M11/84
Inventor LOXAM-KOHL, DEBORAH
Owner LOXAM KOHL DEBORAH
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