Welded Textile Mat and Methods for Manufacturing Same

Abstract

A rodent and pest resistant textile fabric or material is manufactured using tack welding. The fabric can be made either from continuous, long fibers (also known as filament fibers), or from short, cut fibers, also known as staple fibers. The source material may comprise coarse or medium grade 434 stainless steel. The fabric or material is bonded together through a welding process to create a final metal textile. The material may be welded in a variety of ways including, but not limited to, feeding through a welding machine, electrode disc welding and spot welding or point-bonding.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional patent application No. 63 / 781,527, filed Apr. 1, 2025, the entirety of which is hereby incorporated by reference.BACKGROUND OF THE INVENTION1. Field of the Invention

[0002] The present invention relates, in general, to rodent and pest resistant textile materials and, more particularly, to a rodent and pest barrier material comprised of metal fibers that are bonded together.2. General Background of the Invention

[0003] Many rodents are fossorial, or burrowers. Burrowing rodents, pests and other animals can not only damage the health and appearance of the ground, including damage to roots and crops themselves, but can also affect the structural integrity of the ground and thus the structures above it. As a result, there has been a need to inhibit these animals from being able to burrow into the ground in certain locations such as, but not limited to, landfills, dumps, cemeteries and groves.

[0004] Currently, it is known to use coarse stainless steel or landscape fabrics to try and prevent such animals from burrowing into the ground and causing damage. Among other things, burrowing around landfills or dumps can lead to holes in the underground barrier, thus allowing contaminants to enter the ground and water systems.

[0005] While these barriers have had some success in limiting the amount of burrowing that occurs, over the years, for a variety of reasons, rodents and other burrowing animals have been considered to have become more aggressive as they look for food or shelter, thereby reducing the efficacy of such materials.

[0006] Accordingly, there is a need for a more efficient and effective rodent resistant barrier material for use in the ground to prevent or inhibit burrowing.BRIEF SUMMARY OF THE INVENTION

[0007] The present invention comprises a rodent and pest resistant textile fabric or material with beneficial features, and methods of making the same. This fabric can be made either from continuous, long fibers (also known as filament fibers), or from short, cut fibers (also known as staple fibers). A variety of different metal alloys and grades can be used for this product; however, preferred embodiments utilize both coarse and medium grade 434 stainless steel. Although not necessarily a preferred embodiment, it is also contemplated that composite or other nonmetal materials may alternatively be included in the fabric.

[0008] Notably, the fabric or material is bonded together through a welding process to create a final metal textile. It is appreciated that the material may be welded in a variety of ways including, but not limited to, feeding through a welding machine, electrode disc welding and spot welding or point-bonding.

[0009] Accordingly, it is an object of the present invention to provide a rodent and pest resistant fabric that is economical and easy to utilize.

[0010] It is another object of the present invention to provide a method of making a rodent and pest resistant fabric that is economical and easy to manufacture.

[0011] Other objects, features and advantages of the invention will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like reference numerals refer to like parts.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0012] FIG. 1a is a schematic view of a metal fiber shaving and cutting apparatus that may be used in the formation of metal fabric in accordance with the present invention;

[0013] FIG. 1b is a schematic view of a cross lapping apparatus that may be used in the formation of metal fabric in accordance with the present invention;

[0014] FIG. 1c is a schematic view of a needle felting apparatus that may be used in the formation of metal fabric in accordance with the present invention;

[0015] FIG. 1d is a schematic view of a nonwoven carding apparatus that may be used in the formation of metal fabric in accordance with the present invention;

[0016] FIG. 2 is a perspective view of one embodiment of the metal fabric of the present invention, shown after it has been formed and before welding;

[0017] FIG. 3 is a perspective view of one embodiment of the metal fabric of the present invention, shown after welding;

[0018] FIG. 4a is a process flow diagram of a first method of manufacturing a metal fabric in accordance with the present invention;

[0019] FIG. 4b is a process flow diagram of a second method of manufacturing a metal fabric in accordance with the present invention;

[0020] FIG. 4c is a process flow diagram of a third method of manufacturing a metal fabric in accordance with the present invention;

[0021] FIG. 4d is a process flow diagram of a fourth method of manufacturing a metal fabric in accordance with the present invention;

[0022] FIGS. 5a through 5l are top plan schematic views of various embodiments of alternative welding patterns which may be used in the manufacturing of a metal fabric in accordance with the present invention;

[0023] FIG. 6 is a simplified schematic view of an apparatus for manufacturing a metal fabric in accordance with a first embodiment of the present invention; and

[0024] FIG. 7 is a simplified schematic view of an alternative apparatus for manufacturing a metal fabric in accordance with the first embodiment of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0025] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments, with the understanding that the present disclosure is to be considered merely an exemplification of the principles of the invention and the application is limited only to the appended claims.

[0026] U.S. Pat. No. 6,583,074 discloses methods of making metal fibers and manufacturing a nonwoven metal fabric of superior strength, and its disclosure in the entirety is hereby incorporated by reference. While a variety of metal fibers may be utilized in the processes, in order to increase the materials'efficacy of resisting damage by rodents or pest, a metal fiber having rough or jagged outer surfaces, such as those disclosed by U.S. Pat. No. 6,583,074, is preferred for those applications. The metal fibers may be of a variety of lengths depending on the particular size and application for the material.

[0027] A first embodiment of manufacturing a welded textile mat according to the present invention is shown in FIG. 4a. In this embodiment, a textile mat is manufactured by cross-lapping and welding a continuous filament. Referring to FIGS. 4a and 1a, coarse wool shaving step 100 is first performed. Metal wire 23, which may comprise 434 stainless steel wire in coiled form, is fed into a shaving apparatus configured to form coarse grade steel wool. Sharp, serrated blades 25 cut wire 23 into thin strands or filaments of metal (or steel wool). Specifically, a mass or batt of loose filaments 22 is formed by shaving metal wire 23 with a succession of serrated blades, of which one is indicated at 25. A suitable lubricant 26, such as oil, is applied to the metal wire 23 as it is being acted upon by blade 25, and the resulting loose filaments 22 retain the oil on their outer surfaces. Alternately, lubricant 26 may be applied directly to filaments after they have been shaved from the metal wire 23, or during other processing steps.

[0028] By using a succession of serrated blades with a variety of serration patterns thereon, the filaments 22 are provided with irregular cross-sections and rough outer surfaces. The irregular cross-sections vary along the length of the filaments 22 produced by the foregoing process, and generally have average cross-sectional diameters of 25 to 125 microns. The variation in cross-sections of the filaments 22 forms barbs in the outer surfaces of the filaments to enhance interengagement.

[0029] It is appreciated that the quality and grade of the strands of steel wool may be controlled through the configuration and setting of the metal fiber shaving and cutting apparatus, and the types of blades used. By adjusting these parameters, the production line can yield a diverse output of steel wool, ranging from ultra-fine to extra-coarse. Medium or coarse grade wool are, however, the preferred grades for the manufacture of metal webs according to the present invention.

[0030] The use of serrated blades for cutting coiled steel wire adds microscopic sharp edges to the filaments during the manufacturing process, an attribute not typically found in filaments generated through other wire forming techniques. The serrated blades' cutting action not only tailors the filament's physical dimensions, but also imbues it with a level of sharpness that can lead to injuries such as cuts or splinters upon contact, thereby providing a deterrent to rodents and pest.

[0031] While 434 stainless steel is described herein for use in connection with the various methods, it is appreciated that the present invention may utilize a variety of different metals, including other types or alloys of stainless steel, aluminum, brass, bronze, and copper.

[0032] In addition, while a variety of sizes of metal filaments may be utilized, it is appreciated that the average size be at least 90 um for structural strength. Once the metal is cut into smaller filaments 22, it may be collected and formed into rolls of steel wool in a known way in step 100 for transport and use. In one embodiment, the rolls may be 7 inches wide and have a linear weight of 0.6 oz / ft, though it is appreciated that it may be of a variety of sizes and weight based on the particular application and intended use for the finished product.

[0033] Referring to FIG. 4a, once coarse steel wool has been shaved as described above, it is positioned on reels. Multiple reels of coarse steel wool are placed next to one another and are simultaneously fed into either a needle loom in order to perform needle roving at step 105, or a compression rolling apparatus at step 115.

[0034] In the needle roving 105 option of FIG. 4a, a needle loom is employed to entangle filaments 22 together to produce an initial textile. An example of a suitable needle loom is the Hunter Model Fiber Locker single-sided needle loom. Examples of suitable needles that may be used in the needle roving step are Grotz-Beckert Gebecon Needles Model 15×19×25×3.5 M332 G 530P7. It is appreciated that webs having a variety of basis weights may be produced, with exemplary ranges being from 800 to 4000 grams per square meter (“GSM”), and widths ranging from 12 to 72 inches. However, it is appreciated that the parameters may be changed, with the specific combination of equipment and settings selected being tailored to the unique requirements of each product's end use case.

[0035] In the compression rolling option 115 of FIG. 4a, multiple rolls of coarse steel wool are fed in parallel through a compression rolling apparatus, consolidating the output of the individual reels into a consolidated structure, smoothing any loose metal fibers on the surface.

[0036] Next, the output from either needle roving step 105 or compression rolling step 115 is utilized in cross-lapping step 110. Referring to FIG. 1b, an embryonic fiber web 33, created by either needle roving step 105 or compression rolling step 115, is fed into textile lapping apparatus 34, which folds embryonic web 33 back and forth across its width, thus forming a multi-layer structure 37. Lapping apparatus 34 preferably changes the orientation of embryonic fiber web 33 as it is being deposited on successive layers 39. In this way, the orientation of adjacent ones of the layers 39 are rotated out of alignment from each other by a preselected angle, and the direction of the fibers 22 in the fiber web 33 varies between adjacent layers 39 of the resulting multi-layer structure 37.

[0037] It is appreciated that various cross-lappers may be utilized including, but not limited to, camel-back cross-lappers and horizontal cross-lappers. During the cross-lapping operation, both the basis weight and structural stability of the material are enhanced. In particular, the metal fibers are lapped by a suitable textile apparatus that changes the orientation of the fibers as they are being deposited in successive layers, thereby creating a multi-layer structure having layers that extend out of alignment with adjacent layers.

[0038] In one embodiment, the camel-back portion of a Proctor & Schwartz Inc. Model K59261 carded nonwoven prototype line may be utilized for cross lapping. Setting the feed apron to a speed of 15 feet per minute (fpm), the camel-back to a speed of 8 feet per minute (fpm), and the floor apron speed of 2.43 fpm, a basis weight of 1,200 GSM may be obtained. It is appreciated that webs having a variety of basis weights may be produced, with exemplary ranges being from 800 to 4000 GSM, and widths ranging from 12 to 72 inches. However, it is appreciated that the parameters may be changed, with the specific combination of equipment and settings selected being tailored to the unique requirements of each product's end use case.

[0039] From the cross-lapping procedure, both the basis weight and structural stability of the material are enhanced due to fiber re-orientation. In one embodiment, the multi-layer structure 37 may have a basis weight of 1,200 GSM. It is appreciated that webs having a variety of basis weights may be produced, with exemplary ranges being from 800 to 4000 GSM, and widths ranging from 12 to 72 inches. However, it is appreciated that the parameters may be changed, with the specific combination of equipment and settings selected being tailored to the unique requirements of each product's end use case.

[0040] Next, referring to FIG. 4a, either a second compression rolling step 115, as previously described, or a needle felting step 120, is performed on multi-layer structure 37. Compression rolling step 115, if selected, further consolidates multi-layer structure 37. Alternatively, in needle felting step 120, and referring to FIG. 1c, the resulting multi-layer structure 37 is fed through a nip 41 and suitable needle felting apparatus 45 to needle felt (or needle punch) the structure, thereby interlocking and entangling the fibers to form a non-woven metal fabric 43 (as shown in FIG. 2) to enhance the material's stability, structure, and mechanical strength. One example of a suitable needle felting apparatus is Dilo DI / Tack 6 needle felting machine. In one embodiment, the finished product can have a needle punch density of 2-100 punches per square centimeter and a final consolidated thickness of 0.3-0.5 inches. Examples of suitable needles for us in the needle felting apparatus are Grotz-Beckert Gebecon Needles Model 15×19×25×3.5 M332 G 530P7. Based on the unique requirements of each end product's use case, the equipment and settings may be modified the final web's thickness, weight, and porosity.

[0041] Finally, in the first embodiment of manufacturing a welded textile mat according to the present invention of FIG. 4a, the material output from either compression rolling step 115 or needle felting step 120 is bonded together through a welding process to create the final metal textile. The welding process may comprise point-bond welding 130, seam welding 140, or a combination of point-bond and seam welding 150. It is appreciated that the material may be welded in a variety of ways including, but not limited to, feeding through a welding machine, electrode disc welding and spot welding or point-bonding. In one embodiment, the material may be point-bonded using one or more resistance welding apparatuses to create an array of “point-bonds”, as exemplified by step 130. An example of a suitable resistance welding apparatus is an ACME welding unit, model PS2450, equipped with Equatip Holders capable of delivering two welds at a time.

[0042] An example of a welded textile mat manufactured in accordance with one of the methods of the present invention is shown in FIG. 3 as comprising mat 350, having a plurality of spot welds or point welds 360. In the example of FIG. 3, mat 350 has a “point-bond” pattern consisting of ½″ dots 360, positioned 2″ apart across the roll width and 1″ apart along the roll length in a staggered manner. This pattern is also shown schematically in FIG. 5e.

[0043] As shown in FIGS. 5a through 5l, a wide variety of alternative welding patterns may be used. In one embodiment, referring to FIG. 5b, the “point-bond” pattern may consist of ½″ dots 360, positioned 2″ apart across the roll width and 1″ apart along the roll length. It is also appreciated that the shape, size, and spacing of the welds may vary. Examples of the types of spot welding are shown in FIGS. 5a through 5i, 5k and 5l. The welds are preferably spaced apart on the material to create localized strengthened portions to inhibit intrusions by rodents or pests, while increasing throughput and enhancing porosity in the finished product to allow roots and other materials to pass therethrough while still inhibiting rodents and pests. Referring to FIGS. 5g and 5h, seam weld stations may also be utilized in step 140 or step 150 to create a pattern of continuous or discontinuous lines of seam welds 370 that strengthen the edges of the material, which are often more susceptible to damage, or, as shown in FIG. 5j, can be utilized across the interior of the structure as well.

[0044] As shown in the example of FIG. 5k, a combination of both point and seam welding techniques may be utilized in step 210. For instance, point bonded welds 360 may be used in the central sections of the structure while seam welds 370 may be applied around the structure's outer edges. Together, these techniques create a secure bond that prevents the edges of the structure from unraveling. This also reduces the creation of a raw-edge texture, which can be easily damaged during handling.

[0045] A first representative apparatus for manufacturing a welded textile mat in accordance with the first embodiment is shown in FIG. 6 as comprising multiple reel unwinding stations 250, cross-lapper 300, multiple pairs of compression rollers 310, needle loom 320, welding station 330, and winding station 400. Reel unwinding stations 250 feed the camelback portion of cross-lapper 300 which comprises a Proctor & Schwartz Inc. Model K59261. A first set of compression rollers 310 consolidates the cross-lapped material for further processing by needle loom 320, which comprises a Dilo Model Di / Tack 6. Needle loom 320 preferably compresses the web to a thickness of ½ inch, enabling the web to proceed to welding station 330 after passing through an additional set of compression rollers 310. Welding station 330 comprises a resistance tack welder, namely an ACME tack welding unit, Model PS2450, which is equipped with multi-tip holders.

[0046] A single welding station 330 has the capacity to apply two tack welds, spaced 1 inch apart. For wider products, multiple welding stations may be arranged in a side by side fashion or, alternatively, the material can undergo several passes through a single welding station. The final output of welding station 330, in the form of a finished welded textile mat, may be taken up by winding station 400 and placed into rolls of material. Further modifications and optimizations of this processing line are also contemplated, such as using a Wise Industries, Inc. horizontal cross-lapper model HL-72×72, a Bywater needle loom, and wire mesh welding machines, which will allow for wider widths, higher throughputs, and a more welds per linear width of material.

[0047] A second, alternative representative apparatus for manufacturing a welded textile mat in accordance with the first embodiment is shown in FIG. 7. In this alternative apparatus, no needle loom is employed between cross-lapper 300 and welding station 330. Instead, multiple sets of compression rollers 310 are solely employed between cross-lapper 300 and welding station 330 to compress the material.

[0048] An example of a welded textile mat manufactured in accordance with this first embodiment is a mat measuring 12 inches in width and 50 feet in length. The resultant product has a basis weight of 1,700 GSM. This mat features a distinctive welding design, comprising 1-inch by 1-inch square patterns. Each square weld in this pattern had measurements of ¼ inch by ⅜ inch.

[0049] A second embodiment of manufacturing a welded textile mat according to the present invention is shown in FIG. 4b. In this embodiment, a textile mat is manufactured by the nonwoven carding of cut fibers followed by welding. In step 200, and with reference to FIG. 1a, medium grade wool shaving is first performed, and the shaving apparatus is configured to form loose filaments 22 of medium grade steel wool. Specifically, for this embodiment, it is preferred the to utilize a mixture of medium grade steel wool, with the average fiber diameter ranging from 65-89 μm.

[0050] Next, in step 160 and as shown in FIG. 1a, the mass of loose filaments 22 is cut using a suitable metal fiber cutting apparatus 28, such as a rotating knife, produce cut fibers 21 of a predetermined length ranging between about 1 to about 10 inches, which may be deposited upon a suitable conveyor 29.

[0051] Next, in step 220, the cut fibers 21 are then fed into a conventional card or garnet textile apparatus, such as the one shown in FIG. 1d, which separates the mass of cut fibers 21 in order to form an embryonic web 33. The conventional card or garnet textile apparatus may comprise a suitable nonwoven carding apparatus such as, for example, a Proctor & Schwartz Inc. Model K59261. The carding apparatus may utilize one or more worker cylinders 31 and stripper cylinders 35 to form embryonic fiber web 33. The spacing of the stripper cylinders 35 and the associated carding cloth of the apparatus may depend upon on the size and strength of the cut metal fibers 21 being acted upon. The carding process generally imparts a “machine direction” to the fibers 21, as that term is understood in the textile art.

[0052] The nonwoven carding machine may be composed of a feedbox, a carding machine with three (3) sets of workers and stripper rolls, a camel-back cross-lapper, and a needle loom. The carding process begins with the input of the cut fibers into the feedbox. The nonwoven card then untangles these fibers and aligns them to form a nonwoven product or web.

[0053] Next, in steps 110 and 120, cross lapping and needle felting are sequentially performed upon the embryonic web, in the same manner as described above with respect to the embodiment of FIG. 4a. Following needle felting step 120, the material output from needle felting step 120 is bonded together through a welding process to create the final metal textile. The welding process may comprise point-bond welding 130, seam welding 140, or a combination of point-bond and seam welding 150, in the same manner as described above with respect to the embodiment of FIG. 4a.

[0054] An example of a welded textile mat manufactured in accordance with this second embodiment is a mat measuring 8 inches by 12 inches. The resultant product has a basis weight of 2,300 GSM, and features a distinctive welding design, comprising 1-inch by 1-inch square patterns. Each square weld in this pattern had measurements of ¼ inch by ⅜ inch.

[0055] A third embodiment of manufacturing a welded textile mat according to the present invention is shown in FIG. 4c. In this embodiment, a textile mat is manufactured by the nonwoven airlaying and welding of cut fibers. In step 100, coarse wool shaving is first performed, in the same manner as described above with respect to the embodiment of FIG. 4a. Next, in step 160, fiber cutting is performed in the same manner as described above with respect to the embodiment of FIG. 4b.

[0056] Next, in step 170, nonwoven airlaying is performed. In this step, air laid technology, a process that uses air to disperse cut fibers into a fast-moving stream and forms a web by randomizing them, is utilized. Specifically, cut fiber 21 is input into an air-laid nonwoven apparatus to form a high bulk and three-dimensional isotropic structure or web. It is appreciated that webs having a variety of basis weights may be produced, with exemplary ranges being from 800 to 4000 GSM, and widths ranging from 12 to 72 inches. However, it is appreciated that the parameters may be changed, with the specific combination of equipment and settings selected being tailored to the unique requirements of each product's end use case.

[0057] Next, in step 120, the resulting web is needle felted in step 120, in the manner described above with respect to the embodiment of FIG. 4a. Following needle felting step 120, the material output from needle felting step 120 is bonded together through a welding process to create the final metal textile. The welding process may comprise point-bond welding 130, seam welding 140, or a combination of point-bond and seam welding 150, in the same manner as described above with respect to the embodiment of FIG. 4a.

[0058] A fourth embodiment of manufacturing a welded textile mat according to the present invention is shown in FIG. 4d. In this embodiment, a textile mat is manufactured by needle roving and welding a continuous filament. In step 100, coarse wool shaving is first performed, in the same manner as described above with respect to the embodiment of FIG. 4a. Next, in step 105, needle roving is performed in the same manner as described above with respect to the embodiment of FIG. 4a. Following needle roving step 105, the material output from needle roving step 105 is bonded together through a welding process to create the final metal textile. The welding process may comprise point-bond welding 130, seam welding 140, or a combination of point-bond and seam welding 150, in the same manner as described above with respect to the embodiment of FIG. 4a.

[0059] While the metal web is disclosed as being provided to resist rodent and pest penetration, it is appreciated that it may be used in other applications such as but not to: exhaust filtration; fireproofing building materials such as, but not limited to, ridge vents, soffit and gable vents by providing a material that would be durable, able to retain its shape, and act as a physical barrier to prevent flame propagation; fire blankets and various thermal blankets; and particle filtration using fine and super fine steel wool.

[0060] It will be understood that modifications and variations may be effected without departing from the spirit and scope of the present invention. It will be appreciated that the present disclosure is intended as an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated and described. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.

Claims

1. A rodent and pest resistant textile material comprising a wool comprising a plurality of metal fibers have irregular cross-sections, wherein certain of the metal fibers are bonded together.

2. The material of claim 1 wherein the metal fibers are bonded via welding.

3. The material of claim 2 wherein the metal fibers are bonded using an array of welds.

4. The material of claim 3 wherein the welds are made by resistance welding.

5. The material of claim 3 wherein the welds are spaced apart by about 1 inch.

6. The material of claim 3 wherein the material has a material width and a material length, and wherein the welds are spaced apart 2″ along the material width and 1″ along the material length.

7. The material of claim 3 wherein the welds are about ½″ in diameter.

8. The material of claim 3 wherein the welds are substantially circular.

9. The material of claim 1 wherein the material is formed into a particular shape.

10. The material of claim 1 wherein the material is stored on a roll.

11. The material of claim 1 wherein the metal fibers are stainless steel.

12. The material of claim 1 wherein the material has a density between 800 GSM and 4000 GSM.

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