Patent Application
20190309454
The invention relates to the production of felt.
“Felt” is a fabric formed by “felting” which entails mechanically agitating (rather than weaving) precursor material (such as wool, silk, gauze or velvet) until it is matted down to form a solid.
‘Nuno felt’ or ‘laminated felt’ is formed using a carrier material (often silk or light fabric) as part of the precursor material. The carrier material is typically woven and becomes enmeshed with the wool (and/or other precursor). The carrier can be a single layer base or as two layers below and above the wool (and/or other precursor).
There are a wide variety of felts to suit a wide variety of applications. “Industrial” felt is employed in applications such as sound deadening in cars, whereas “artisan” felt is highly sought after by the fashion industry.
Artisan felt is typically made by depositing precursor materials onto a flexible sheet of plastic film (or other suitable material). The precursor materials are laid out by hand to form a desired aesthetic. Often the precursor material is unspun wool fibre. Once the precursor material has been artistically laid out, it is wetted down and then overlaid by a further sheet of plastic film. This sandwich construction is then wrapped about a suitable carrier such as a soft roller and then secured in place on the roller with an elastic band (or other suitable restraint).
The wrapped roller is then rolled on a table top to agitate the precursor material. From time to time the artisan will inspect the material wrapped about the roller, and potentially vary the amount and location of the pressure that they apply thereto to achieve the desired degree of felting in the desired locations, e.g. to achieve uniform felting.
Selecting and laying out the precursor material is skillful and rewarding, whereas the rolling is hard work. By way of example, producing a scarf can entail up to 6,000 rolls of the roller. Larger items require more rolling. Producing a dress formed of artisan felt can entail in excess of 40,000 rolls.
Whilst the production of artisan felt is a rewarding craft that produces beautiful results, many artisans give the craft away as they age simply because the rolling becomes too hard for them. Accordingly, various attempts have been made to automate the rolling process, although these machines are not popular.
The existing rolling machines typically include a pair of parallel, horizontally-spaced rollers between which the precursor-wrapped roller is nested. A third roller of the machine is then screwed down from above to compress the precursor-wrapped roller. One of the three rollers of the machine is driven.
The present inventor has recognised that these existing machines are less than ideal.
Screwing down the top roller of such machines is burdensome and time consuming. This is particularly problematic since the top roller must be screwed up and down each time that the artisan is to check on the progress of the felting and/or to turn the precursor-wrapped roller about so that it is rolled in a different direction. Typically this will be done every 500 rolls or so.
The safety of typical existing machines is questionable. Surprisingly, many operate unguarded. The present inventor has recognised significant risk of injury. There is a risk of a crushing injury should one's hand be drawn into the machine. There is also a risk of injury should one's hair or article of clothing become entangled with any of the rollers. Some machines are guarded but do not allow the artisan to view or check the material positioning whilst the machine is operative. As such the material can skew and become tangled.
Most existing machines are conveniently-sized bench top units not suited to the production of larger items. For many, the purchase of a dedicated larger machine for such larger items is not economic and the storage of such a large machine is also problematic.
The present inventor has also recognised that the control of typical existing machines is rather rudimentary. Typical existing machines enable the direction of rotation to be varied by turning the precursor-wrapped roller about as previously described and allow the relative pressure to be varied by adjusting the screw-down mechanisms, but leave little room for other adjustments. This is in contrast to the nuanced and skilled approach of the artisan observing and hand-adjusting the location and amount of pressure and the number of rotations.
A search of patent literature revealed U.S. Pat. No. 3,331,113 disclosing felting apparatus not previously known to the inventor.
The felt and core combination 31, 32 is compressed between and driven to rotate by a trio of driven rollers. The upper roller 19 of those rollers is carried by an arm mounted to pivot about the joint 29 whereby the roller can be lifted away from the combination 31, 32 by lifting the handle 30.
At least preferred forms of the present invention aim to provide improvements in and for felting, or at least to provide alternatives for those concerned with felting.
One aspect of the invention provides a felting apparatus including
a carrier for externally carrying precursor material to rotate with the carrier;
a drive for driving the carrier and the precursor material to rotate; and
one or more agitators to agitate the rotating precursor material;
wherein each agitator is a non-driving agitator.
Preferably, each agitator is associated with a biasing mechanism
In this case, at least one of the agitators may be mounted to follow a path inclined so that the weight of the at least one agitator biases the at least one agitator towards the carrier. The apparatus preferably includes a mechanism by which the path is adjustable.
Another aspect of the invention provides a felting apparatus including
a carrier for externally carrying precursor material to rotate with the carrier;
a drive for driving the carrier and the precursor material to rotate; and
one or more agitators to agitate the rotating precursor material;
wherein each agitator is associated with a biasing mechanism
at least one of the agitators is mounted to follow a path inclined so that the weight of
the at least one agitator biases the at least one agitator towards the carrier; and
the apparatus includes a mechanism by which the path is adjustable.
The drive may be configured to periodically reverse the rotation of the carrier and the precursor material.
Another aspect of the invention provides a felting apparatus including
a carrier for externally carrying precursor material to rotate with the carrier;
a drive for driving the carrier and the precursor material to rotate; and
one or more agitators to agitate the rotating precursor material;
wherein the drive is configured to periodically reverse the rotation of the carrier and the precursor material.
The drive may be configured to periodically reverse after not more than three revolutions of the carrier and the precursor material in each direction. Preferably, the number of revolutions after which the drive reverses is user-selectable. Most preferably, the number of revolutions in each direction after which the drive reverses is separately user-selectable. To replicate hand rolling, and maximise agitation, reversing after one rotation is often desirable.
The apparatus may include a user-interface by which the drive is adjustable to vary at least one of:
Another aspect of the invention provides a felting apparatus including
a carrier for externally carrying precursor material to rotate with the carrier;
a drive for driving the carrier and the precursor material to rotate;
one or more agitators to agitate the rotating precursor material; and
a user-interface by which the drive is adjustable to vary at least one of:
Optionally, a number of rotations to be completed prior to automatic deactivation are variable via the user-interface. Optionally, a speed of rotation is variable via the user-interface. Optionally, a number or rotations to be completed prior to reversing direction is variable via the user interface.
The user-interface is a preferably touch screen.
The apparatus may include
an end structure at one end of the carrier;
another end structure at the other end of the carrier; and
one or more spacing members to position the end structure relative to the other end structure;
wherein the spacing member(s), carrier and agitator(s) are each releasably attachable to each of the end structure and the other end structure.
Another aspect of the invention provides a carrier for externally carrying precursor material to rotate with the carrier;
a drive for driving the carrier and the precursor material to rotate;
one or more agitators to agitate the rotating precursor material; and
a portion carrying the carrier and the agitator(s) and from which a module including the drive and a user interface is separable.
Another aspect of the invention provides a felting apparatus including
a carrier for externally carrying precursor material to rotate with the carrier;
a drive for driving the carrier and the precursor material to rotate;
one or more agitators to agitate the rotating precursor material;
an end structure at one end of the carrier;
another end structure at the other end of the carrier; and
one or more spacing members to position the end structure relative to the other end structure;
wherein the spacing member(s), carrier and agitator(s) are each releasably attachable to each of the end structure and the other end structure.
Preferably, each end of at least one of the agitators is carried by a respective pivotally mounted agitator-carrier. Each of the pivotally mounted agitator-carriers may have a mechanism by which an effective length of that agitator-carrier is variable. Preferably, each of the pivotally mounted agitator-carriers includes a two or more upwardly open formations into which a respective end portion of an agitator can be selectively dropped to select an effective length of that agitator-carrier.
Preferably, at least one of the agitators is mounted to be toollessly swapped out whilst the apparatus is in motion.
Preferably, the drive includes a motor co-axial with the carrier. The agitators may be rollers. The carrier may be a roller.
Another aspect of the invention provides a method, of felting, including
arranging precursor material to be externally carried by and rotate with a carrier;
machine rotating the carrier and the precursor material; and
arranging one or more agitators to agitate the rotating precursor material;
wherein each agitator is a non-driving agitator.
Another aspect of the invention provides a method, of felting, including
arranging precursor material to be externally carried by and rotate with a carrier;
machine rotating the carrier and the precursor material; and
arranging one or more agitators to agitate the rotating precursor material;
adjusting an inclined path that at least one of the agitators is mounted to follow to adjust a bias of the at least one agitator towards the carrier.
Another aspect of the invention provides a method, of felting, including
arranging precursor material to be externally carried by and rotate with a carrier;
machine rotating the carrier and the precursor material;
arranging one or more agitators to agitate the rotating precursor material; and
periodically reversing the rotation.
Another aspect of the invention provides a method, of felting, including
arranging precursor material to be externally carried by and rotate with a carrier;
machine rotating the carrier and the precursor material;
arranging one or more agitators to agitate the rotating precursor material; and
adjusting via a user interface at least one of:
a number of rotations to be completed prior to automatic deactivation;
a speed of rotation;
a number or rotations to be completed prior to reversing direction.
The adjusting preferably includes touching a touch screen of the user-interface.
Another aspect of the invention provides a method of varying a length of a felting apparatus;
the apparatus including
the method including
Another aspect of the invention provides a method of varying a length of a felting apparatus;
the apparatus including
the method including
Another aspect of the invention provides a method, of felting, including
arranging precursor material to be externally carried by and rotate with a carrier;
selecting an agitator from a plurality of agitators;
arranging the selected agitator to agitate rotating precursor material;
machine rotating the carrier and the precursor material.
The felting apparatus 1 includes a carrier 3, a drive 5 and a pair of agitators 7, 9.
In this example, the carrier 3 takes the form of an elongate roller the exterior of which is fitted with robust bubble-wrap material. Whilst in other variants the carrier 3 may have a simple cylindrical exterior, the present inventor has found that equipping the exterior of the carrier with a compliant and/or textured exterior leads to improved felting. In particular, the combination of compliance and texture offered by the robust bubble-wrap has been found advantageous.
According to a preferred use of the apparatus 1, a sandwich made up of precursor material between two layers of plastic film is wrapped about the carrier 3 and held in place with a series of elastic bands EB spaced along the length of the carrier 3.
The drive 5 in this example takes the form of an electric motor mounted coaxially with the carrier 3. A suitable coupling connects a stub axle at the end of the carrier 3 to the output shaft of the motor. The coupling and the arrangement by which the other end of the carrier 3 is mounted are preferably configured to enable the carrier 3 to be conveniently and toollessly swapped in and out. This enables the carrier 3 to be laid over the flat precursor and plastic film sandwich so that that sandwich can be conveniently rolled up, and then the wrapped carrier can be conveniently returned to the apparatus 1.
In a preferred form of the apparatus 1, each and every agitator of the apparatus is a non-driving agitator. In this example, the agitators 7, 9 take the form of idler rollers (i.e. non-driving rollers) and are mounted to bear against the carried precursor and film sandwich to agitate the precursor material as the carrier 3 and precursor therewith are rotated.
The agitators 7, 9 make take a wide variety of forms and the present invention is not limited to having the illustrated two agitators. Any convenient number of agitators could be applied. Indeed, the present inventor has achieved advantageous results by swapping the agitators 7, 9 in and out based on his own observation of the felting of the precursor material. In
In the illustrated example, the agitator roller 7 has a long cylindrical exterior. In other examples, the agitator may be configured to present an axially shorter working portion whereby the operator can position that shorter portion to preferentially work a selected band of the rotating precursor material, e.g. a band in which felting is not advancing as fast as in other regions. In one preferred form, the agitator takes the form of a sleeved roller whereby the sleeve can be maneuvered along the roller to a suitable location.
Non-roller agitators are also contemplated. By way of example, a stiff brush or flexible blade may also be employed.
The apparatus 1 includes an end structure 11, which includes the drive 5, and another end structure 13. Four spacing members 15 run parallel to each other to connect the end structure 11 to the end structure 13. In this example, the spacing members take the form of simple extruded profiles, although more elaborate (e.g. non-unitary) spacing members are possible.
The spacing members 15 serve to position the end structure 13 relative to the end structure 11. The end structure 13 includes an upright wall 13a perpendicular to the members 15.
The wall 13a has at its centre a socket 17 for receiving the stub axle at the end of the carrier 3. Of course, other mounting arrangements are possible. An agitator-carrier in the form of an arm 21 is carried on an inner side of the wall 13a and mounted to pivot relative thereto about an axis 23 perpendicular to the wall 13a. The arm 21 has a set of five upwardly-open cut-outs 21a into each of which an end extension of the agitator 7 is selectively placeable. When the agitator 7 is engaged with a selected one of the cut-outs 21a, the agitator 7 (or more specifically the centroid of the agitator 7) is constrained to follow the path P about the axis 23. By selecting a different one of the cut-outs 21a, the path P can be adjusted.
Suspending the agitator 7 in this way causes the weight of the agitator 7 to at least partly bear against the carrier 3 (or more specifically, the plastic film-precursor sandwich carried thereby). As such, the agitator 7 is biased towards the carrier 3. By adjusting the path P, the extent to which the agitator 7 bears against the carrier 3 can be adjusted.
The arm 21 is but one example of a mechanism by which the agitator 7 might be constrained to follow an adjustable inclined path. By way of example, the stub axle extension of the roller 7 might instead be mounted to roll down a ramp.
The effective angle of the arm 21 is the angle between horizontal and a notional line connecting the centroid of the agitator 7 to the axis 23. The effective length of the arm 21 is the distance between the axis 23 and the centroid of the agitator 7.
Without wishing to be bound by any particular theory, this geometry has been found to be particularly advantageous when using compliant rollers such carrier 3 equipped with bubble-wrap. When the carrier 3 is rotated in an anti-clockwise sense (as drawn in
Biasing the agitator towards the carrier 3 has appreciable safety advantages over existing devices in which rollers are rigidly located by screw-down mechanisms. The apparatus 1 can be safely operated without any form of guarding. If one's finger is inadvertently drawn into the nip-point between the rollers 7, 9, the arm 21 simply pivots away so that one's hand can be drawn out without injury or even any real discomfort. It will also be observed that the agitator 7 can be simply dropped into the cut-outs 21a. This combination of safety and simple toolless changeover allows for the agitator 7 to be swapped in and out whilst the apparatus 1 is in motion.
The end structure 13 further includes a guide 25 defining an upwardly-open vertical slot 25a into which an end extension of an agitator can be dropped so that the agitator bears against the carrier 3 under the agitator's own weight. This gives operators further choice and flexibility. The wall 13a is internally contoured so that the arm 21 sits within a suitable recess to be at least approximately co-planar with the guide 25, whereby the guide 25 is configured to receive the same agitators as the arm 21.
The agitator 9 is carried by an arm (not shown) similar to the arm 21 symmetrically arranged on the other side of the opening 17. The end structure 11 is likewise equipped with arms and a guide akin to the arm 21 and guide 25.
The apparatus 1 is advantageously equipped with a user interface (not shown) by which the drive 5 is controllable. A touchscreen device is a preferred form of user interface, in that it allows for convenient and intuitive operation. User-selectable icons may be presented via the touchscreen which may be particularly advantageous for older users potentially intimidated by other user interfaces. The use of a touchscreen device also enables more elaborate functions to be incorporated. By way of example, in a preferred form of the apparatus 1, the device may be programmed to follow a predetermined sequence of steps which may be user-customised. The touchscreen also provides a convenient method of providing a user with instructions.
Preferably, the device 1 is configured to periodically reverse its direction of rotation. By allowing only a limited number of turns in any given direction before reversing operation, the risk of an entanglement injury is reduced.
As described, the connections between the carrier 3 and agitator 7 on the one hand and the end structures 11, 13 on the other hand are preferably simple, releasable connections to enable these components to be conveniently removed. The connections between the members 15 on the one hand and on the other hand the structures 11, 13 are likewise preferably simple, releasable connections, e.g. screw joints, whereby the apparatus 1 may be quickly and conveniently stripped down to separate from each other the end structures 11, 13, the carrier 3, the agitators 7, 9 and the members 15. In this way, the apparatus 1 has a modular construction by which it can be conveniently extended to process large items. By replacing components 3, 7, 9 and 15 with longer items, the apparatus 1 is extendable without the expense of replacing the end structures and control arrangements, etc. With longer rollers in place, the machine can be used to produce pieces too bulky/awkward to produce by hand.
Of course, screw joints are but one example of a releasable connection that might be conveniently employed.
The roller unit 102 includes rollers 103, 107, 109 carried between an end assembly 111 and another end assembly not shown. The end assemblies are mutually connected by spacing members 115. The end assemblies together with members 115 constitute a portion for carrying the rollers 103, 107, 109. A stub axle extension 103a projects from the end of the roller 103 through the assembly 111.
The drive unit 104 includes a housing 133 having a front wall 135 from which four threaded spigots 137 project.
The assembly 111 incorporates an array of through holes 139 complementary to the spigots 137. The plate 135 further includes a through hole 141 to receive the extension 103a when the units 102, 104 are mated so that the spigots 137 project through the assembly 111. To mutually secure the units 102, 104 wing nuts are engaged with the projecting end portions of the spigots 137. The spigots 137 and wing nuts are but one example of a toolless connection mechanism by which the units 102, 104 are mutually connectable. Other forms of toolless connection mechanism, and indeed other connection mechanisms, are possible.
This toolless connection mechanism enables the unit 104 to be conveniently removed from the roller unit 102 to be mated with a different roller unit, e.g. with a roller unit having a different length.
The drive unit 104 further includes within its housing a motor unit 143 incorporating a motor 143a and a gearbox 143b. In this embodiment of the apparatus the motor unit 143 is a windscreen wiper motor. As in the apparatus 1 the main roller is driven by a driven portion coaxial to the roller but in this embodiment the coaxial driven portion takes the form of an output portion of the gearbox 143b co-operable with the extension 103a. The motor 143a is perpendicular to the roller 103. The gearbox 143b redirects the drive from the motor 143a.
The motor 143, and in turn the roller unit 102, is controlled via the user interface 145. A control arrangement 147 connects the user interface 145 to the motor unit 143.
The user interface 145 is preferably a touch screen. In this example it is a Nextion touch screen selected for its easy programmability although lower cost options are also contemplated. The control arrangement 147 incorporates a programmable PLC board 147a, which in this example takes the form of an Arduino UNO, and a motor controller board 147b. The motor controller board 147b takes signals from the PLC 147a and turns the motor on and off and changes its direction. The board 147b has sufficient capacity to handle the current drawn by the motor 143a and is controlled by the board 147a which is not able to handle this current.
Also within the housing is a power supply 149 from which a suitable lead exits the housing 133 to be plugged into, to receive power from, a mains supply. The power supply 149 supplies DC voltage to the board 147b which in turn powers the board 147a. A cooling fan 151 is mounted to a wall of the housing 133.
There are many simple and convenient methods by which the user interface and control arrangement 147 may be programmed and configured. Arduino code, C+ code or a mobile phone app would all be suitable for programming the PLC. Details of these and other options are now readily accessible online.
Pressing icons 153, 155 likewise leads the user to menu screens by which the number of rotations can be varied. In this example the number of rotations is variable between zero and 300% of a rotation, i.e. between zero and three rotations.
Associated with each of the icons 153, 155, 157 are display fields 153a, 155a, 157a which convey to the user the selected setting for that parameter. Display fields 159a likewise displays the number of cycles selected prior to operation, but once operation commences that field is dynamically updated to display the remaining number of cycles. At the same time display field 159b is dynamically updated to show the number of cycles completed.
The menu of
The button 161 is pressable to return the user to another menu from which a user can select the menu of
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016904914 | Nov 2016 | AU | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AU2017/051308 | 11/28/2017 | WO | 00 |
