PROCESS FOR MAKING NON-WOVEN INSULATING SHEETING AND PRODUCTS OF SUCH PROCESS

Abstract

A process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

Claims

1. A process for making insulating fabric, comprising: mechanically orienting wool fibers into a batting capable of being used for insulation; and tacking said batting to a scrim with a loom via needles coupled to a needle board of said loom, wherein said needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with said batting when stroking in a first direction, and substantial disengagement with said batting when stroking in a second direction, and wherein said tacking is performed primarily without the use of an adhesive.

2. The process of claim 1, wherein said wool fibers are one of a Merino or Alpaca superwashed wool fibers.

3. The process of claim 1, wherein a loom punch speed is one from a range of 200 to 400 strokes per minute.

4. The process of claim 1, wherein a needle penetration per square inch (NPPSI) of said loom is one from a range of 200 to 450.

5. The process of claim 1, wherein a needle density of said needle board is one from a range of 75 to 115 needles per linear board inch.

6. The process of claim 1, wherein said production width of said loom is a multiple of 30, 45, 36, or 72 inches, wherein a maximum production width is 160 inches.

7. The process of claim 1, wherein a scrim weight is one from a range of 8 to 34 grams per square meter.

8. The process of claim 1, wherein a loom speed is one of a range of 12 to 30 feet per minute.

9. The process of claim 1, wherein a batting weight is one of a range from 70 to 300 grams per square meter.

10. The process of claim 1, wherein a loom punch speed is approximately 400 strokes per minute, an NPPSI is one of a range from 350 to 450, said scrim is a weight of approximately 17 grams per square meter, and a loom speed is approximately 25 feet per minute.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The following figures are included to illustrate certain aspects of the present invention, and should not be viewed as an exclusive embodiments. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to one having ordinary skill in the art and the benefit of this disclosure.

[0015] FIG. 1 depicts a loom capable of generating wool batting from wool fibers, according to one or more embodiments.

[0016] FIG. 2 depicts a loom capable of tacking batting to a scrim, according to one or more embodiments

[0017] FIG. 3 depicts an enlarged cross-sectional view of one of the needles of a needle board, according to one or more embodiments.

[0018] FIG. 4 is a flow diagram of a process for making insulating fabric, according to one or more embodiments.

DETAILED DESCRIPTION

[0019] The present disclosure relates to processes for the production of non-woven insulating materials and to product of such processes.

[0020] An illustrative embodiment includes a process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

[0021] Other illustrative embodiments includes a non-woven insulating fabric that includes a batting comprised of wool fibers mechanically oriented in a fashion capable of being used for insulation, and a scrim having the batting tacked thereto via a loom having needles coupled to a needle board. The needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the batting is tacked to the scrim primarily without the use of an adhesive.

[0022] Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout the various views and embodiments of a unit. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of the ordinary skill in the art will appreciate the many possible applications and variations based on the following examples of possible embodiments. As used herein, the present disclosure refers to any one of the embodiments described throughout this document and does not mean that all claimed embodiments must include the referenced aspects.

[0023] FIG. 1 depicts a loom 100 capable of generating wool batting from wool fibers, according to one or more embodiments. As depicted, the loom 100 includes an intake 102, a means for mechanically orienting the wool fibers 104, and an output portion 106. In exemplary operations, the loom 100 may be fed clumps of wool fibers 108 via the intake 102. The loom 100 then processes the wool fibers 108 into more individualized strands, and then combines or mechanically re-orients the strands together via the means for mechanically orienting wool fibers 104, thereby forming a batting 110, as known to those skilled in the art. Such means for mechanically orienting wool fibers 104 may be, for example and without limitation, one or more wire cylinders 112, which comb and align the wool fibers 108, carting and crosslapping the wool fibers 108 into the batting 110. In some embodiments, the wool fibers 108, and therefore the batting 110, may be one of a Merino or Alpaca superwashed wool fibers as known to those skilled in the art. In further embodiments, the batting may be a weight ranging from 70 to 300 grams per square meter.

[0024] FIG. 2 depicts a loom 200 capable of tacking the batting 110 to a scrim 210, according to one or more embodiments. In some embodiments, for example and without limitation, the loom 200 may be a Hunter, model 54, double beam, down-stroke needle loom, as known to those skilled in the art. As depicted, the loom 200 (hereinafter, the needle loom 200), includes an intake 202, a needle board 204 that includes needles 206 coupled thereto, and an output 208. FIG. 2 also depicts the batting 110 and a scrim 210 arranged near the intake 202 of the needle loom 200, wherein the batting 110 and scrim 210 are tacked together by the needle loom to form an insulating fabric 212. In some embodiments, the scrim 210 may be a weight ranging from 8 to 34 grams per square meter.

[0025] In exemplary operations, the batting 110 and the scrim 210 are arranged near the intake 202 of the needle loom 200. The batting 110 and the scrim 210 are they conveyed into the needle loom 200, wherein they are tacked together via the needle board 204 and the needles 206. For example, the needle board 204 may move in a first direction A (e.g., in a downward direction or a down-stroke as implemented by some looms), wherein the needles 206 engage with and pull one or more wool fibers (e.g. wool fibers 108) in the direction A, and through the batting 210. Afterwards, the needle board 204 may move in a second direction B, opposite of direction A, (e.g. in an upward direction or an up-stroke as implemented by some looms), wherein the needles 206 disengage or release the wool fibers 108, thereby leaving the wool fibers 108 intertwined with the scrim 210 (i.e., tacked to the scrim 210) and forming the insulating fabric 212.

[0026] In some embodiments, the production width of the needle loom 200 is a multiple of 30, 45, 36, or 72 inches, including have a maximum production width of 160 inches. In further embodiments, the loom speed (i.e., the speed the insulating fabric 212 is produced) may range from 12 to 30 feet per minute.

[0027] Briefly referring to FIG. 3, depicted is an enlarged cross-sectional view of one of the needles 206 of the needle board 204, according to one or more embodiments. As depicted, the needle 206 includes a body 302 having barbed edges (shown as barbs 304), and a pointed end 306. Such barbs 304 enable the exemplary operation previously described. For example, as the needle 206 moves in the first direction A towards the batting 110, the barbs 304 may engage with one or more wool fibers 108, thereby pulling the wool fibers 108 through the scrim 210, and causing intertwinement of the two.

[0028] Afterwards, the needle may move in the second direction B, wherein the barbs 304 disengage from the wool fibers 108, thereby leaving the wool fibers 108 intertwined with the scrim 210 (i.e., tacked to the scrim 210) and forming the insulating fabric 212. Advantageously, such process of tacking enables a coupling of the batting 110 to the scrim 210 primarily without the use or employment of adhesives, resins, glues, or the like. Substantial reduction or elimination of such additional chemicals both reduces cost to manufacture the insulation fabric 212, and enables such manufacturing to be environmentally friendly.

[0029] Referring now back to FIG. 2, in some embodiments, a loom punch speed (the rate at which the needle board 204 completes one cycle of moving in the first direction A and back in the second direction B) may range from 200 to 400 strokes per minute. In further embodiments, a needle penetration per square inch (NPPSI) of the needle loom 200 may range from 200 to 450 NPPSI. Moreover, in some embodiments, the needle board 204 may have a needle density ranging from 75 to 115 needles 206 per linear board inch. In other embodiments, the loom punch speed is approximately 400 strokes per minute, the NPPSI is one of a range from 350 to 450, the scrim is a weight of approximately 17 grams per square meter, and the loom speed is approximately 25 feet per minute. Advantageously, such embodiments enable manufacturing of insulation with various bulk weight, CLO ranges, and durability.

[0030] FIG. 4 is a flow diagram of a process 400 for making insulating fabric, according to one or more embodiments. At block 402, wool fibers are mechanically oriented into a batting capable of being used for insulation. Such may occur via a loom, where chunks or clusters of the wool fibers are arranged at an input of the loom and conveyed therethrough. The wool fibers are broken into more individualized strands, and then recombined and reoriented back together, for example, via one or more wire cylinders or other similar means as known to those skilled in the art which may comb and crosslap the wool fibers into a resulting batting. In some embodiments, the wool fibers, and therefore the batting, may be one of a Merino or Alpaca superwashed wool fibers as known to those skilled in the art. In further embodiments, the batting may be a weight ranging from 70 to 300 grams per square meter.

[0031] At block 404, the batting is tacked to a scrim with a loom via needles coupled to a needle board of the loom (thus, hereinafter, the needle loom). In some embodiments, for example and without limitation, the needle loom may be a Hunter, model 54, double beam, down-stroke needle loom, as known to those skilled in the art. In other embodiments, the scrim 210 may be a weight ranging from 8 to 34 grams per square meter.

[0032] The needles may each include a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction (e.g., in a downward direction or a down-stroke as implemented by some looms), and substantial disengagement with stroking in a second direction (e.g., in an upward direction or an up-stroke as implemented by some looms), thereby substantially coupling the batting to the scrim to form the insulation fabric.

[0033] More particularly, in exemplary operation, the barbed edges act to couple the batting to the scrim by first engaging with one or more of the wool fibers of the batting when stroking in the first direction (e.g., the downward direction or down-stroke). As the needle moves through the scrim, the wool fibers are correspondingly pulled through the scrim, thereby causing intertwinement of the batting to the scrim. Afterwards, the needle moves in a second direction (e.g., in the upward direction or up-stroke) and the barbs disengage from the wool fibers, thereby leaving the wool fibers intertwined with the scrim (i.e., tacked to the scrim) and forming the insulating fabric. Advantageously, such process of tacking enables coupling of the batting to the scrim primarily without the use or employment of adhesives, resins, glues, or the like. In turn, due to the substantially reduction or elimination of additional chemicals, manufacturing costs are reduced, and the insulation fabric is more environmentally friendly.

[0034] In some embodiments, the production width of the needle loom is a multiple of 30, 45, 36, or 72 inches, including have a maximum production width of 160 inches. In further embodiments, the loom speed (i.e., the speed the insulating fabric is produced) may range from 12 to 30 feet per minute. In other embodiments, a loom punch speed (the rate at which the needle board completes one cycle of moving in the first direction and back in the second direction) may range from 200 to 400 strokes per minute. In further embodiments, a needle penetration per square inch (NPPSI) of the needle loom 200 may range from 200 to 450 NPPSI. Moreover, in some embodiments, the needle board may have a needle density ranging from 75 to 115 needles per linear board inch. In other embodiments, the loom punch speed is approximately 400 strokes per minute, the NPPSI is one of a range from 350 to 450, the scrim is a weight of approximately 17 grams per square meter, and the loom speed is approximately 25 feet per minute. Advantageously, such embodiments enable manufacturing of insulation with various bulk weight, CLO ranges, and durability.

[0035] Although the disclosure has been described and illustrated with respect to exemplary objects thereof, it will be understood by those skilled in the art that various other changes, omissions, and additions may be made therein and thereto without departing from the scope of the present disclosure.