A FILL OR EFFECT MATERIAL

Abstract: A method of manufacturing a fill or effect material, the method including feeding a synthetic or natural fibrous material 2 to a woollen opening mechanism 1 with its outlet 13 closed, running the opening mechanism 1 for a predetermined period, opening the outlet 13 from the opening mechanism 1 so that the rotating member 9 throws therefrom a plurality of modified neps, each of which has a nep shaped region from which extends a tail of fibres which modified neps are hereinafter referred to as long tailed neps. The fibrous material can be scoured wool, a synthetic fibrous material or woollen fibres in an unclean state with vegetable matter and other contaminants entrained therewith. In addition there is provided a mechanism for manufacturing a fill or effect material, the mechanism including a means 3 for feeding a synthetic or natural fibrous material 2 to a housing 8 having a closable inlet and a closable outlet 13, the housing 8 forming a chamber in which a rotating member 9 is mounted, the rotating member having on its periphery a plurality of teeth 10 which co-operate with teeth on the inner pheriphery of the chamber, the arrangement being such that material fed through the inlet and allowed to spin in the closed chamber for a predetermined period is formed by the interaction of the teeth into a plurality of modified neps each of which has a nep shaped region from which extends a tail of fibres which modified neps are hereinafter referred to as long tailed neps. The housing 8 preferably includes a fan doffer type roller 14 alongside the rotating member 9, the doffer type roller rotating at a higher speed than the rotating member and being adapted to beat from the teeth 10 on the rotating member 9 the partly processed material and feed same toward the outlet.

Description: The invention relates to a process for producing a fill material or effect fibre and a fill or effect fibre material produced thereby which can be used in bedding products or to produce effect yarns. A number of materials are currently used as fill materials in duvets, eiderdowns, jackets, sleeping bags and other such items. The fill material is chosen for its light weight, fill ability and insulating properties. Known materials used in these situations include synthetic fills, e.g. dacron and carded wool and down. The known fill materials suffer from inherent disadvantages, for example, carded wool because of the linear orientation of its fibre suffers in use from disentanglement thereby resulting in a loss in its bulk. At present existing knops or neps produced from woollen fibres are used to create effect yarns and the knops or neps are produced in a number of ways. Each knop is a small ball of entangled fibres which are wrapped and/or felted on themselves. A problem with existing knops or neps in effect fibres is that there is a lack of entanglement between the fibres of the knop or nep and the fibres of the yarn with which they are entrained. This can result in the knops or neps falling off or away from the yarn or effect material. An object of the present invention is to provide a process for producing a fill material or effect fibre material and a fill or effect material produced thereby. A further object of the present invention is to provide an effect material usable in the preparation of synthetic and natural effect yarns for example in woollen or semi-worsted processing. Yet a further object of the invention is to provide a process for handling wool and wool textiles in a rapid and efficient manner which results in the removal of vegetable matter and other contaminants from the wool and wool textiles. Further objects and advantages of the invention will become apparent from the following description which is given by example only. According to a first aspect of the present invention there is provided apparatus for manufacturing a fill or effect material comprising means for feeding a synthetic or natural fibrous material to a housing having a closable inlet and a closable outlet, the housing forming a chamber in which a rotating member is mounted, the rotate member having on its periphery a plurality of teeth which co-operate with teeth on the inner periphery of the chamber, the arrangement being such that material fed through the inlet and spun at high speed in the closed chamber for a predetermined period is entangled and felted by the interaction of the teeth into a plurality of long tailed neps each of which has a nep shaped region from which extends a tail of fibres. The housing preferably includes a fan doffer type roller alongside the rotating member, the doffer type roller rotating at a higher speed than the rotating member and being adapted to beat from the teeth on the rotating member the partly processed material and feed same toward the outlet. Preferably, the rotating member can rotate at a speed of about 200 rpm while the doffer roller can rotate at not less than 500 rpm. The housing can be a woollen opening mechanism in which the relationship between the standard worker stripper rollers and the swift can be reversed. The long tailed neps if produced from scoured wool or synthetic fibrous material can be used as a fill or effect material. The long tailed neps if produced from unclean wool and wool textiles is in a cleansed state usable in a variety of further wool processing steps. An electronic control system can be used to regulate the time the door of the opening mechanism is closed, the time of spraying of the water into the fan doffer region, the rate of feed of the input material and the time the outlet of the machine is held open is an essential feature of adaption of the mechanism for industrial use. If a standard woollen opening mechanism is used it can have one or more of its stripper and worker rollers removed or modified prior to the mechanism being used to produce the long tailed neps. According to a second aspect of the present invention there is provided a method of manufacturing a fill or effect material, the method comprising feeding a synthetic or natural fibrous material to an opening mechanism with its outlet closed, rotating the opening mechanism for a predetermined period, opening the outlet from the opening mechanism so that the rotating opening mechanism throws therefrom a plurality of long tailed neps, the neps being formed by a combination of the fibrous material being rotated in a confined chamber of the opening mechanism and the fibrous material being entangled by the interaction of teeth on a rotating member in the chamber with teeth situated at the inner periphery of the opening mechanism, each of the neps has a nep shaped region from which extends a tail of fibres. The fibrous material can be scoured wool, a synthetic fibrous material or woollen fibres in an unclean state with vegetable matter and other contaminants entrained therewith. The method can in addition include fitting an arrangement for spraying water into a fan doffer region of the opening mechanisms. For example the water can be sprayed into a fan doffer region of the opening mechanism. The amount of water sprayed can be varied to alter the characteristics of the long tailed nep material produced. The method can also include adding water to a woollen fibrous material prior to its insertion into the opening mechanism. According to an alternative aspect of the invention there is provided a process for treating long tailed neps, the process including treating the long tailed neps in a solvent scouring process including tumbling the long tailed neps in a solvent scouring machine to increase the entanglement of the peripheral fibres with each other to reduce the tendency of the dried long tailed neps to form clumps. The product produced by this process is referred to hereinafter as soft knops. The solvent scouring can include the use of any dry cleaning solvent which has added thereto treating chemicals giving particular additional properties to be added to the properties of the soft knops. The additive can include a silicon treatment. Further aspects of the invention will become apparent from the following description which is given by way of example only. Examples of the invention will now be described with reference to the accompanying drawings in which: Figure 1 : is a schematic section through a woollen opening mechanism modified in accordance with the present invention; Figure 2: shows an example of spray boom adapted to fit in the opening mechanism shown in Figure 1; Figure 3: shows unmodified worker and stripper rollers of the type incorporated in the conventional woollen opening mechanism; Figure 4: shows the worker and stripper rollers of Figure 3 in a modified form usable according to the present invention; and Figure 5: shows on an enlarged scale a photograph of a typical long tailed nep. The invention utilizes as an input product either a synthetic or natural fibrous material and the example will be described with reference to the use of a scoured fleece or alternatively a mixture of waste from other wool treatment processes. The fibre orientation of the input product is not important. In Figures 1 to 4 an existing woollen opening machine 1 is utilized. The woollen opening machine 1 is normally used to open or increase the bulk of woollen fibres. In normal use the opening machine 1 has the input material 2 fed onto feeding aprons 3 via a feed hopper 4. The feed hopper has an input feeder 5 which fills the feed hopper 4. The feeder 5 can be an elevator 6 and feed roller 7 adapted to convey input material 2 to the hopper 4. The woollen opening machine 1 has a drum shaped housing 8 within which is mounted a drum or swift 9 on the periphery of which there is a random array of teeth 10 which catch the wool from a set of feed rollers 11 to which the fibres are directed by the feeding apron 3. Normally the input material 2 is carried through the housing passed stripper and worker rollers 12 (shown in conventional form in Figure 3). The teeth on the rollers 12 remove some of the fibres from the teeth 10 as they rotate. The opened fibres are beaten from the swift 9 by a fan doffer roller 14 and are normally blown or dumped from an outlet 13 at the end of the opener. The fan doffer roller 14 is mounted in the extension 15 of the housing 8. In the past the woollen material has been removed for further processing and is in an opened condition relative to its initial compressed form so as to be suitable for the next processing step. As shown in Figure 4 the opener can be modified and the worker and stripper rollers 16 and 17 respectively of the conventional construction (as shown in Figure 3) are reversed in position so that the path of the material 18 is in part changed as indicated in the different yarn paths shown in Figures 3 and 4. One of the sets of worker stripper rollers 12′ is shown removed from the mechanism. When modified in accordance with the present invention the outlet 13 is preferably positioned relative to a collector cage 19. The operation of the outlet 13 can be pneumatic as shown and the flow of material is in the direction of the arrows shown. The direction of flow and direction of rotation of the respective rollers are shown in the drawings. The fan doffer roller extension 15 of the housing 8 can have mounted therein a spray boom 20 (shown in Figure 2) connected to a supply of water to dampen the material being spun in the housing 8. The applicants have discovered that by feeding the input material 2 to such a modified opening machine as shown in Figure 1 with its normal outlet 13 closed, running the opener for a preselected time controlled by a timer in a controller 21 there is produced an end product which has a fibre orientation which lends itself for a variety of uses for example as a fill or effect material. The preselected time can depend on the input material. The applicants have discovered that with modifications to the stripper and worker rollers 16, 17 as shown in Figure 4 and with the doffer or fancy roller 14 retained in the housing 8 a proportion of the wool is beaten from the teeth 10 by the beaters of the doffer roller to be spun at high speed within the housing 8 or extension 15 until the outlet 13 is opened. The fibres of the output material are randomly wrapped on themselves to produce a plurality of nep like products from each of which a tail extends with a high degree of entanglement between the nep shaped part and its tail. Such an end product is referred to as a long tailed nep. A typical example of a long tailed nep is shown in Figure 5. In the drawing the long tailed nep is shown enlarged to about twice its normal size. The applicants' trials have indicated that the long tailed neps maintain their fibre orientation and are therefore useful as a substitute fill material or effect material. The controller 21 preferably includes an infinitely variable automatic sequence controller for a single or double spray cycle usable to produce bath loads of soft knops. A typical operating sequence includes the following steps: (0) Delay Start (1) Feed Time (2) Hold For 1st Spray (3) Spray Time (4) Hold For 2nd Spray (5) Spray Time (6) Hold Empty Time (7) Empty Time (8) Delay Close Trap. For single spray cycle the controller can jump steps 3 to 6. A minor problem with the use of the long tailed neps formed by the process described hereinbefore is that in use the long tailed neps have a tendency to clump together thus reducing in part their effectiveness as a fill or insulation material. This is caused by interfibre entanglement between the loose or free fibres on the periphery of the long tailed neps. In order to ameliorate this problem the long tailed neps as produced can be immersed in a dry cleaning solvent in a dry cleaning machine. The drum of the dry cleaning machine is rotated thereby tumbling the neps while immersed in the solvent. The neps are then spun dry and dried whilst being continually tumbled. The applicants have discovered that the treated long tailed neps when dry have their peripheral hairs folded into the central felted region of the nep. The surface of the treated neps therefore has few if any free fibre ends which can link with other free fibres to cause clumping of the treated long tailed neps. The size of the treated long tailed neps is dependent on the initial fibre length and diameter and the products are referred to herein as soft knops. A variety of sizes can be produced to suit particular use requirements. In certain circumstances the dry cleaning solvent can have added thereto additives, for example, a silicon additive to produce in the final product particular properties. For example a silicon treatment produces a more slippery product which moves readily relative to each other when incorporated in a finished product. Preferably the input material fed into the opening machine is dampened as this can improve the wrapping entanglement of the fibres forming the product while it is formed in the opening machine. The applicants' trials have shown that if the material is allowed to be spun in the opening machine for at least 20 seconds and typically 60 seconds an acceptable end product is produced. Alternatively a modified wool dag crushing machine can be used or a machine can be purpose built specifically to make the long tailed neps. Such a machine would preferably have a fan doffer roller or similar device capable of revolving at in excess of 500 rpm. Facility to fully enclose the device for a predetermined period is also desirable. Thus by this invention there is provided a process for producing a fill or effect woollen material which retains its bulk and fibre orientation during normal use conditions.

Claims: Apparatus for manufacturing a fill or effect material comprising means (3) for feeding a synthetic or natural fibrous material to a housing (8) having a closable inlet and a closable outlet (13), the housing forming a chamber in which a rotating member (9) is mounted, the rotating member (9) having on its periphery a plurality of teeth (10) which co-operate with teeth on the inner periphery of the chamber, the arrangement being such that material fed through the inlet and spun at high speed in the closed chamber for a predetermined period is entangled and felted by the interaction of the teeth into a plurality of long tailed neps each of which has a nep shaped region from which extends a tail of fibres. Apparatus according to claim 1 in which the housing (8) is a woollen opening mechanism (1) having a set of stripper and worker rollers (12) which provide the teeth at the inner periphery of the chamber, a fan doffer roller (14) and a swift as the rotating member (9). Apparatus according to claim 2 in which one of the stripper and worker rollers (12') is removed and in which the relationship between the worker stripper rollers (12) and the swift (9) thereof is reversed. Apparatus according to claim 3, in which the swift (9) rotates at about 200 rpm while the fan doffer type roller (14) rotates at not less than 500 rpm. Apparatus according to any preceding claim further comprising means (20) for spraying water into the region (15) of the fan doffer roller (14), and an electronic control system to regulate the time the outlet (13) of the housing (8) is closed, the time of spraying of the water into the fan doffer region (15), the rate of feed of the input material (2) and the time the outlet (13) of the machine is open. Apparatus according to claim 5 in which the material is spun in the opening machine (1) for at least 20 seconds. A method of manufacturing a fill or effect material, the method comprising feeding a synthetic or natural fibrous material to an opening mechanism with its outlet closed, rotating the opening mechanism for a predetermined period, opening the outlet from the opening mechanism so that the rotating opening mechanism throws therefrom a plurality of long tailed neps, the neps being formed by a combination of the fibrous material being rotated in a confined chamber of the opening mechanism and the fibrous material being entangled by the interaction of teeth on a rotating member in the chamber with teeth situated at the inner periphery of the opening mechanism, each of the neps having a nep shaped region from which extends a tail of fibres. A method according to claim 7 in which the method additionally includes spraying water into a fan doffer region of the opening mechanism. A method according to claim 8 in which the amount of water is varied to alter the characteristics of the material produced. A method according to any of claims 7 to 9 including adding water to the fibrous material prior to its insertion into the opening mechanism. A method according to any of claims 7 to 10 in which the fibrous material is scoured wool, synthetic fibrous material or unclean woollen fibrous material. A method according to any of claims 7 to 11 in which unclean woollen fibrous materials are spun in the opening machine (1) to remove vegetable matter and other contaminants simultaneously with the formation of long tailed neps. A process for treating long tailed neps produced by either the method of claims 1 to 6 or from apparatus of claims 7 to 12, the process comprising treating the long tailed neps in a solvent scouring process including tumbling the long tailed neps in a solvent scouring machine to increase the entanglement of the peripheral fibres with each other to reduce the tendency of the long tailed neps to form clumps when dried to thereby form soft knops. A process according to claim 13 in which the solvent scouring includes the use of dry cleaning solvent which has added thereto treating chemicals giving particular additional properties to be added to the properties of the soft knops. A process according to claim 14 in which the additive is a silicon treatment agent.

Inventors: CLARE, LESLIE THOMAS, JONES, MELVIN CUSTODIAN HOUSE, MCFARLANE, IAN DUNCAN, RADFORD, EDWARD CHARLETON, WALLS, RICHARD JAMES, WATSON, MARK
Applicants: WOOL RESEARCH ORGANISATION OF NEW ZEALAND INC.
Application year: 1986
Main classification: D01G9
IPC codes: D01G15, D01G9, D01G99