Patent GB-997205-A (GB)
Title: Moulded felt and the manufacture thereof
IPC: A42C1/02
Filed: 1962-09-18
Abstract: 997,205. Fibrous fabrics. COMMONWEALTH SCIENTIFIC & INDUSTRIAL RESEARCH ORGANISATION. Sept. 18, 1962 [Sept. 27, 1961; April 18, 1962; July 23, 1962], No. 35444/62. Heading D1R. A felt having at least one non-planar surface is made from subjecting a fibrous mass consisting wholly or largely of feltable fibres treated with steam or other felting fluid to pressure and to relative vibratory movements within a mould comprising separable members 10, 12 and wherein the mould is formed at least partly of resilient material and one at least of the mould members has a non-planar moulding surface adapted to effect a distribution of the fibres within the mould space. The felt may be made of fibres of wool or rabbit's fur or a mixture of fibres including synthetic fibres. The felt produced is of approximately uniform density throughout. In one embodiment, Fig. 1, a batt 14 of feltable fibres is compressed between platens 10, 12 at least one of which is arranged to be vibrated horizontally. The platen 10 is formed with projections 10a, 10b, and recesses 18, 18a, the ends of the projections 10a being convex and the ends of the projections 10b inclining upwardly and outwardly from the centre thereof, as shown. To assist in gripping the batt, the surface of the platen 12 is roughened or lined with a frictional material, e.g. heavy canvas 16. The illustrated portion of the platen 10 is composed of rubber or other resilient material. To prevent slippage of the felt, as the operation proceeds, the amplitude of the vibrations is decreased. Preferably, the required felting pressure is progressively applied as the operation proceeds. The batt may be subjected to a fluctuating pressure e.g. by imparting vertical vibrations to either of the platens 10, 12. The felting fluid may be supplied through apertures (not shown) formed in one or both of the platens 10, 12. The felt formed may have a pattern of indentations in the surface only or may be of lace-like form having spaced openings extending completely therethrough. Soluble fibres or other soluble material, e.g. alginates, strips of paper or cellulosic material removable by carbonizing with sulphuric acid, may be contained in the batt to render the felt more soft and more porous. The relief pattern may be formed on either or both of the platens 10, 12 and preferably is formed on a replaceable mat of rubber. In a modification, Fig. 6 (not shown), two sheets of felt are formed simultaneously by interposing a rubber core sheet between two batts 14 arranged between the platens 10, 12. In a further modification, Fig. 7, an endless rubber belt 26 moves intermittently across the low platen 28 and has the required pattern moulded thereon, the platens 28, 34 being relatively vibratable. An industrial felt mitten 46, Fig. 10, is formed by pressure and vibration between plates 48, 50, Fig. 8, around a floating core member 54 which may be of rubber or of soluble material so as to be removed without cutting the article. Some articles may be formed using core members having a relief pattern thereon, e.g. a beret, Figs. 11 and 12 (not shown). A hat mould, Fig. 13, comprises an upper mould member 64 shaped as shown and a lower mould member 62 having a projection 62a. Preferably, the member 62 vibrates laterally and the member 64 vertically. A garment bodice may be formed from a preshaped, compressed batt steam pressed or bonded with a suitable bonding agent, such as soap or gelatine. In a further embodiment, Fig. 18, a mould for forming a circular felt disc comprises rigid plates 70, 74 and a resilient body 72 preferably secured to the plates 70, 74. A rigid member 80 is vertically movable to apply pressure to the feltable material. The plate 70 is vibrated in its own plane, The body 72 may be reinforced by coaxial rings 82 or by spaced rods 84. In a still further embodiment, Fig. 19, parallel rollers 36 are reciprocated axially and coact with rollers 38 in an upwardly urged vertically movable frame. The rollers 36, 38 are driven in unison. The batt 30 is supported between the rollers by an endless band 39 and an endless belt 40 having a pattern 40a thereon. The moulds may be formed of rubber surrounded or backed by a filling material, e.g. fragments of rubber or a viscous liquid, polyvinyl chloride or felt.