Patent Publication Number: US-8991020-B2

Title: Hand held felting machine

Description:
BACKGROUND 
     1. Field 
     The present disclosure relates to a portable, powered hand held machine for felting a material. 
     2. Description of Related Art 
     Various crafts can use fabrics or materials that are meshed together through a process called felting. For example, quilters can use pieces of felted fabrics. 
     Industrial machines such as those disclosed in U.S. Pat. Nos. 3,703,752; 4,070,738; 4,384,393; 4,891,870; and 7,430,790 have been used to produce felted webs of material. One disadvantage of such devices is that a user is generally limited to factory or industrial produced designs of a larger scale. 
     Personal felting machines in the form of table-top designs that look like sewing machines have been provided in the market by companies such as Janome and Baby Lock, and the noted assignee, Simplicity. However, such machines can be limiting, in that they are limited in area for which the fabric can be moved in, as well as an area that the machine is positioned on. Moreover, performing felting on smaller areas is difficult. 
     SUMMARY 
     One aspect of the disclosure provides a hand held felting device. The device has a body with a motor therein that is configured to selectively receive power from a power source. A handle is attached to the body for holding and for moving the body relative to materials for felting. One or more felting needles are mounted to a shaft in the body that is configured to move the one or more felting needles in a continuously reciprocal motion. The motor is configured to selectively move the shaft reciprocally upon receipt of power from the power source such that the one or more felting needles are moved continuously reciprocally in order to felt two or more materials together when the body is positioned adjacent and relative to the two or more materials. 
     Another aspect of the disclosure provides a portable felting device. The device has a body with a motor therein that is configured to selectively receive power from a power source. A handle is attached to the body for holding and for moving the body relative to materials for felting, and one or more felting needles are removably mounted to a needle holder. The needle holder is removably connected to a shaft in the body that is configured to move the one or more felting needles in a continuously reciprocal motion upwardly and downwardly along a vertical axis. The motor is configured to selectively move the shaft reciprocally along the vertical axis upon receipt of power from the power source such that the one or more felting needles are moved to felt two or more materials together. The device also includes a safety switch that is configured for movement between a first position for preventing movement of the shaft and the one or more felting needles and a second position for activating the motor to move the shaft and the one or more felting needles continuously reciprocally. 
     Yet another aspect of the disclosure includes a method for felting materials using a hand held felting device having a body with a motor therein that is configured to selectively receive power from a power source; a handle attached to the body for holding and for moving the body relative to materials for felting; and one or more felting needles mounted to a shaft in the body, the shaft configured to move the one or more felting needles in a continuously reciprocal motion. The motor is configured to selectively move the shaft reciprocally upon receipt of power from the power source such that the one or more felting needles are moved continuously reciprocally in order to felt two or more materials together. The method includes:
         providing the hand held felting device;   providing the materials;   providing power to the motor from the power source;   manually positioning the one or more felting needles adjacent to the materials, and   felting the materials.       

     These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description of the preferred embodiments relative to the accompanied drawings, and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a side view of a hand held felting device in accordance with an embodiment of this disclosure. 
         FIG. 2  shows a side view of a power supply device and cord for use with the device of  FIG. 1 . 
         FIG. 3  shows a cross sectional view of the hand held felting device of  FIG. 1  taken along line A-A in  FIG. 1 , showing internal parts of the device. 
         FIGS. 4A and 4B  show a detailed plan and top views of a needle holder used in the hand held felting device of  FIG. 1 , with and without needles therein, in accordance with an embodiment. 
         FIG. 5  shows accessories for use with the hand held felting device of  FIG. 1 . 
         FIG. 6  illustrates a method of use of the hand held felting device of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The hand held felting device of the present disclosure is designed to felt two or more materials together, such as, but not limited to, yarn, cotton, silk, satin, felt, wool, and canvas. Needle felting is a process that meshes fiber to fiber with an up and down motion. As will be described further herein, the felting of the materials is accomplished by manually moving the device in an up and down motion across fibers of the material. The device can use any number of interchangeable needles, which are held in a needle holder that is attached to a shaft that is selectively movable by a motor. Moreover, in an embodiment, a retractable guard is used as a safety device that limits power to the motor until fully compressed. The hand held felting device may be used to felt materials for smaller projects or in reduced areas, such as those used in any type of project including crafting, sewing, embellishing, needlework, and quilting, for example. 
       FIG. 1  illustrates a side view of a hand held felting device  10  in accordance with an embodiment of this disclosure. The hand held felting device  10  includes a housing or body  12  that is configured to house motor  20 , a gear train  26 , safety switch  28 , driver  30 , shaft  32 , and other components for supplying power and movement to the parts of hand held felting device  10 . Motor  20 , such as an electrically powered motor (see  FIG. 3 ), is contained in the body  12  and is configured to selectively receive power from a power source. For example, an input jack  13  may be provided on a rear side of the body  12  to receive a plug device with power cord  22  and power supply  24 , such as shown in  FIG. 2 . For example, the device may be designed for universal electronic sources and be UL approved for the United States and Australia. The plug device and its cord may be attached directly to, or removably attached to, the device via jack  13 , for example. The cord  22  may have a connection device at one end for connection to the power supply  24  and a plug at its other end for connection to an electrical wall outlet. Motor  20  may be an AC induction motor or a DC motor. Motor  20  operates using electrical power to rotatably drive a shaft  32  upon receipt of power so that felting needles mounted in the device  10  are reciprocally moved. In an embodiment, the speed of the motor  20  used in the hand held felting device  10  is between about 800 to about 900 rpms. However, other motor speeds (e.g., 700 rpms) may also be used, and thus it not limiting. 
     A handle  14  is attached to the body  12  for holding the device and for its portability. Moreover, the handle  14  is used for moving and controlling the body  12  and felting needles therein relative to materials for felting. One or more felting needles  40  are mounted to a shaft  32  in the body  12  and are configured for movement such that fibers of two or more materials can be felted or meshed together. Specifically, the motor  20  is configured to selectively move the shaft  32  reciprocally upon receipt of power from the power source by rotating gears of the gear train  26 , which in turn moves the driver  30  that is operatively connected to the shaft  32 . The gears of gear train  26  may be spur gears, for example, which are selectively rotated about a respective axis (e.g., horizontal axes). In the exemplary illustrated embodiment of  FIG. 3 , for example, gear train  26  comprises a first gear  50  that is configured to be rotated about its axis by motor  20 . First gear  50  cooperatively rotates a second gear  52  and a third gear  54  about their same axis, which in turn rotates a fourth gear  56  about another axis (each of the axes being horizontally parallel to each other). The rotation of fourth gear  56  operatively causes activation of driver  30 . Specifically, the driver  30  is rotated about the same axis as fourth gear  56  in a circular motion. Driver  30  is configured to impart a reciprocating motion to shaft  32  via a crank connection  35  to shaft  32 , which is formed by connecting a part of a rotating crank arm of driver  30  to a part on the shaft  32 . One or more guides such as guide  36  may be mounted in body  12  to guide and maintain movement of the shaft  32  within the body  12 . 
     The movement of shaft  32  in a reciprocal motion, as indicated by arrow  33 , is configured to move the one or more felting needles  40  in a continuously reciprocal motion. As shown in the cross-sectional view of  FIG. 3 , the shaft  32  and a plurality of felting needles  40  (in this illustrated case, six felting needles) are positioned for a continuously reciprocal motion upwardly and downwardly along a vertical axis Y-Y (an axis that is relative to a height of the machine) such that the needles move into, through, and from fibers of the materials so that the fibers are interlocked and meshed with each other. 
     Each of the needles is a felting or barbed needle that is configured to catch and intertwine fibers of material(s) it is inserted through. Such needles are generally known in the art and therefore are not described in detail herein. Also, differently sized and shaped felting needles may be used alone or in concert with other differently sized and shaped felting needles. 
     The vertical stroke of the felting needle(s)  40  used with this device should not be limiting. In an embodiment, the needle stroke of each needle is approximately ¾ inches long. 
     As shown in  FIG. 3  and in greater detail in  FIGS. 4A and 4B , the hand held felting device  10  may further include a needle holder  34  that is connected to the shaft  32 . The needle holder is sized so that it can fit within a stationary extension part  31  of the body  12  (further described below). The one or more felting needles  40  may be configured to be removably mounted to needle holder  34 . Needle holder  34  includes a rounded base  36  that has a number of openings  70  accessible on one side (e.g., a bottom or downward facing side) for receiving each of the needles  40  therein. When positioned and mounted in the openings  70 , each needle  40  mounted in the needle holder  34  is held and locked in place with fasteners that are perpendicularly accessible through holes  42  around a side of the base  36 . The holes  42  are threaded so as to receive a rotatable screw or fastener therein. In an embodiment, needle holder  40  is removably connected to the shaft  32  in the body  12 . It can include a bore  72  through a center of the base  36  so as to receive a mounting portion (e.g., a screw attached to shaft  32 ) therein for connection to the shaft  32 . 
       FIGS. 4A and 4B  show views of a needle holder  34  with and without needles therein. The number of felting needles  40  used in the device  10  is not meant to be limiting. For example, in an embodiment, based on the materials being felted, one to six needles may be mounted in needle holder  34 . However, any number of felting needles may be used in the machine. In an embodiment, one felting needed is used for felting (e.g., for finer detail work). In another embodiment, six felting needles are used for felting. Also, more than six needles may also be used. The needle holder  34  can be configured to hold any number of felting needles therein. 
     To remove and/or replace needles in the needle holder  34 , tools such as allen wrenches  44  and  46  and tweezers  48 , shown in  FIG. 5 , may be included with the hand held felting device  10 . The longer allen wrench  44  can be inserted into the device  10  (e.g., into the body  12 ) and into a fastener or allen screw inside the needle holder  40  (e.g., in a center portion thereof), then turned to loosen the respective screw. Using tweezers  48 , a user can grasp a needle or the holder itself and slide or pull the needle holder  40  out of the machine. Then, using the shorter and smaller allen wrench  46 , a user can insert an end thereof into a hole  42  of the needle holder  40 . Each hole  42  has a fastener or allen screw inside for holding and locking needles  40  therein (e.g., the fastener extends perpendicularly to the needle). The screw holding the needle for removal/replacement can be loosened by turning the allen screw in the respective hole  42 . Then, using tweezers  48 , the user can remove the old needle, and then insert a new needle into the needle opening. The user can hold the new needle in its opening while turning and tightening the allen screw in hole  42 . After any or all of the needles  40  are removed or replaced, as needed, the needle holder  40  can be inserted back into the machine using tweezers  48 , and then tightening the allen screw of the needle holder  40  using wrench  44 , to secure the holder in place for use. 
     In accordance with an embodiment, different types of needle holders can be used with hand held felting device  10 . For example, the removable felting needles  40  can be placed into modified needle holder (not shown) and mounted into the device  10  for use. 
     The hand held felting device  10  also includes a power (ON/OFF) switch  18  to control operation of and power to the portable device. The power switch  18  may be provided on a top side of body  12 —on handle  14 , for example—or anywhere else (e.g., a side wall) on the device  10 . On/off switch  18  includes a switch module (generally shown in  FIG. 3 ) mounted on an inside wall of body using fastening devices, and a manually engageable portion that moves pivotally between an ON position and an OFF position (i.e., a rocker switch). The switch module has a movable element (not shown) that connects to the manually engageable portion to move the switch module between its states. Movement of the manually engageable portion of switch  18  moves the switch module between states. In the illustrated embodiment shown in  FIG. 3 , the switch module connects a motor  20  to the power supply. This connection may be direct or indirect, such as via a controller. 
     In order to reduce or prevent injury to a user and to provide better control of the device  10  when felting, a safety switch  28  may be included with the device in order to selectively activate the motor  20  to move the needles  40  (or, alternatively, selectively prevent the motor  20  from moving the shaft  32 ). The safety switch  28  is configured for movement between a first position for preventing movement of the shaft  32  and the one or more felting needles  40  (e.g., by preventing activation of motor  20  for rotating gear train  26 ) and a second position for activating the motor  20  to move the shaft  32  and the one or more needles  40  continuously reciprocally. 
     In an embodiment, hand held felting device further includes a needle guard  60  operatively associated with the safety switch  28 . The needle guard  60  is configured to shield access to at least the ends of the one or more felting needles  40  in an extended (first) position and allow use of the one or more felting needles in the retracted (second) position. More specifically, body  12  has a stationary extension part  31  surrounding needle holder  34  and needles  40  when mounted in the body, and a movable arm  62  connected to the stationary extension part  31 . The movable arm  62  moves relative to the stationary extension part  31 . Attached to an end of the movable arm  62  is needle guard  60 . Throughout this disclosure, it should be understood that any reference to movement of guard  60  also includes movement of movable arm  62 . 
     The movable arm  62  and/or needle guard  60  are spring-loaded relative to stationary extension part  31  via one or more resilient devices (not shown). The resilient devices (springs) are mounted in the body  12  in order to force the arm  62  and guard  60  into a default extension position. By applying pressure to a bottom portion of needle guard  60 , for example, the springs are compressed, and both the needle guard and moveable arm  62  are moved to cover stationary extension part  31  and retracted towards an edge  45  of the body  12 . In addition to shielding a user from the needles, the needle guard  60  also cooperatively works with the safety switch  28 . Movement of the needle guard  60  between the extended position (where movable arm  62  is away from edge  45 ) and the retracted position (where movable arm  62  is adjacent edge  45 ) triggers movement of the safety switch  28  between the first position (in which it is activated to prevent the motor from running) and the second position (in which it is deactivated), respectively. That is, when the guard  60  is extended the safety switch  28  is provided in a position that prevents motor from running, and when the guard  60  is retracted, the safety switch is provided in a position to activate the motor. 
     In an embodiment, the needle guard  60  is moved to the second position when manual pressure is applied (e.g., in a downward direction) and used to push and compress the guard vertically in an upward direction (e.g., as shown by arrow B in  FIGS. 1 and 6 ) to the retracted (second) position from the extended (first) position (e.g., when pushed towards a work piece or materials for felting). Once the pressure or force is released, the force in the compressed springs moves the arm  62  and guard  60  back towards the extended position. Additional details regarding movement of guard  60  and use of the hand held felting device  10  are described further below. 
     Placement of the needle guard  60  in the retracted (second) position controls the safety switch  28  and thus activates the motor  20  to move the shaft  32  and the one or more needles  40  continuously reciprocally for felting. For example, even though a user may turn the power switch  18  to an “ON” position, the motor  20  would not rotate gear train  26  and thus move shaft  32  and needles  40 . Once the guard is compressed, power is supplied to the motor, and the shaft  32  and needles  40  reciprocate. Needle guard  60  allows a user to selectively enable the operation of the device  10 . Generally, the construction and operation of the switches  18  and  28  and devices for controlling a motor are well known, and any construction for these may be used. 
     Needle guard  20  is open at a bottom end to enable needles  40  to selectively extend outwardly therefrom when guard  60  is retracted. Needle guard  20  can be made of a clear material, such as a molded plastic, to enable the user to see the one or more needles  40  therethrough (e.g., so that a number of needles  40  mounted in needle holder  34  may be easily viewed). 
     In some embodiments, the guard  60  does not allow the motor to start movement of the needles  40  until it is fully compressed a predetermined distance. The predetermined amount or distance which needle guard  60  needs to be moved or compressed can vary, and should not be limiting. In an embodiment, for example, the guard is configured for moving at least one inch before the motor  20  is activated. In another embodiment, the predetermined distance is determined based on the distance which an edge of movable arm  62  moves to be positioned adjacent to edge  45 . In an embodiment, when the pressure towards a work piece is released by the user, such that the guard  60  is no longer retracted the minimum predetermined distance (e.g., the movable arm  62  moves away from edge  45 ), the safety switch is triggered and the motor  20  is deactivated, thus stopping movement of the needles  40 . 
     When using the hand held felting device  10  for felting, such as shown in  FIG. 6 , it is helpful to use a support such as a felting foam material on a back side of the material(s). This also prevents damage to the ends of the needles  40  as they puncture the support and it allows the needles to move through the fibers. The material or fiber for felting can be placed on a base of the support/felting foam. Felting can be performed in small sections, with the option of adding fibers/materials and layering the same to form a work piece for felting. 
     Once fibers are ready to be felted and positioned on the support, for example, the hand held felting device  10  is placed adjacent to or on top of the work piece. The power supply  24  for the device  10  is attached to the input jack  13  on the body  12  and a plug at the end of electric supply cord  22  is plugged into a polarized electrical outlet or wall socket. A user grasps the handle  14  and turns the power switch  18  is turned to its “ON” position. Using handle  14 , the user can apply manual pressure in a downward direction towards the work piece such that the needle guard  60  and movable arm  62  are retracted towards the body  12  and the safety switch  28  is deactivated, thus activating the motor  20  and the reciprocal movement of the one or more felting needles  40 . The user can continue to manually move the device  10  in an up and down motion across and around the fibers of material. When the motor  20  is turned on, the needles  40  will be pushed down into the foam to secure the fibers (as you push down) and continuously moved in a reciprocating manner for felting. When the device is lifted away from the work piece, the needle guard  60  and movable arm  62  are released (e.g., via spring motion) to cover the needles  40  and stop movement thereof. 
     The needles  40  do not need to be held in one place for a long period of time. A user can optionally move and apply the device  10  around a desired area to have the area for felting at least partially meshed, and then move the device over the entire work piece area several times until all of the fibers are secured to the user&#39;s satisfaction. The longer the fibers are punctured by the needles  40 , the more fused they will become. Both of the front side of the felted fabric and its back side will have been textured from the fibers that have been meshed together. 
     Once the felting of the work area on the work piece is complete to a user&#39;s satisfaction, the device  10  can be lifted to deactivate the motor  20 . The power switch can be turned to its “OFF” position when the device  10  is not in use. 
     In an embodiment, it is envisioned that the hand held felting device may receive power from batteries supplied in a battery compartment (not shown). The battery compartment may be provided as an alternative to or in addition to an electrical cord with a plug. 
     Accordingly, the herein disclosed hand held felting device  10  provides a portable, powered machine configured to felt materials, including materials with a reduced working area and/or that require smaller details, such as in areas that a standard power table machine can not be used, e.g., inside a pocket or pant leg, or within a middle of a project. The needles  40  are configured to mesh or intertwine fibers together to create new color and/or texture combinations. 
     The device  10  includes safeguards to ensure safety and prevent and/or reduce injury to the user. For example, switch  28  is designed to prevent reciprocal movement of the shaft  32  (and hence, the felting needle(s)  40 ) via deactivating the motor  20  when the needle guard  60  is in an extended, first position. Also, needle guard  60  is provided to prevent direct and/or accidental access to the needles mounted in the machine. Turning power off to the machine manually (e.g., using power switch  18  or unplugging it) and/or using switch  28  and guard  60  aids in preventing accidental injury to the user. 
     The construction and configurations of hand held felting device  10  are shown as examples and not intended to be limiting. Any parts of the device  10  may be made of plastic, metal, other materials, or any combination thereof. The parts of the device  10  may optionally be made from molded plastic. Also, each of the features described herein may be formed separately or integrally with the structures they are associated with. Devices such as fasteners, screws, or bolts, nuts, glue or adhesive, or other attachment and/or fastening devices may be used to secure parts together, if needed. Additionally and/or alternatively, shock absorbing elements, vibration absorbing elements, and/or springs may be used in hand held felting device  10 . 
     While the principles of the disclosure have been made clear in the illustrative embodiments set forth above, it will be apparent to those skilled in the art that various modifications may be made to the structure, arrangement, proportion, elements, materials, and components used in the practice of the disclosure. For example, it is to be understood that indicia may be provided on the housing of the hand held felting device. 
     It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems/devices or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.