IMPROVEMENTS IN FELTING MACHINERY
Year: 1877

page_text: LETTERS PATENT to James Ledger, Engineer and Patent Agent, of 61, Fleet
Street, London, for the Invention of "IMPROVEMENTS IN FELTING MACHINERY."
A communication from abroad by the Felting and Felt Hat Company, of
Brussels, in the Kingdom of Belgium, and Paris, in the French Republic.
aled the 5th April 1878, and dated the 8th October 1877.
PROVISIONAL SPECIFICATION left by the said James Ledger at the Office
of the Commissioners of Patents on the 8th October 1877.
JAMES LEDGER, Engineer and Patent Agent, of 61, Fleet Street, London.
IMPROVEMENTS IN FELTING MACHINERY." A communication from abroad by the
Felting and Felt Hat Company, of Brussels, in the Kingdom of Belgium, and Paris,
in the French Republic.
This Invention consists in machinery for making hat shapes for the manufacture
of felt hats in a more effectual and cheaper manner than heretofore.
It is well known that in making hat shapes the principal object is to obtain
thickness at the edges and thinness in the centre or top of the said hat shape.
The operation performed by this machinery is effected in a regular manner by
causing the hat shape to pass between two series of cylinders, to which continuous
rotary and alternate motions are given.
The operation is repeated as often as required, or the cone may be worked in
another machine placed close to the first.
The machines can be made double or triple, that is to say, furnished with the
same cylinders (arranged on one bed), to which motion is given by the same motive
organs.
The hat shape felted in the first machine is taken up by the second, and so on
until completed.
The machinery constructed according to this Invention is as follows:-A first
series of horizontal rollers are held in a suitable frame suspended on spindles, so that
a slight lengthwise to-and-fro motion may be given to the said rollers. A second
series of rollers are placed beneath the first series, and are also held in a frame
suspended on spindles.

page_text: The rollers are made of wood or such like suitable material, and are furnished
with axles working in plumber blocks, and pinions gearing into each other.
The cylinders are covered with compressed felt made of animal hair or of any
other felting substance.
The second or lower frame also receives a to-and-fro motion in a contrary direc-
tion to the top one in such a way that when the first series of rollers are working in
one direction the others shall work in a contrary one, and vice versa.
This double alternate motion is obtained as follows:-On each of the frames above
described are hinged links united at their other ends to double levers worked by
This
connecting rods fixed excentrically on the driving shaft of the machine.
arrangement gives the alternate motion to the frames and rollers, the said rollers
also receiving a rotary motion by means of a worm and worm wheel keyed on a
shaft furnished with a toothed wheel which gears with another toothed wheel fitted
on parallel shafts, which communicate their motion to the rollers.
On the first of the above shafts is keyed a toothed wheel, over which passes a
chain giving motion to an endless band working on rollers.
A trough is moved up and down by means of an excentric in such a manner that
when the said trough is down it plunges into warm water, and when up empties
itself on the felting rollers. This water can be used over again, and kept at the
same temperature by means of steam..
The hat shape, having been previously built up, is brought in front of the bed of
the machine, where it is taken up by the rollers, which act as rolling mills, carrying
them through.
The shape when taken up is not only compressed by the rotary motion, but also
crumpled by the to-and-fro motion of the two series of rollers, between which it is
forced to pass. This continual crumpling taking place crosswise during the forward
motion forms the felting by pressing the hairs one against the other in combination
with the slightly heated acidulated warm water above referred to.
The hat shape, after having passed through the rollers as often as will be found
necessary, comes out with an increase of thickness on the edges when it is carried
away by the aforesaid endless band.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent, and of
an Order of the Lord Chancellor, filed by the said James Ledger in the Great
Seal Patent Office on the 20th April 1878.
JAMES LEDGER, Engineer and Patent Agent, of 61, Fleet Street, London.
"IMPROVEMENTS IN FELTING MACHINERY." A communication from abroad by the
Felting and Felt Hat Company, of Brussels, in the Kingdom of Belgium, and
Paris, in the French Republic.
The improved felting machine has for its chief object the felting of hat shapes
intended to be made into felt hats.
The apparatus and means heretofore employed have failed to give the results
which are obtained by the improved machinery herein-after described.
As is well known in the felting of hat shapes the main object is to obtain greater
thickness towards the edges, whilst the centre or crown of the cone of the hat shape
should be left considerably thinner.
This operation is effected in a regular manner by causing the shapes to pass
between two series of rollers having a continuous rotary motion and an alternating
rectilinear horizontal motion.
The operation is repeated as many times as may be requisite, or the shapes may
pass through a second machine in connection with the first, but, as will be seen from
the improved arrangement of felting rollers, this combination of several machines is
not necessary, the simultaneous fulling and felting being regularly accomplished by
a few passes only.
Nevertheless double or triple machines may be constructed, that is to say, furnished
with similar rollers disposed on the same plane, the movements of which shall be
derived from the same organs.
A great economic in time and labour will thus be
obtained.
The shapes felted in the first machine will be taken again and finished in the
second, and so on.
It will not be necessary to enter into further detail at this part of the Specifi-
cation, as the description herein-after given in reference to the Drawings clearly sets
forth the details and their respective positions.
It will have been already obvious that the improvements introduced into felting
machinery by the said Invention have reference both to the general arrangement
and to the details of construction and manufacture.
And in order that the said Invention may be fully understood I shall now proceed
more particularly to describe the same, and for that purpose shall refer to the several
Figures on the explanatory Sheets of Drawings hereunto annexed, the same letters
of reference indicating corresponding parts in all the Figures.
Figure 1 (Sheet 1) is an elevation of the right-hand side of the improved felting
machine.
Figure 2 is an elevation of the opposite side.
Figure 3 is a general plan of the upper part of the machine corresponding to
Figure 1.
Figure 4 is a longitudinal vertical section of the machine taken transversely
through the axes of the rollers along the line A-B, in Figure 3.
Figure 5 (Sheet 2) is a front or end elevation of the said machine.
Figure 6 (Sheet 1) illustrates in detail the eccentric which actuates the trough or
scoop.
Figure 7 (Sheet 2) is a side elevation of the same machine, wherein the arrange-
ment for actuating the trough is modified by the substitution of a crank and con-
necting rod; Figure 8 is a plan of the same.
In these Figures A represents the series of upper rollers disposed horizontally in
a frame B, supported by four rods a, forming pivots, in order to permit of their
receiving a slight to-and-fro motion in the direction of the length of the rollers.
A' is the series of lower rollers, also disposed in a similar framo B, which is also

page_text: supported by the rods or pivots a'. These rollers are composed of a covering of
compressed felt of animal hair or other good, felting substance; they are traversed
by wrought-iron axles supported in bearings, and having toothed pinions keyed on
to one end gearing with each other for each series.
This
The second frame receives also a to-and-fro inotion, which is always opposed to
that of the first frame, so that when the first series of rollers is moved in one direc-
tion the second series is moved in the opposite direction, and vice versa.
double alternate motion is obtained by a very simple but peculiar arrangement of
mechanism, which enables the stroke to be varied at will. To each one of the two
frames there are jointed the links C, C¹, which are connected at their extremities to
the double levers b, actuated by the connecting rods D. These two rods, mounted
eccentrically upon the lateral shaft d, form cranks, and transmit their motion to the
levers b, and through them to the two roller-carrying frames; thus, at each revo-
lution of the shaft d, each of these frames receives a rectilinear horizontal motion,
which is greater or less according as the heads of the rods D are nearer to or further
from the axes of motion of the levers b.
The two series of rollers mounted in their frames equally receive this alternate
rectilinear motion. Each roller in addition receives a continuous rotary motion
more or less rapid by the aid of spur pinions G keyed on to the ends of the shafts of
the rollers. This rotary motion is communicated to them by the shaft & fitted with
a fast driving pulley L, and loose pulley L', and having also keyed thereon the
endless screw gearing with the worm wheel M, the shaft of which traverses the
frame B. Upon this shaft there is keyed a spur wheel, which gears in a similar
wheel N mounted upon a parallel shaft, which latter transmits the rotary motion to
the rollers of the frame B. Upon the first of these two shafts there is keyed a
toothed wheel O, over which passes an endless pitch chain, which actuates the endless
travelling apron F mounted on two rollers.
The fast and loose driving pullies P and P¹ are mounted on a shaft, the extremity
of which carries a bevel pinion gearing into the bevel wheel R, upon the shaft of
which there is keyed the eccentric Q. Upon the periphery of this eccentric runs an
antifriction roller, which imparts motion to the lever arm 7 (Figure 6, Sheet 1) the
shaft of which is carried in two bearings.
The scoop or trough J is mounted upon this rocking shaft, which follows the
movements of the eccentric, whence it follows that each time that the smallest radius
of the eccentric is in contact with the antifriction roller, the scoop or trough will
plunge into the liquid contained in the reservoir 1', and becomes filled with the said
liquid, and when the eccentric has made half a revolution the scoop or trough
describes an arc of a circle, and empties its contents into the box U, and so on.
The box U being slightly inclined towards the front, and perforated with holes u,
the liquid escapes, flows over the incline U, and by escaping through the slits made
in the inclined surface descends on to the felting rollers beneath.
The boiling water, which has moistened the rollers, and the articles to be felted
falls into the vessel I, and may be used over again, the said vessel being in commu
nication with the reservoir II by the pipes S; K is the emptying pipe and stop-
cock. In order to keep this liquid always at the boiling point superheated steam
is admitted into each reservoir by the pipe H (see Figure 1).
The thin picce called the "shape," which has been previously built up by an
apparatus for that purpose, is brought to the front of the machine by the workman,
who simply places it upon the board E, presenting it to the entrance between the
two first rollers, which is about on a level with or directly opposite the said
board.
"
The rotary motion of the rollers tends to draw in the "shape," and cause it to be
engaged between the succeeding pair, and so on throughout the series. The "shape
thus engaged is not only squeezed by the rotary pressure, but is moreover powerfully
rubbed by the to-and-fro longitudinal motions of the two series of rollers. It is this
rubbing which effects the felting properly speaking by pressing the hairs one against
the other. This operation can only be effectually carried out by submitting the

page_text: "
shapes" to the action of the acidulated boiling water already mentioned, which
operation will be herein-after more fully referred to.
The hat body or shape, after having undergone the said operation, issues from the
end rollers with an increase of thickness, and falls on to the endless travelling apron
F, which conducts it to the receptacle F1 (Figure 5). This operation is repeated as
often as may be found necessary.
The workmen in attendance on this machine must after each passage spread out
the hat body upon a convenient board or table in order to straighten it and refold
it in the proper manner,
but so that the folds shall not remain.
At Figures 7 and 8 (Sheet 2) there is illustrated another arrangement for actuating
the scoop by means of a connecting rod and crank. This arrangement enables the
endless pitch chain previously described to be dispensed with, and the endless band
to be driven from the shaft itself of its roller.
The right is reserved of applying this other combination of parts to the improved
felting machine as a substitute for the eccentric motion herein-before described.
Figure 9 (Sheet 2) is a side elevation of the machine, showing the application of
the connecting rod and crank and pressing screws.
It must be remembered that the constant watering of the rollers may be adopted
for certain felts, whilst it would be injurious for others.
This new combination permits of the watering of the rollers being effected inter-
mittently by the aid of the scoop. A moistening of the felting rollers is thus pro-
duced, which facilitates their operation, and consequently accelerates the process of
felting.
This result is obtained by means of the following arrangement:-The shaft a
(Figures 7, 8, and 9), supported in bearings fixed to the frame of the machine, and
carrying the driving pullies b, b¹, actuates through the bevel gearing c the shaft d,
which constitutes the axle of one of the rollers which carry the endless apron. At
the end of this shaft there is keyed the crank e, which by means of the connecting
rod fand lever g, fixed on the axle of the scoop, imparts motion to such scoop. The
trunnions h, which support the scoop, may be made to move horizontally in a slide,
and be capable of adjustment at will in order to vary the course of the scoop, and
permit it to take up more or less liquid as may be found requisite.
The pressing screws 1, fitted to the four angles of the frames beneath the cups i,
which receive the rods or supports j, j, of the moveable frames, have for their object
the permitting of the two series of rollers being moved more or less apart, according
to the requirements of the work or material operated upon, the intervening space
varying from the entrance to the exit of the rollers, that is to say, by this means
facility is afforded for obtaining greater pressure at the last rollers. These pressing
screws, are eight in number, four of which enable the frame carrying the upper
series of rollers to move in a parallel manner, whilst the other four permit of a
similar movement in the frame carrying the lower series of rollers. This is obtained
ad libitum the desired pressure at the entrance to as well as at the exit from the
rollers.
This new system of pressing screws possesses the advantage of permitting a greater
optional distance between the first rollers in order that the felt may receive at the
outset all the properties imparted by the heat, and above all by the boiling liquid,
whilst on tightening them progressively a powerful pressure will be obtained at the
exit rollers, in this way imitating, but with more perfect regularity, the manual
labour of the fuller, who steeps the article, rolls it progressively, tightens it, and
finally squeezes or presses it its expel the liquid before giving it a fresh crossing or
folding.
As will be seen this mode of regulating or adjusting the two frames carrying the
rollers is very important, and therefore I reserve to myself the right of employing
any equivalent arrangement for accomplishing the same end.
Figure 18 (Sheet 3) is a plan of two vats provided with circulating steam coils
for maintaining the acidulated water in a constant state of ebulition. This is an

page_text: essential object, as it is upon the mode of heating the baths that depends the quality
of the felted goods.
The coils are placed on the bottom of each vat, which should be composed of
materials not liable to be attacked by acids. Through the said coils superheated
steam is caused to circulate, which maintains the liquid at the boiling point.
The use of the boiling water has further for its object the moistening of the
rollers situate above the vat by the action of the steam arising from the boiling
liquid.
U (Figure 18) is a wooden vat, in which the scoop dips; V is a leaden vat placed
beneath the rollers; X represents the heating coils; Y, communicating pipe between
the two vats; u, communicating pipe between the two coils; v, the inlet for the
steam; x, the outlet for the same; y, water level indicator.
Figure 10 (Sheet 3) represents a square of felt, seen on all sides; Figure 11 is a
wrought-iron spindle or axle, which receives the felt to constitute a roller. It has
already been stated that the felting rollers were composed of a central core of iron,
and a covering of felt composed of animal hair, by preference calf hair. The employ-
ment of the latter is most important, as from its use excellent results have been
obtained.
After many experiments as to the best modes of covering the wrought-iron
spindles with an envelope of felt the following has been found to answer the best in
practice, both as regards efficiency and economy:-Sheets of calves' hair felt are
first produced in the usual manner. These sheets are laid upon a table, the surface
of which is formed with longitudinal and transverse parallel grooves or channels.
By the aid of a cutter the sheet of felt is cut by following the longitudinal parallel
grooves, and afterwards cut transversely by following the transverse parallel grooves,
by which means uniform squares of felt are obtained, as indicated at Figure 10.
a represents a piece of felt (seen in plan) of about 4 inches square; b, an edge view
of the same of a thickness of about 3/ths of an inch. By the aid of a punch a circular
hole c is cut through the centre of a diameter equal to that of the wrought-iron
spindle. Having obtained a sufficient number of these perforated squares of felt
they are strung on to the spindle A, which spindle serves as a support to the felt,
and receives a driving pinion at the extremity d. c is the journal, which works in
the frame of the machine. Each roller so prepared is then conveyed to a screw or
other press, by the aid of which the several combined squares of felt are subjected
to a pressure, by preference, of at least 45,000 lbs.
8
Figure 13 is a side elevation of the said press; Figure 14 is a corresponding plan
of the same; Figure 15 is an end view of the actuating end of the press; and
Figure 16 is a similar view of the opposite end. His a frame or standard sup-
porting the apparatus; I, I', connecting pieces, in which are bolted the ends of the
bars J, J; K is a pressing screw working through a fixed nut in the piece I, and
actuated by the lever m, the pull of which operates upon a double ratchet wheel l, l';
n is a fly wheel keyed on to the end of the screw spindle; O, a piston or slide
working between the bars J, J', and receiving the thrust of the screw; P, a sleeve
or stationary resisting piece receiving the pressure; 7, a lever mounted loose upon
the bar J', its free end being near the axis of the indicator or pointer 1, as shown at
q; s, a graduated quadrant indicating the pressure.
A roller clothed in felt B is shown under pressure, and the indicator marks the
pressure applied, say, 45,000 lbs. Under this enormous pressure the felt after a few
hours begins to contract or consolidate, and the indicator shows a reduced pressure,
whereupon the screw is again tightened up until the pressure is again restored to
the original amount, at which it is allowed to remain for about 24 hours. The
compression of the felt may be considered sufficient when the point of the indicator
? rests between, say, 33,000 lbs. and 44,000 lbs. or thereabouts on the quadrant.
The workman then screws up the nuts g on the screwed end f of the wrought-irou
spindle or axle (see Figure 12), introducing them through the opening t (see
Figure 16) in the sleeve P; he then removes the roller from the press, replacing it
by a fresh one, and so on until he has a sufficient number to fit up the felting

page_text: machine. As will be seen, the several compressed pieces of felt form a compact
whole, but the surface is not cylindrical by reason of the square form of the
component parts.
The last operation is the turning of the roller with a view to obtain a perfect
cylinder. For this purpose a parallel lathe similar to those employed for turning
the iron spindles is made use of. The roller is placed in the lathe after having
been first moistened with water to facilitate the operation. The workman adjusts
the rest to the proper distance in order to preserve the required diameter of the
felt roller. It is by the operation of turning that rollers of different diameters are
obtained by removing more or less of the felt. On no account must the pieces of
felt for the iron spindle be cut of different diameters, because after the compression
an uneven roller would be obtained altogether unfitted for use in the improved
machine. It is however of great importance that the diameters of the two series of
rollers shall diminish progressively from the entering to the delivering end of the
series in order to obtain a proper felting action.
Figure 17 (Sheet 3) represents on a different scale the two series of rollers manu-
factured in the manner herein-before specified. The six rollers of the upper series
should by preference have the following diameters, diminishing in about the propor-
tion given, namely:-Assuming the first roller to have a diameter of 4 inches, which
may be represented by the number 100, the succeeding five rollers will decrease in
diameter in the proportions of 98, 96, 94, 92, 90, whilst the diameters of the lower
series should be as follows, that of the first roller being represented by the number
99, the succeeding six rollers will be 97, 95, 93, 91, 89, 87.
As already explained, it is the covering of felt B which is more or less reduced in
the lathe, the spindle A being of uniform diameter for all these rollers.
It is to be understood that what is claimed as the said Invention in the mechanical
fulling and felting of felts, hats, and other like articles, is the new and improved
machine with all its appendages indispensable for its proper working, substantially
as has herein-before been described; and with a view to indicate more precisely that
which I claim as novel and original, I will now proceed to set forth precisely the
principal features which characterise this Invention, namely,―
First. The application and use in a felting machine of felting rollers, the diameters
of which diminish progressively, and which rollers are composed of felted animal
hair powerfully compressed over their entire circumference in such a manner that
the hairs present themselves end wise to effect the felting operation.
Secondly. The construction and arrangement of felt rollers as herein-before
described,
Thirdly. The application and use of the herein-described special form of press for
compressing the felt coverings of the rollers, but it is to be understood that I reserve
to myself the right of applying any other suitable mode of compression.
Fourthly. The heating by boiling water in order to impart all the felting properties
to the material by means of baths of acidulated water constantly maintained at the
boiling point.
Fifthly. The system of intermittent watering in conjunction with a second reser-
voir for supplying the scoop, which reservoir is in communication with a vat situate
beneath the rollers in such a manner that the liquid returns always to the same
level, and is used again and again repeatedly, as herein-before described.
Sixthly. The placing in the two vats or reservoirs of superheated steam circulating
coils in combination with the water level indicator, as described.
Seventhly. The application and use of a system of pressing screws for separating
or bringing nearer together the felting rollers as required, and the regulating the
two frames carrying the said rollers, such system permitting of the desired pressuro
being obtained at the entering and delivering end of the series of rollers, as
described.
Eighthly. The various arrangements of scoops for the intermittent watering of
the felting rollers, with variable range of notion, so as to take up more or less
liquid, as described.

page_text: Ninthly. The arrangement of endless travelling apron for carrying the pressed
and fulled felts to the front of the machine with the simultaneous working of the
scoop from the same mechanism, as described.
Tenthly. The general construction, arrangement, and combination of machinery
or apparatus for fulling and felting, and the mode of constructing the felting rollers,
permitting their immediate renewal when worn, as described.
In witness whereof, I, the said James Ledger, have hereunto set my hand and
seal, this Fifteenth day of April, in the year of our Lord One thousand
eight hundred and seventy-eight.
Witness,
FRED. J. RAPSON,
Clerk to E. P. Alexander,
Consulting Engineer & Patent Agent,
14, Southampton Buildings,
Chancery Lane,
W.C.
JAMES LEDGER. (L.S.)