MAESTRELLI, Graziano (Via Veneto 11, Empoli, I-50053, IT)
| CLAIMS 1. Method for the realization of a stuffing for clothing or lap in general comprising at least the operations of: - gathering of a textile material with fibre's flake shape (3) or similar inside a container; - The unload and subsequent proceeding of said flakes along a predefined processing direction; - Compaction of said flakes according to a layer (5) that proceeds along said direction; - Stabilization of said layer (5) in order to realized a lap; - Exit and further rolling of the realized lap; characterized by the fact that said stabilization operation comprises the reciprocal overlapping of the layer (5) and of a textile supporting belt (10) that proceeds along the same direction of the processing and further reciprocal needle punching able to realize an anchorage of the layer (10) with the supporting belt (10), realizing this way a stable lap strip. 2. Method for the realization of a stuffing for clothing or lap in general, according to claim 1, where said overlapping operation happens close to the entrance of the stabilization section and said operation of needle punching is realized through the insertion of a plurality of needles (7) through the entire section constituted by said layer (5) overlapped to said textile supporting belt (10), said plurality of needles realizing a reciprocal anchorage of the respective fibres of the layer with the fibres constituting the textile supporting belt. 3. Method for the realization of a stuffing for clothing or lap in general, according to claim 1 and 2, where said layer (5) is overlapped above the textile supporting belt (10), said supporting textile belt and said layer being realized in natural fibres as cotton or similar. 4. Method for the realization of a stuffing for clothing or lap in general, according to one or more of the previous claims, where said textile supporting belt is unrolled by a specific additional section (11) and pulled inside a needle punching section through overlapped conveyor belts (12) or similar, said exiting layer (5) from the compaction section overlapping above said textile supporting belt (10) in correspondence to said conveyor belts (12) and pulled inside said needle punching section. 5. Machinery for the realization of stuffing for clothing in general or laps comprising: - At least a gathering section (1) to contain a textile material in fibre flakes shaped (3) or similar, said section being able to unload said flakes to allow the proceeding along a processing predefined direction; - At least a compaction section (4) of the flakes to realize a layer (5) constituted by said compacted flakes and oriented according to a predetermined compaction direction; - At least a stabilization section (6) of said layer according to a lap, said section comprising at least a needle punching section; - At least an exit section and further rolling (8) of the realized lap; and characterized by the fact that it is prearranged at least an additional section (11) for the unrolling of a textile supporting belt to allow its proceeding and entering toward the stabilization section (6), the exiting layer (5) from the compaction section, overlapping to said textile supporting belt (10) in correspondence to said stabilization section (6) close to the entrance of the needle punching section. 6. Machinery for the realization of stuffing for clothing in general or laps, according to claim 5, where said additional section (11) is modular, and can be installed or removed in correspondence to a selected installation position. 7. Machinery for the realization of stuffing for clothing in general or laps, according to claim 6, where said additional section is positioned in correspondence or close to the stabilization section (6) and interposed between said section of stabilization (6) and the exit section (8) . 8. Machinery for the realization of stuffing for clothing in general or laps, according to one or more of claims from 5 to 7, where said additional section comprises means of positioning to fix it in a removable manner in correspondence to said stabilization section and unrolling means to support the reel of the textile supporting belt and allow its unrolling. 9. Machinery for the realization of stuffing for clothing in general or laps, according to claim 8, where said unrolling means comprise a supporting axis for the reel and two arms projecting from the ground and holding said axis in correspondence to its two ends, said arms being supplied with rolling bearings. 10. Machinery for the realization of stuffing for clothing in general or laps, according to claim 9, where said axis is assembled in neutral. 11. Machinery for the realization of stuffing for clothing in general or laps, according to claim 8, where said unrolling means comprise centres. 12. Machinery for the realization of stuffing for clothing in general or laps, according to claim 8, 9 or 11, where said unrolling means comprise a rotational engine to pull into rotation said axis or said centres . 13. Stuffing for clothing in general characterized by the fact that it comprises a first surface (5) made in natural fibres and overlapped and connected to a second surface (10), said second surface constituting a textile support for said first surface. 14. Stuffing for clothing in general, according to claim 13, where said textile support (10) is in cotton or similar and is realized through weft and warp while said first surface (5) is a layer of a predetermined thickness constituted by compacted fibres and realized in one of the following materials: - Bamboo; - Bamboo mixed to cotton; - Cashmere mixed to virgin whool; - Camel; - Virgin wool mixed to camel. 15. Stuffing for clothing in general, according to claims 13 and 14, where the basic weight of said layer (5) and/or of 'the support is lower than 200 grams for square metre. 16. Stuffing for clothing in general, according to claim 15, where said basic weight is variable from 100 and 150 grams for square metre. |
METHOD OF PRODUCTION OF NEW TYPES OF THERMAL STUFFING WITH LOW BASIC WEIGHT FOR CLOTHING
Technical Field The present invention regards to a method of production of stuffing for clothing in general. In particular, it refers to an innovative method that allows the realization of innovative stuffings with low basic weight. Moreover, the invention refers to a machine that performs such method.
State of the Art
Since far back are known the methods and relative machineries for the realization of stuffing, also called laps, for clothing, as snow jackets, winter jackets, pants and similar.
According to the prior art, it is prearranged, inside a first bin collection, some materials with flake shape necessary for the realization of a lap strip. The bin, so prearranged, reverses the content inside a second bin placed in line with all the production machinery to start the processing cycle. For this aim, generally, the first bin has an adjustable hole and controlling means that can perfectly dose the quantity of flakes that are needed for the realization of a certain size of a lap strip. The flakes are constituted by synthetic material, as polyester or similar. By proceeding with the production cycle, the second bin reverses on specific conveyor belts the quantity of flakes that is needed. These are then conducted through a first section of compaction, also _ p _
called carding section, constituted by a castle of overlapped pressure rollers. The rollers, through their contra-rotation, have the aim of compacting and orienting the fibre flakes in such a way to realize a first layer of material with fibres oriented according to the proceeding direction of the same layer.
In particular, a section of carding comprises a big central roller, called big swift and rotating at a predetermined speed, and a plurality of cylinders placed in adherence around its lateral perimeter, and rotating at independent speeds. The lateral cylinders (alternatively a working cylinder and a doffing cylinder) , in combination to the big swift, realize the compacting and "brushing" operation of the fibres, forcing the passage of the flakes through the route that is predefined by their prearrangement .
With the aim of optimising the compaction and the orientation of the layer's fibres, the cylinder's surface will opportunely comprise particular rubber or similar relieves able to make this brushing effect.
The layer exiting the compacting section is then towed (through overlapped conveyor belts that catch the layer) toward a stabilization section of the lap in which it is made the so called needle punching. This operation gives to the layer a right degree of compactness, resistance to stretches and elasticity, connecting to each other the fibres that constitute it. For this aim, the layer is brought to the above section realized by two plates that are overlapped and which define the advancing route. A plurality of needles, generally in an intermittent way, are set on through specific through holes realized in the upper plate, penetrating this way through the fabric and forcing the fibres to interlace, connecting to each other.
The strip so stabilized, continues to be pulled toward the " exiting section where an appropriate rewinder realizes a bobbin of finished material and ready to use.
The disadvantages of this technique are many and listed hereafter.
The realized laps, as already said, shall necessarily present a good grade of stability, or rather, when pulled or placed in traction, they shouldn't ravel or disjoin and this means that the product shall necessary present a good grade of elasticity. If this is not the case, the functionality of the lap wouldn't be optimal, as after some time it would loose its compactness and would fall at the bottom of the same clothing within which it has been placed, leaving wide gaps lacking of insulation.
At the moment, according to the present prior art of production, the sole solution to this problem is to use exclusively synthetic fibres that already possess a good grade of compactness, limiting this way the range of production to this kind of materials. The synthetic fibres utilized in general have thus an elevated basic weight, anyway not less than 200/220 grams in square metres, and that guarantees all the mechanical peculiarities listed above after the needle punching operation.
In any case, when it is necessary to realize laps with high mechanical features of elasticity, it should be processed a heavy needle punching, or rather with a certain "pressure". This causes the realization of a lap considerably less thick and thus with a lower ability of insulation. Moreover, a synthetic material is an oil derivative and thus it is strongly pollutant and not biodegradable. This entails further costs for the disposal of the product. In the case it is necessary to proceed with the colouring of ' the clothing, there is the further inconvenient that the polyester, respect to the external fabric of the clothing which is generally in natural fibres, have totally different colouring temperatures. This greatly complicates the colouring proceedings with a remarkable increase in the costs.
Not at last, all the materials in polyester and thus not natural, are less tolerated by the human body, which is more subject to allergies' annoyances and phenomenon of sensitisation of the skin.
Disclosure of invention
Therefore, it is the aim of the present invention to give a method for the realization of stuffing for clothing that overcomes all the above inconvenient. In particular, it is the aim of the present invention to give a method of realization of stuffing that allows the use and the realization of laps in different materials different from the synthetic, but conserving a great grade of resistance and elasticity. Thus it is the aim of the present invention to give a method of production of stuffing for clothing that allows the use of material with low basis weight.
It is also the aim of the present invention to give a method that allows the realization of stuffing entirely natural, limiting this way the discharging costs, problems of production's pollution and comfort in using it.
It is also the aim of the present invention to give a method that realizes a stuffing that is structurally innovative in all its aspects respect to the preceding ones .
These and other aims are reached through the present method for the realization of a stuffing for clothing or lap in general comprising at least the operations of:
- gathering of a textile material with fibre' s flake shape (3) or similar inside a container; — The unload and subsequent proceeding of the flakes along a predefined processing direction;
- Compaction of the flakes according to a layer (5) that proceeds along said direction;
- Stabilization of the layer (5) in order to realize a lap;
- Exit and further rolling of the realized lap; and characterized by the fact that the stabilization process comprises the reciprocal overlapping of the layer (5) and of a textile supporting belt (10) that proceeds along the same direction of the processing and further reciprocal needle punching able to realize an anchorage of the layer (5) with the belt (10) , realizing this way a stable lap strip. In this way, by adding a new unwinder section of the textile support 10, it is possible to connect the layer to the same support realizing this way a new lap. Naturally, the known operation of needle punching, will bind the layer together to the support. In particular, the needle punching operation is realized by means of the insertion of a plurality of needles through the entire section constituted by the layer (5) overlapped above the textile supporting belt (10), said plurality of needles realising a reciprocal anchoring of the respective fibres of the layer with the fibres constituting the textile supporting belt.
The preferred solution, comprises then that the layer 5 results to be overlapped above the textile supporting belt 10. Naturally, this configuration is referred to the insertion into the machine of the layer and of the support. In particular the layer 5 will result directly placed underneath the needle of the needle punching, while the support 10 is found underneath it.
Advantageously the textile supporting belt and the layer are realized in natural fibres as cotton or similar. In particular, the textile supporting belt 10 is unrolled by an appropriate additional section 11 and pulled inside a needle punching section by means of overlapped conveyor belts 12 or similar, the layer 5 exiting the compaction section overlapping on top of the textile supporting belt 10 in correspondence to the conveyor belts 12 and pulled inside the needle punching section.
The lap so obtained will have softness features typical of the natural materials, while all the mechanical characteristics will be supported by the textile supporting belt.
It is subsequently also described a machinery for the realization of stuffing for clothing in general or laps comprising: - At least a gathering section (1) to contain a textile material with fibre flakes or similar shape, said section being able to unload the flakes to allow the proceeding along a processing predefined direction.
- At least a compaction section (4) of the flakes to realize a layer (5) constituted by compacted flakes and oriented according to a predetermined compaction direction;
- At least a stabilization section (6) of the layer according to a lap, said section comprising at least a needle punching section;
- At least an exit section and further rolling (8) of the realized lap; and characterized by the fact that it is prearranged at least an additional section (11) for the unrolling of a textile supporting belt (10) to allow its proceeding and entering toward the stabilization section (6), the layer (5) exiting from the compaction section, overlapping to the textile supporting belt
(10) in correspondence to said stabilization section close to the entrance of the needle punching section.
In particular, the additional section is modular, it can be installed and removed in correspondence to a selected installation position.
This solution, naturally, makes the use of the additional section very versatile. according then to a selected positioning, the additional section is placed in correspondence or close to the stabilization section and interposed between said stabilization section and the exiting section.
Naturally, in order to allow the positioning of the additional section, are then prearranged means of positioning. Moreover the unrolling means support the reel of the textile supporting belt and allow its unrolling.
Advantageously the unrolling means comprise a supporting axis of the reel 14 and two arms emerging from the ground 15 and holding the axis in correspondence of its two ends, said arms being supplied with rolling bearings. In particular the axis is assembled in neutral or, alternatively can be supplied with a rotation engine.
According to other equivalent solutions, the unrolling means comprise centers.
As already said, the present method completely innovative allows the realization of a new type of lap. In particular allows the realization of a stuffing for clothing in general characterized by the fact that it comprises a first surface 5 made in natural fibres and overlapped to a second surface 10, said second surface constituting a textile support for said first surface, said first and second surface being joint to each other by means of a needle punching.
Advantageously the textile support (10) is in cotton or similar and realized according to weft and warp while the first surface (5) is a layer of a predetermined thickness constituted by compacted fibres and realized in one of the following materials:
- Bamboo;
- Bamboo mixed to cotton; - Cashmere mixed to virgin wool;
- Camel;
- Virgin wool mixed to camel.
Brief description of drawings Further features and advantages according to the invention, will be clearer with the description of one of its pattern realization that follows, made to illustrate but not limit, with reference to the annexed drawings, in which:
- The figures from 1 to 3 describe the machinery and the relative- method according to the prior art;
- The figures from 4 to 6 show schematically a detail of the stabilization section according to the present invention;
- Figure 7 described schematically the fabric obtained through the present method.
Description of a preferred pattern realization
With reference to figures from 1 to 3, it is schematically described a machinery that allows the processing and the realization of stuffing for clothing according to the prior art. In particular, figure 1 described schematically the gathering section 1 comprising a bin within which are contained the fibres flakes 3 in synthetic material to unload on the conveyer belt 2.
The conveyer belt allows thus the processing of the flakes until it is reached the compaction or carding section 4 (look at the scheme of fig 2) , constituted by the big swift and by workers and doffers. The action of compression and brushing of the cylinders in combination to the big swift realises thus a strip of continuous layer 5 pulled forward toward the stabilization zone 6. The grasping and advancing of the layer 5 is realized by means of overlapped strips 12 that grab and pull the same in the entrance to the needle punching zone (look figure 3) . The needle punching is realized by means of the plurality of needles 7 which, in an intermittent way, raise and lower running through the entire section of the layer and play the action of connection of the fibres .
A further exit and rolling section 8 allows the realization -of the lap reel rolled around a rotating axis 9. Naturally, only for schematic simplicity reasons, the sections of the machinery have been represented in separated figures, as the layer 5. Naturally, both the layer and the finished lap produced are to be intended as a continuous strip of material. According to the present innovative method, in order to make usable a material in natural fibre with low basis weight, it is necessary that the stabilization process, first of all, realizes a reciprocal overlapping of the layer 5 with the textile supporting strip that proceeds along the same direction of the process and that has a function of element "containing". In this way, the textile support made with a natural material as cotton, gives sufficient elasticity to maintain compacted the realized lap. Practically any traction action is held by the textile support .
Naturally it is necessary at this point of the method the following reciprocal needle punching between the two material in order to realize the anchoring (or connection) of the layer 5 to the supporting strip.
For this aim, as it is schematically described in figure 4, the stabilization section 6 comprises the possibility to unwind a supporting textile reel 10 entering inside the needle punching section. For this aim it is prearranged a specific additional section 11 of modular type, or rather removable and which can be positioned according to the needs. The additional section allows thus the unrolling of the textile supporting strip 10 with a reel shape and its further process and entrance toward the stabilization section. For this aim, appropriate draft rollers 13, as schematically indicated in figure 4, allow take and guide the strip 10 inside the opposed strips 12.
In detail, the additional section 11 is placed in correspondence or close to the stabilization section and interposed between the same stabilization and the exit section 8. According to the outline of figure 4, it comprises unrolling means constituted by a simple axis 14 supporting the reel of the supporting textile 10 and two arms projecting 15 from the ground that hold the axis in correspondence of its two ends.
Moreover generic positioning means, not described in figure, allow to fix this section in correspondence to the chosen position.
Between the different constructive solution, the unrolling axis of the reel can be in neutral, using entirely the pulling action of the appropriate conveyor belts 12.
Alternatively it can be prearranged an unrolling engine synchronized with the proceeding speed of the same belts 12. Obviously, without moving apart from the concept of the present invention, solutions equivalent to the unrolling axis could be used. For example an equivalent solution can be constituted by simple centres that get partially inserted inside the core of the reel, grabbing and unrolling it.
The needle punching operation is realized in a traditional manner, or rather by means of the insertion of the plurality of needles 7 through the entire section constituted by the layer 5 and the textile supporting belt 10 (look at sequence figure 5 and 6) through the perforated upper plate 16.
Obviously, the passage of the textile supporting belt 10 inside the stabilization section, could be realized in any equivalent manner. In the specific case, but not limited, it has been chosen a passage from the lower part of the same section toward the belts 12. Obviously any other positioning of the additional modular section 11 could have been easily chosen in an equivalent manner, to allow the input of the belt 10 inside the section 6.
The undertaken method, thus, allows the realization of a lap entirely innovative (look at figure 7) . A first surface of the natural material shaped as layer 5 is thus overlapped and connected to a second surface of natural material called textile support 10 and realized, for example, with cotton fibres interlaced in weft and warp. Generally, as also shortly represented in figure 7, the thickness of the layer 5 is much greater respect to the support 10, just because the support is realized through weft and warp while the layer 5 is a collection of compacted fibre flakes. The textile support gives stability and elasticity to the entire lap while the core of the fabric will maintain the features of softness that are typical of the natural fibres.
Thus, the layer 5 can comprise materials as bamboo, the bamboo mixed with cotton or cashmere mixed with virgin wool, camel and virgin wool mixed to camel. Moreover the usable basic weights, thanks to the innovative method, will be much lower than the preceding ones and comprised between values of 100 or 150 grams for square metre.
It is at this point clear how the aims of the present inventing have been reached. In particular it is clear how the new lap realized with the present method, possesses all the features of the natural materials and at the same time is highly elastic and resistant. Moreover, the lap realized with the textile support allows a very light needle punching, also when the use of the same requires elevated mechanical performances. This on a quality level, equals to laps with high thickness and good insulation capacity, together to elevated mechanical features integrated by the textile support used.
It is also clear at this point how the problems regarding the colouring of the clothing, the discharge of the product and the production costs, have been resolved.
The above description of a specific shape is able to show the invention from the conceptive point of view, in a way that others, by using the art, can modify and/or adapt in different applications this specific shape without any further research and without going apart from the inventive concept, and, therefore, it is intended that these adaptations and transformations will be considered as equivalent to this specific realization. The means and materials to make- the many described functions can be of various nature without exiting the area of the invention, it is intended that the expressions or the terminology used have a simple descriptive aim and therefore not limiting.