Apparatus for forming fiber-filled articles
United States Patent Willis et a1.  
 1451 Apr. 22, 1975 1 1 APPARATUS FOR FORMING FIBER-FILLED ARTICLES [75] lnventors: Arnold L. Willis. Chicago; Harold Wortman. Morton Grove, both of 111.  
 [73] Assignee: CWW Research and Development Company, Elkgrove Village. 111.  
 [22] Filed: July 6, 1973 [21] Appl. No.: 377,072  
 [52] U.S. Cl. 141/67; 19/1445; 53/125; 141/248 [51] Int. Cl. B65h 1/00; DOlg 13/00 [58] Field of Search 53/24. 125; 141/8. 12, 141/59, 65. 67, 71. 248; 156/276. 285-287, 324; 19/144. 144.5; 5/337 [56] References Cited UNITED STATES PATENTS 2,347,431 4/1944 Paul 141/67 3.546.846 12/1970 Sens... 53/125 X 3.673.036 6/1972 Lipe 53/125 X Primary E.\&#39;uminerRobert L. Spruill Allorney. Agenl. or Firm-Dressler. Goldsmith. Clement &amp; Gordon. Ltd.  
 157 ABSTRACT This application discloses a method and apparatus for forming fiber-filled articles. such as pillows. cushions. and the like. The method consists of feeding fibers into position adjacent a compartment having at least one opening in which is provided an air-penetrable casing. The fibers are directed into the casing into a position whereby the fibers are substantially layered and at least a majority of the fibers are oriented parallel to the direction of force applied thereto. The apparatus for performing the method consists of a conveyor means wherein fibers are directed into a vacuum chamber in which an aiir-penetrable casing has been supported. A suction. fan creates the air stream directed through the vacuum chamber directing the fibers into the casing so that at least a majority of fibers lie parallel to the force applied by the user of the pillow or other fiber-filled article.  
 4 Claims, 5 Drawing Figures isvmm PATENTEDAPRZZIQYS sum 2 s 2 APPARATUS FOR FORMING FIBER-FILLED ARTICLES BACKGROUND OF THE INVENTION The present invention relates generally to a method and apparatus for forming fiber-filled articles. such as pillows and the like.  
  Current fiber-filled articles. while generally satisfactory. have a certain lack of stability and durability after continuous use. Essentially. a product. such as pillows. made in the present conventional manner. does not retain its fluffy or spongy characteristics over an extended periodv This has resulted in public dissatisfaction with pillows and other fiberfilled articles currently on the market. It can be appreciated that if it is possible to greatly improve the bulk and durability of fiber-filled articles. a long-felt need will be satisfied.  
  One of the reasons for the lack of&#34;fluffabilit of pillows made under current practices is the arrangement of the fibers within the pillow casing. Currently. the typical method of making a fiber-filled pillow includes forming a web by opening. combing and arranging the fibers; folding the web into a predetermined number of superimposed layers. rolling the layered web to form a substantially cylindrical-batt; placing the batt into an open ended pillow casing; and sewing the open end of the pillow casing. thus forming the finished pillow.  
  Many observations may be made with respect to an article such as a pillow which is made by this conventional method. Due to the folding of the web. which is performed by a device known as a lapper. the web must have sufficient fiber-to-fiber cohesion. so that it does not break up during this operation. Similarly. sufficient fiber-to-fiber cohesion is necessary when the layers of fibers are rolled to form a batt.  
  in order to achieve the requisite cohesion between fibers. at relatively large amount of garnetting or carding is necessary. The result of this operation is to remove the crimp of the fibers which is placed therein by the fiber manufacturers in order to enhance the resiliency of the fiber-filled article. Any reduction in fiber crimp obviously reduces the loft and refluffability of a pillow. or the like. Furthermore. garnetting or carding tends to parallel the fibers to a large extent. thereby increasing the tendency for a felting action of the batting. The high degree of paralleling of the fibers creates a condition whereby when the pillow is compressed. the fibers interlock with a resulting felting action. thereby removing much of the fluffiness or sponginess of the pillow.  
  As previously mentioned. extensive garnetting or carding parallels the fibers into a cohesive web. which is necessary so that it will not break during the subsequent lapping operation. When the web is folded-into layers and rolled into a batt. the fibers tend to lie in horizontal planes relative to the force applied by the user. That is to say. the fibers are randomly oriented in layers. which tend to matt or felt between planes during use. with the result that the pillow reduces in size and eventually after a period of use loses its fluffy and spongy characteristics.  
 SUMMARY OF THE INVENTION The present invention relates to an improved method and apparatus whereby fibers are inserted into an airpenetrable casing in such a manner that at least a majority of the fibers of the finished article lie parallel to the direction of the force applied by the user. In a particular embodiment. there is illustrated a method and apparatus for producing a pillow that will retain a high loft. be readily re-fluffable and be economical to manufacture: specifically. one which will retain its original shape and thus provide maximum cushioning and insulating properties and withstand thorough cleaning without loss of mechanical or aesthetic properties. These characteristics must be maintained through many cycles of compression and &#34;fluffing&#34; over long periods of use and repeated washings.  
  The method of a preferred embodiment of the present invention contemplates introducing fibers into a garnett or carding machine which opens. combs and longitudinally orients the fibers into a loosely formed web. Because the web does not have to be folded and rolled into the conventional type batting. a minimum amount of garnetting is required. Essentially. the gar netting or carding action is to open the fibers supplied thereto. Garnetting or carding is not necessary if the fibrous material does not require any opening action. For example. if one were to use continuous filament tow. it would not be necessary to use garnetting or carding equipment.  
  The loosely formed web is removed from the garnett or carding machine and is placed on a conveyor adjacent to one end thereof. In this preferred embodiment. the web is split in half so that two pillow casings may be produced simultaneously. The web formed on the conveyor is directed toward a vacuum chamber located adjacent to. but below the end ofthe conveyor opposite the garnetter. The vacuum chamber has four openings positioned to receive the web of fibers coming off the end of the conveyor.  
  The suction in the vacuum chamber acts to separate the web into sections and dispose the generally longitudinally oriented fibers in a generally horizontal direction in the casings. The sections of web will be deposited in a generally layered arrangement. with the result that substantially all of the fibers will be disposed generally parallel to the direction of the force applied to the pillow when in use. The suction in the chamber will be varied to maintain the volume of air passing through the chamber at a uniform rate during the entire filling operation.  
  The apparatus is designed to take fibers from a supply. form a loose web and place the web within a casing in such a position that substantially all the fibers are parallel to the direction of the force applied by the user of the pillow. The apparatus includes a garnett or carding machine which opens. combs and longitudinally orients the fibers into a loosely formed web. A comb removes the web from the garnetter and introduces it onto a conveyor which moves the web to a vacuum chamber. The web is split by. for example. a ring or tape at the center of the garnett drum. or by leaving out the wire on the surface of the garnett drum for approximately one inch at its center. The vacuum chamber is located immediately below and adjacent the second end of the conveyor. The vacuum chamber is provided with a plurality of top openings into which airpenetrable pillow casings or tickings are suspended with their open ends facing the source of the web coming down from the adjacent end of the conveyor. The pillow tickings are supported at their open ends by a suitable means so they will not be sucked into the vacuum chamber. The bottom portion of the casing is supported in the vacuum chamber by a perforated metal frame which can be adjusted to take care ofthe various lengths of pillows.  
  In the illustrated embodiment. the vacuum chamber is split into two halves. with each half having two openings in the top thereof into which pillow casings are suspended. With this arrangement. two pillows are being formed in one half of the vacuum chamber while the operator may remove the two pillows that have been previously filled in the other half of the vacuum chamber and replace empty casings therein for the next sequence. The number of openings in the chamber is governed only by the method used to split the web and the time required for the operator to change the casings.  
  The bottom of the vacuum chamber communicates with a suction fan by means of a duct. An air gate closes one of the halves of the chamber, thus directing the air stream created by the suction fan through the other half.  
 In order to eliminate turbulence in the casing during the filling operation and in order to create an essentially uniform laminar or layered formation of fibers in the pillow. it is necessary to hold constant the volume of air passing through the casing. This may be performed. for example. by varying the speed of the suction fan or by introducing a damper inside the duct which increases the negative pressure to overcome the resistance to the flow created by fibers accumulating inside the casing during the filling operation.  
  The laying of sections of the web in a layered fashion results in a spongy configuration in which substantially all of the fibers are oriented in the horizontal direction. The horizontal direction is relative to the way the casing is supported and thus the fibers are essentially in a vertical position when the pillow or other fibrous article is used. That is to say. the direction of the force applied on the pillow by the user is parallel to substantially all the fibers.  
  The layered configuration of the fibers within the casing also permits the pillow or other article to be compressed to V2 to As its normal size for ease of shipping and storage in inventory. The orientation of the fibers permits the pillow to be compressed end to end with a minimum amount of felting and matting. Furthermore. during the use of the pillow. the orientation ofthe fibers generally in the direction parallel to the direction of the force applied by the user has a high order of recovery. whereby the pillow formed by this novel method has the characteristics similar to that of a down pillow. This reduces the amount of felting and matting between fibers. Also. since there is a minimum of. or no garnetting or carding employed. the fibers have retained their crimp. This results in a greater fluffability or recovery and is much more attractive. efficient and usable than the existing conventional pillow.  
 BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS FIG. 1 is a side elevation view of the apparatus of the present invention;  
  FIG. 2 is a partial perspective view of the vacuum chamber and air gate;  
  FIG. 3 is a partial perspective view broken away of the vacuum chamber;  
  FIG. 4 is a partial sectional view of the upper part of one-half of the vacuum chamber; and  
  FIG. 5 is a schematic view of a modified control device for the apparatus.  
 DETAILED DESCRIPTION While this invention is susceptible of embodiment in many different forms. there is shown in the drawings and will herein be described in detail a preferred embodiment. with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.  
  Basically. the invention includes taking randomly oriented fibers. directing the fibers into a pillow casing. and orienting the fibers in the pillow casing so that at least a majority of the fibers lie horizontal relative to the position of the casing during the filling operation.  
  FIG. I of the drawings essentially discloses the preferred embodiment of the present invention for forming pillows and other fibrous articles. In the preferred embodiment. a loosely formed web is formed prior to the introduction of the fibers into the casing. This aids in orienting substantially all ofthe fibers in the horizontal direction and. in addition. generally orients the fibers in the direction parallel to the direction of the force applied by the user.  
  The apparatus 20 consists of a web-forming means. such as a garnett or carding machine 22. which opens. combs and parallels the fibers into a web W. which is then moved to a vacuum chamber 24 by means of a moving means. such as conveyor 26. The garnetter 22 and conveyor 26 are conventional pieces of equipment that are driven by suitable means. not shown. The web emerging from the garnett or carding machine 22 is loosely formed with relatively little fiber-to-fiber cohesion and with the fibers generally longitudinally oriented. This allows the fibers to retain the maximum amount of crimp. thereby aiding the resiliency of the finished product. Various fibers can be used to form the web. including polyesters such as DuPont No. 808 polyester fiberfill. or other types of artificial or natural fibers.  
  The web is removed from garnett roll 29 and placed on conveyor 26 at first end 27 by means of comb 28. Since in the embodiment illustrated two pillows are manufactured simultaneously, the garnett roll 29, which has many teeth for opening, combing. and paral leling the fibers into the web, has a 1 inch section 35 approximately at the center of garnett roll 29 where there are no teeth to attract fibers. Other means for splitting the web include. for example. splitting the roll 29 by means of a ring or a tape at its center.  
  The web W moves on conveyor 26 from the first end 27 to the second end 34. As illustrated in FIG. 1, the conveyor may be tilted upward and should be of such a length. so as to allow an operator space to stand underneath it when working with vacuum chamber 24.  
  As best shown in FIGS. 1 and 3, vacuum chamber 24 consists of first and second compartments 36 and 38 which are separated by primary plate member 40. Regulating means such as air gate 42 is provided to switch the air flow between compartments so that while the pillows in one compartment are being filled. the finished pillows may be removed and new casings placed in the other compartment. The top surface 44 of vacuum chamber 24 has two pairs of essentially oval openings 46, each pair opening to one of the compartments of vacuum chamber 24 as best illustrated in FIG. 3. Ad-  
 justable perforated support means 48 consists of perforated baskets 63 secured to secondary plate member 65 by suitable adjustable mounting means such as hooks 67 and eyes 69. The open end of casin 50 is wrapped around lip portions 49 and 51, and the bottom portion of casing 50 rests upon perforated basket 63 of support means 48.  
  To secure casing 50 to vacuum chamber 24, the open end of casing 50 is wrapped around lip portions 49 and 51. Lip portion 51 expands by means of spring biased support means 55 to create tension on the open end of casing 50 and to fully expand the open end. More specifically. as best shown in FIGS. 3 and 4. support means 55 includes member 57 that is slidably mounted on top surface 44 of vacuum chamber 24. Lip portion 51 extends upwardly from member 57 for support of casing 50. Support means 55 further includes rod members 59 and 61 extending from the underside of member 57 vertically downward to the bottom of chamber 24 where they are pivotally mounted at a single point by any suitable means (not shown Cross-member 71 ex tends from rod member 59 to rod member 61. Tension spring 73 is disposed between cross-member 71 and primary plate member 40. Spring 73 acts to expand lip portion 51 of support means 55 which creates tension on the open end ofcasing 50. It further provides for the maximum opening of casing 50 for sufficient intake of fibers.  
  As best shown in FIG. 2, the bottom of vacuum chamber 24 communicates with suction fan 52 through duct means 54. The bottom of the vacuum chamber 24 has a series of openings 56 through which air is drawn by the suction fan 52. As best shown in FIG. I. this action of the suction fan 52 draws sections 58 of web W through the openings 46 formed in the top of vacuum chamber compartment 36. The action of the suction severs these sections 58 from the main web W and draws them down into the casing in a horizontally disposed layered condition. with the result that the fibers that have been paralleled by the action of the garnetter 22 are disposed in a horizontal position in the casings 50. As shown in FIG. 1. the air gate 42 seals off the duct 54 from the chamber 38 with the result that the suction is imposed on chamber 36, as aforementioned. While the casings 50 in chamber 36 are being filled with fibers. the operator may remove the finished pillows and place new casings in compartment 38.  
  The volume of air passing through the air-penetrable casings 50 inside vacuum chamber 24 is controlled by means of damper means 62 (FIGS. 1 and 2) located in duct 54. Damper 62 operates automatically in conjunction with a conventional timer for controlling air flow through compartments 36 and 38. At the start of the filling operation. the damper 62 is partially closed and opens gradually to compensate for the resistance to the air flow created as the casing is being filled with sections of the web. The speed at which the damper operates can be controlled by pressure valves and gauges. The weight or rate of flow of fibers coming from the garnetter can be predetermined and thus at the appropriate time when the desired amounts of fibers have been deposited within the casing. air gate 42 may be automatically switched. so that the air flow goes through the other compartment of the vacuum chamber.  
  Alternative means are available for switching the suction force from one compartment of the vacuum charm ber to the other when the casings disposed therein have been tilled. This may be accomplished by sensing the relationship between the pressure inside one of the compartments of vacuum chamber 24, which is affected by the amount of filling material inside the casing.  
  By way of example. during the filling operation of compartment 36, air gate 42 is positioned to direct the air flow therethrough (as best shown in FIG. 5 As web sections are being added to casing 50, the negative pressure inside compartment 36 will increase and register on gauge 68. Simultaneously. baffle 62 gradually opens to control the air passing through compartment 36. When the pressure gauge 68 reaches a predetermined level. it will actuate control 70, which in turn actuates air cylinder 66 through air valve 72 thereby actuating air gate 42 switching the suction from compartment 36 to compartment 38 and returning baffle 62 to its starting position.  
  Although in the illustrated embodiment a loosely formed web is constructed from the fibers prior to their insertion into the pillow casing. it should be considered within the scope of this invention to feed fibers by any suitable means and direct them by means of a suction force into an air-penetrable casing so that at least a majority of the fibers lie parallel to the direction of the force applied by the user. Any fibers which are of sufficient length and resiliency so that they may be oriented in the desired manner may be utilized. This may include short fibers as well as continuous filament tow.  
 OPERATION The method of the present invention will be described in connection with the operation described in FIGS. I and 3. The operator attaches four airpenetrable casings 50 inside compartments 36 and 38 of vacuum chamber 24 with their open ends facing the second end of conveyor 26. More specifically. the open ends of casings 50 are wrapped around lip portions 51 which expand to create tension. thus securing casings 50 thereto. By way of example. air gate 42 is switched so that the suction force from suction fan 52 will be di&#39; rected through compartment 36 of vacuum chamber 24.  
  Garnetter 22 is actuated and fibers from a source (not shown) are directed into garnetter 22, which opens, combs and parallels the fibers into the web W. The web W is removed from garnetter 22 and is placed on conveyor 26 at end 27 by comb 28. The web is in two essentially equal widths. which is accomplished by the elimination of a one-inch section 35 of teeth on the surface of garnett roll 29. The web W travels to the end 34, where it comes down from conveyor 26 and sections 58 thereof are severed from the web and are forced by the air flowing into openings 56 in compartment 36 into the two air-penetrable casings located therein. The sections 58 of web W settle inside the easings in a substantially layered or laminar manner. with substantially all of the fibers being horizontally disposed and thus parallel to the direction of the force applied thereto by the user. This formation is evidenced by their being a fair degree of uniformity along the entire length of the pillow as it is being filled.  
  As sections 58 of web W are being filled in casings 50, damper 62, which is partially closed at the beginning of the filling operation. gradually opens as the web sections accumulate in the casings. Damper 62 varies the suction force thereby achieving a relatively constant rate of filling of casings 50. It also eliminates the possibility of turbulence inside the casings and aids in creating a substantially uniform laminar or layered formation of fibers therein.  
  Since the weight or rate of flow of fibers coming from the garnetter 22 can be predetermined. a timer T may be utilized to effect automatic switching of the air gate 42 to switch the application of the suction force from compartment 36 to compartment 38. Simultaneously. damper 62 is returned to its partially closed position. While the operator removes the finished pillows from compartment 36 and reinserts empty casings. the suction force web W into compartment 38. thus creating a substantially continuous operation.  
  As best shown in FIG. 3. removal of pillows from compartment 36 is accomplished by slightly compressing lip portion 51 to remove the tension from the open end of casing 50. unwrapping the open end from lip portions 49 and 51. and removing the fiber-filled casings from compartment 36. Empty casings are then inserted into compartment 36, open end up. The open end is wrapped around lip portions 49 and 51 which expand to secure casing 50 thereto.  
 EXAMPLE The following is a list of criteria that are employed for making a pillow X 26 inches having a filling material weighing l8 ounces and the type of fiber being DuPont No. 808 polyester fiberfill. The speed of the conveyor 26 is 105 feet per minute. and it receives 270 pounds per hour of material from the garnetter 22. With this speed and output. it takes approximately 30 seconds to fill a pair of pillows in one of the compartments. The static pressure in the vacuum chamber 36 begins with one half inch of static pressure. which gradually builds up during the l5 cycle time to a static pressure of 6 inches. In this embodiment. the air permeability of the pillow ticking is 20 standard cubic feet per minute.  
  Other apparatus may be utilized to employ the method described herein. lt is. of course. intended to cover by the appended claims all such modifications which fall within the scope thereof.  
 We claim:  
  1. Apparatus for forming articles having sections of a web of substantially parallel fibers enclosed in an air penetrable casing comprising: means for feeding and moving a fibrous web from a first end to a second end of a conveyor means; a chamber having means dividing the interior thereof into at least two compartments: means for supporting a casing in each compartment of said chamber. with an open end of said casings located essentially below and adjacent to said second end of said conveyor means: means for applying a suction in said chamber at an end thereof opposite said conveyor; duct means leading from said suction means to the bottom of each of said compartments; means for regulating the application of suction between each of said compartments. so that the fibrous web directed off the conveyor at said second end is separated into sections and impelled alternately into casings in said compartments. with the fibers being deposited in said casings in layers. whereby when the articles are filled. substantially all of the fibers will be disposed generally parallel to the direction of the force to be applied thereto.  
  2. Apparatus as defined in claim 1 in which each of said compartments has a plurality of openings in the upper portion thereof into which casings are provided.  
  3. Apparatus defined in claim 1 further including means for controlling the flow of air passing through each of said compartments for preventing turbulence comprising a baffle means in said duct means and a timing means. so that as fibers accumulate in said casings. which increases the resistance to said air flow. said baffle means opens to increase the velocity of said air flow to overcome said resistance. and when said casings have been completely filled with fibers. said regulating means applies said air flow to said other compartment.  
  4. Apparatus defined in claim 1 wherein said means for regulating the application of suction between each of said compartments of said chamber comprises means for sensing a change of pressure in said compartments and an air gate in said duct means. so that when said sensing means detects a predetermined change in pressure said air gate directs said suction to said other compartment.