Process For Making Non-Woven Insulating Sheeting And Products Of Such Process

Abstract

A process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

What is claimed is: 
     
         1 . A process for making insulating fabric, comprising:
 mechanically orienting wool fibers into a batting capable of being used for insulation; and   tacking said batting to a scrim with a loom via needles coupled to a needle board of said loom,   wherein said needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with said batting when stroking in a first direction, and substantial disengagement with said batting when stroking in a second direction, and   wherein said tacking is performed primarily without the use of an adhesive.   
     
     
         2 . The process of  claim 1 , wherein said wool fibers are one of a Merino or Alpaca superwashed wool fibers. 
     
     
         3 . The process of  claim 1 , wherein a loom punch speed is one from a range of 200 to 400 strokes per minute. 
     
     
         4 . The process of  claim 1 , wherein a needle penetration per square inch (NPPSI) of said loom is one from a range of 200 to 450. 
     
     
         5 . The process of  claim 1 , wherein a needle density of said needle board is one from a range of 75 to 115 needles per linear board inch. 
     
     
         6 . The process of  claim 1 , wherein said production width of said loom is a multiple of 30, 45, 36, or 72 inches, wherein a maximum production width is 160 inches. 
     
     
         7 . The process of  claim 1 , wherein a scrim weight is one from a range of 8 to 34 grams per square meter. 
     
     
         8 . The process of  claim 1 , wherein a loom speed is one of a range of 12 to 30 feet per minute. 
     
     
         9 . The process of  claim 1 , wherein a batting weight is one of a range from 70 to 300 grams per square meter. 
     
     
         10 . The process of  claim 1 , wherein a loom punch speed is approximately 400 strokes per minute, an NPPSI is one of a range from 350 to 450, said scrim is a weight of approximately 17 grams per square meter, and a loom speed is approximately 25 feet per minute. 
     
     
         11 . A non-woven insulating fabric, comprising:
 a batting comprised of wool fibers mechanically oriented in a fashion capable of being used for insulation; and   a scrim having said batting tacked thereto via a loom having needles coupled to a needle board,   wherein said needles each comprise a body having a pointed end and barbed edges, thereby enabling engagement with said batting when stroking in a first direction, and substantial disengagement with said batting when stroking in a second direction, and   wherein said batting is tacked to said scrim primarily without the use of an adhesive.   
     
     
         12 . The fabric of  claim 11 , wherein said wool fibers are one of a Merino or Alpaca superwashed wool fibers. 
     
     
         13 . The fabric of  claim 11 , wherein a loom punch speed of said loom is one from a range of 200 to 400 strokes per minute. 
     
     
         14 . The fabric of  claim 11 , wherein a needle penetration per square inch (NPPSI) of said loom is one from a range of 200 to 450. 
     
     
         15 . The fabric of  claim 11 , wherein a needle density of said needle board is one from a range of 75 to 115 needles per linear board inch. 
     
     
         16 . The fabric of  claim 11 , wherein said production width of said loom is a multiple of 30, 45, 36, or 72 inches, wherein a maximum production width is 160 inches. 
     
     
         17 . The fabric of  claim 11 , wherein a scrim weight is one from a range of 8 to 34 grams per square meter. 
     
     
         18 . The fabric of  claim 11 , wherein a loom speed is one of a range of 12 to 30 feet per minute. 
     
     
         19 . The fabric of  claim 11 , wherein a batting weight is one of a range from 70 to 300 grams per square meter. 
     
     
         20 . The fabric of  claim 11 , wherein a loom punch speed is approximately 400 strokes per minute, an NPPSI is one of a range from 350 to 450, said scrim is a weight of approximately 17 grams per square meter, and a loom speed is approximately 25 feet per minute.