Devices and methods for heat-setting yarns

Abstract

This invention is directed to flow management improvement to the known yarn texturing process, and is directed to devices and methods to accumulate one or more yarns between texturing device(s) and coiling device(s) prior to treatment in a heat-setting chamber. The devices and methods of the present invention may further provide for the removal of texturizing media from yarn prior to setting. The present invention allows for the deposition of yarn or yarns onto conveyor for a setting treatment to set an applied form to impart desirable properties to the yarn. The present invention may include any natural or synthetically produced yarn. The devices and methods of the invention may be used to improve the production capability of said heat setting and texturing equipment.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims benefit, under 35 U.S.C. §119(e), of U.S. Provisional Application Ser. No. 60 / 752,560, filed 20 Dec. 2005, the entire contents and substance of which are hereby incorporated by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates generally to devices and methods for heat-setting yarn or yarns in the carpet making and textile arts and more particularly to devices and methods for providing textured yarn or yarns to a conveyer belt of a heat-treating chamber, which may provide production rates for textured yarn or yarns similar to rates usually associated with straight set yarn or yarns. [0004] 2. Description of Related Art [0005] The esthetics and performance of carpet are similar in many respects to those of fabric used in clothing. The type of fiber used, the construction of cloth, and color all play a role in the styling, cost, and performance of a finished g...

AI Technical Summary

Benefits of technology

[0032] Thus, it is an object of the present invention to improve the production rates of textured yarns.

[0033] The present invention is directed to devices and methods for taking friezed yarns and depositing yarns to a conveyer belt of a heat-setting machine in a new and non-obvious manner, providing for increased production over conventional methods. Using the devices and methods according to the present invention, yarn may be laid in more mass than conventionally possible, thus achieving both production advantages and cost savings.

[0036] At an exit end of the tubular housing of an exemplary J-Box, an elbow is provided. Such an elbow may provide an angled or arcuate exit. In an exemplary J-Box of the present invention, a ninety (90) degree elbow may be provided, although other orientations may be used. The elbow may be fabricated of the same material as the tubular housing, or it may be fabricated of differing material. At the exit end of the elbow, a guide may be mounted thereto to facilitate the smooth removal of accumulated yarn or yarns. In various embodiments of the present invention, such a guide may be porcelain, or may be constructed from other materials that would tend to not cause undue abrasion to the yarns that might make them less desirable. If yarn abrasion should be desired in a particular circumstance, a rougher textured guide may be utilized according to the present invention.

[0037] Exemplary devices and methods of the present invention may also comprise a step of texturing media removal within a J-Box mechanism as described. In an embodiment of the present invention, steam may be removed from a J-Box mechanism through portals in the pipe portion or the elbow portion using a blower / fan, suction / fan, or other gas moving device. The portal size(s) and portal pattern(s) may include various embodiments, but must be suitable for the proper removal of steam from the yarns. Removal of steam in the J-Box mechanism helps retain the deposited crimp of the yarns.

[0038] Some embodiments of the devices and methods of the present invention are provided for situations that may not require the removal of steam, or other texturing media. If a “near textured” appearance were desired, texturing media removal may not be necessary. Yet, in other embodiments of the present invention, texturing media removal is desirable to make a product that may retain all or at least a large majority of the added texture. The devices and methods of the present invention produce finished carpet products with improved “tip definition.” This tip definition quality is typically associated with a better valued or higher quality carpet product.

[0040] In various embodiments of the devices and methods of the present invention, upon exiting the J-Box, yarn or yarns may pass through a guide or series of guides that eventually terminate in a coiling mechanism. The coiling mechanism may deposit the yarn or yarns onto the stainless steel belt of the Superba® machine or the Kevlar® belt of the Suessen® machine. The coiling action of the present invention enables for increased productivity in the operation of the heat-setting process, wherein the unwinding of the yarn bundle is smoother, and there are fewer faults on the heat-setting machine.

Problems solved by technology

A problem with this conventional process is the relatively low production rates, as the yarn was deposited onto the belt from the texturing machine in a non-preferred manner.

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