Yarn storage system and method for producing textiles by using yarn storage system

Abstract

A yarn storage container for storing a yarn, the yarn storage container (101) comprising a preferably tubular container (101) having an axial length (L), a preferably tubular wall (501), and first and second axial ends (113-115), the first axial end (113) of the container (101) having an opening (123) for receiving an end of a yarn (200), the second axial end (113-115) having an opening (123) for receiving an end of the yarn (200), the second axial end (115) of the container (101) is air-permeable open or closed, and the wall (501) is an air-permeable mesh along the axial length of the container (101). The invention also relates to a yarn storage system (1000) comprising a plurality of containers (101), to a textile production device (2000) and to a method for producing a yarn (200) and a textile.

Description

TECHNICAL FIELD

[0001] The present invention relates to a yarn storage container and a yarn storage system, in particular to a yarn storage system for a plurality of yarns, such as a yarn storage system for yarns used as pile yarns in a tufting process. The present invention further relates to a creeling system.

[0002] The present invention further relates to a method for producing a textile having a plurality of designs, a method for producing a tufted textile and a method for producing a yarn. BACKGROUND

[0003] Tufting machines are known in the art. A large number of yarns, even up to or exceeding 1000 yarns, can be tufted simultaneously into a primary backing to provide a greige product. In the past, for each tufting yarn, a yarn package was held in a creel.

[0004] At certain moments in the tufting process, the colour or design of the greige fabric can be changed. This happens when the same design is tufted with a different colour palette or colour scheme. This can require the replacement of a large number of yarn packages on the creel that feeds the tufting machine. Re-threading all the yarns into the tufting machine is not only labour intensive but also time consuming.

[0005] EP2885235B1 discloses a yarn packaging system comprising a metered quantity of yarns for small batch production of tufted or woven textiles. The packaging system comprises a plurality of vertical yarn containers. The yarns can be laid from the packaging system to a weaving or tufting machine. The change between different packaging systems can be time consuming.

[0006] In some prior art yarn storage systems that store yarn in tubes, the injected yarn can fold over itself during the loading process. In some cases, the unloading process will cause the folded yarn to form a knot that can have a detrimental effect on the machine that consumes the yarn. For example, a tufting machine can not be able to tuft a yarn with a knot through a backing. SUMMARY

[0007] The present invention is first and foremost directed to an alternative yarn storage system, wherein, according to a preferred embodiment, a solution to the problems of the prior art yarn storage systems is obtained.

[0008] It is an object of the present invention, among many others, to provide a yarn storage system that reduces the changeover time for changing a greige product during a change from one set of yarns to another. It is also an object of the present invention to provide a yarn storage container as part of such a yarn storage system and a method of storing yarn in such a yarn storage system. The present invention further relates to a creeling system for loading such a yarn storage system.

[0009] It is another object of the present invention to provide an alternative method for producing textile with a variety of designs, wherein according to a preferred embodiment, the switching time between designs is shortened. The other alternative methods for producing tufted textile and the method for producing yarn are intended to have advantages over the prior art methods.

[0010] It is a further object of the present invention to reduce the number of knots formed within the yarn storage container during loading and unloading.

[0011] According to a first independent aspect of the present invention, a yarn storage container and a yarn storage system are provided.

[0012] In an embodiment of the present aspect, the yarn storage container disclosed and taught herein can be used to store both wound yarn and unwound yarn. Unwound yarn can be yarn that is not wound or coiled on a bobbin or spool. In this embodiment, the yarn can be laid freely and unguided within the void within the tubular container.

[0013] In a preferred embodiment, the interior cavity of the yarn storage container can be empty. That is, there is no obstruction to the yarn in the container while the yarn is being loaded and unloaded. In this way, the loading of the container with yarn can be performed in a uniform manner so that any changes in tension in the yarn can be avoided while feeding the yarn from the container to a tufting machine or a weaving machine. In an alternative embodiment, the container can include internal means for guiding the yarn along a desired path. For example, the container can include a central cone or truncated cone. In this case, the yarn can be guided to lay freely around the circumference of the cone or truncated cone while the yarn is being loaded. This exemplary embodiment can reduce or even eliminate improper tension. Any such exemplary internal means can be air permeable or air impermeable.

[0014] In a preferred embodiment, the walls of the yarn container can be air permeable so as to allow air to pass radially outwardly through the inner walls of the yarn container.

[0015] In one embodiment, each yarn container can be configured to hold only one length of yarn, wherein the length of the yarn is at least twice or at least ten times the axial length of the container and / or is at least twenty times or at least one hundred times the inner circumference of the cross-section of the yarn container. Preferably, the yarn can have a length of at least 5 meters or at least 10 meters. Preferably, the length is less than 2 kilometers, or less than 750 meters, or less than 500 meters, or less than 250 meters. Preferably, the length is at least 5 meters and preferably in the range of 500 meters to 2500 meters. The minimum length of 5 meters is desirable to allow for threading of the weaving or tufting machine. Preferably, the length of yarn used is at least 1.5 meters more than required according to the design to be created in the textile.

[0016] In a preferred embodiment of the yarn storage container, the opening of the first axial end of the yarn storage container can be configured to receive an end of a yarn. This can be provided by leaving the first axial end of the yarn storage container uncovered or open. In one embodiment, this means that the tubular structure extends all the way to the first axial end. In other embodiments, the first axial end can terminate in a cap, flange or lid, but still leave the first axial end open so as to receive an end of a yarn.

[0017] The second axial end of the yarn storage container can be configured with a gas permeable closure cap, such as but not limited to a perforated cap, configured to close the second axial end of the yarn storage container. Alternatively, the second axial end of the tubular container can be closed by a grid, which can be removably secured to the second axial end. The open area of the gas permeable closure cap can be in the range of 30% to 90% of the total cross-sectional area of the yarn storage container. In other embodiments, the open area can be in the range of 40% to 80%. In a preferred embodiment, the open area can be equal to the open area of the wall of the yarn storage container.

[0018] In another embodiment, the second axial end of the yarn storage container can be configured with a fluid impermeable cap. In this embodiment, the end of the yarn loaded into the yarn storage container will be stopped by the cap, and the propellant fluid will have to exit the yarn storage container through other openings.

[0019] The yarn storage system according to the second aspect of the invention can comprise a plurality of yarn storage containers according to the first aspect of the invention. In one embodiment, the plurality of yarn storage containers in the yarn storage system can be loaded with yarn by blowing yarn into each tube. This can be achieved by entraining the yarn in a propellant fluid (e.g. blowing air) through the opening at the first axial end of each of the containers. The end of the yarn blown into the yarn storage container is blown through the length of the yarn storage container until it reaches the closure of the second axial end. Once the end of the yarn is stopped there, additional yarn can be blown in order to gradually load the container as the yarn is freely laid in the volume of the tubular container. The fluid blown in will exit the cavity of the yarn storage container via the gas permeable closure of the second end and / or openings in the wall. In other words, the end of the yarn at least partially plugs and loads the container.

[0020] Once the desired length of yarn is provided in the yarn storage container, the yarn storage system can be moved to a device that will consume the yarn and convert it into a desired textile product. As a non-limiting example, the yarn can be used by a tufting machine as pile yarn. During consumption of the yarn, the yarn can be gently pulled out of the yarn storage container via the opening at the first axial end, thus in a direction opposite to the direction in which it was blown in. The yarn being unloaded from the container will exhibit little or no change in tension, which facilitates tension control of the yarn during conversion into a textile fabric. The device that consumes the yarn and converts it into a desired textile product can be a tufting machine, a loom, a warp or weft knitting machine, a sewing machine, an embroidery machine, and similar machines.

[0021] In a preferred embodiment, the yarn storage container can include a web. The seamless barrel of the web will provide a boundary for the yarn load and an efficient means of allowing the ingress and egress of a propellant fluid (e.g., air). In another embodiment, a web barrel with smooth seams will also provide a boundary for the yarn load and an efficient means of allowing the ingress and egress of a propellant fluid (e.g., air).

[0022] When the yarn is blown into or sucked into the yarn storage container, the yarn will travel to the second axial end and be stopped there by the cap. The propellant fluid will exit the yarn storage container through the web between the first and second axial ends and the cap.

[0023] In a preferred embodiment, the web will be a seamless continuous web. Seams can provide protrusions in the otherwise smooth interior surface of the yarn storage container that can become places for the yarn to catch and hang up while traveling. In another embodiment, the seams in the web barrel can be smoothed to eliminate the protrusions.

[0024] One method of smoothing the seams can be to cover the seams with a strip that provides a smooth edge. The strip can be thin enough to cover the seams while not significantly reducing the overall air permeability of the web. Another method of smoothing the seams can be to apply a coating at the seams that provides a smooth edge. This can be accomplished by spraying a coating on the web at the seams. In a preferred embodiment, the spraying will only smooth the seams without filling in the openings of the web.

[0025] The openings define the sum of the open area along the walls of the yarn storage container, hereinafter referred to as "open area." The average open area per surface unit of the mesh portion of the cavity can be between about 70% and about 95%. In some more preferred embodiments, the range can be between about 90% and about 93%. In a more preferred embodiment, the open space can be or about 91%. This can be accomplished by employing a mesh having connected strands laid at right angles to each other. In one view, these can be referred to as horizontal and vertical strands. However, the actual orientation of the strands need not have the strands oriented vertically and horizontally or at right angles to each other when forming the tube.

[0026] In one embodiment, the nominal diameter of the strands can be 0.008 inches (0.2032 mm), with 16 strands in one direction and 16 strands at right angles to the first set per square inch (6.4516 cm2). Similarly, 0.004 inch (0.1016 mm) strands in a 16 x 16 strand mesh will have an open space of about 88%. Similarly, 0.003 inch (0.0762 mm) strands will have an open space of about 91.5%, and 0.002 inch (0.0508 mm) strands in a 16 x 16 strand mesh will have an open space of about 96.8%.

[0027] In a more preferred embodiment, the strands can be 0.006 inches (0.1524 mm) with the strands in a 16.5 x 16.5 mesh having an open area of about 91% per square inch (6.4516 cm2) of area.

[0028] In other embodiments, the mesh can be a 16 x 18 strand or a 20 x 20 strand using any of the diameters disclosed herein.

[0029] In one embodiment, the horizontal strands can be woven together with the vertical strands to form the mesh. This can be done using 32-gauge wire having a diameter of 0.008 inches (0.2032 mm). More preferably, this can be done using wire between 34-gauge wire and 35-gauge wire, with the 34-gauge wire having a diameter of 0.0063 inches (0.16002 mm) and the 35-gauge wire having a diameter of 0.0056 inches (0.14224 mm). This leaves a surface having the wires crossing each other and overlying each other. The intersections of the wires can be sprayed or coated as disclosed herein to smooth the junctions so that they do not protrude into any area that can catch a yarn filament.

[0030] In preferred embodiments, the mesh can be made from a single layer. This can be accomplished using any material that dries, hardens, or cures to form a smooth surface that will not have protrusions that can catch on the yarn filaments. Alternatively, the mesh can be made from a material that can leave protrusions, which can be smoothed by grinding and / or coating as disclosed herein to produce a smooth interior, thereby smoothing the protrusions.

[0031] The mesh can be made from any suitable material, including but not limited to: polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, other polymers or combinations of polymers, metal, fiberglass, and other fibers.

[0032] According to some embodiments, the first axial end of the yarn storage container can include a cap proximate the first axial end. In preferred embodiments, the cap can be configured with an opening, such as a shaft or hole, for receiving an end of the yarn. Such a cap can further minimize the risk of tangling and / or tensioning of the yarn by being provided with a smooth interior bore. In addition, the cap can be configured to prevent the yarn from being accidentally removed from the container, such as when the container is moved in a non-horizontal orientation. The cap can be configured to fit in and / or on the axial end of the yarn storage container. The cap can be a plug or a cap. The cap can be removably secured to the first axial end. The cap can be attached by a clip, clamp, magnet, or can be held by friction or interference fit.

[0033] In some embodiments, the second axial end of the yarn storage container can include an end cap proximate the second axial end. In preferred embodiments, the end cap can be made from the same mesh material as the wall of the yarn storage container. The end cap can be chemically bonded or mechanically secured to the wall of the second axial end.

[0034] In some embodiments, the first axial end of the yarn storage container can include a grommet for receiving an end of the yarn. The grommet can be part of the cap, providing an opening of the cap. In one non-limiting exemplary embodiment, the grommet can fit into a shaft of the cap, substantially closing the first axial end.

[0035] In other embodiments, the grommet can be configured to mechanically couple with the first axial end of the container.

[0036] In some embodiments, the grommet can be a tubular piece, the length of which is generally relatively short, such as between 0.5 inches and 2 inches (1.27 cm and 5.08 cm). The inner diameter of the opening of the tubular piece can vary, such as between 0.25 inches and 2 inches (0.635 cm and 5.08 cm), or such as between 0.5 inches and 1 inch (0.635 cm and 2.54 cm). The grommet can be electrically conductive.

[0037] The grommet can be made of metal, such as iron, steel, pure copper, aluminum, bronze, brass, or any alternative metal alloy, or can be made of a conductive polymer, such as a carbon fiber or carbon powder filled polymer, such as carbon powder filled polypropylene, polyethylene, polyamide, polyvinyl chloride, etc. In an alternative, the grommet can be made of a ceramic material.

[0038] In some embodiments of the yarn storage container, the first axial end of the container can include a brush for contacting the end of the yarn. The brush can be proximate to an opening provided in a cap that substantially closes the first axial end. In non-limiting exemplary embodiments, the bristles of the brush can close the opening or shaft. The bristles that contact the yarn in or through the opening can be configured to exert minimal tension as the yarn is pulled out of the container. The brush can be a straight brush in which the bristles are all substantially parallel, or can be a circular brush in which the bristles are oriented toward a central point. For a circular brush, the bristles can overlap at the central point, but preferably leave an opening of about 0.25 inches to 1 inch (0.635 cm to 2.54 cm), such as about 0.75 inches (1.905 cm).

[0039] In some embodiments, the cap can be secured to the first axial end. It can be configured such that a portion of the cap fits within the first axial end for a distance. That is, a portion of the cap can be configured to slide within the mesh at the first axial end. As the portion of the cap slides within the first axial end, the diameter of the mesh can be expanded. In embodiments in which a relatively small force is applied over the area of the mesh where the portion of the cap is in contact with the first axial end, the resulting tension fit can be sufficient to removably secure the cap to the mesh of the yarn storage container. However, if a more permanent configuration is desired or required, the mesh at the first axial end can be mechanically secured to the portion of the cap. Alternatively, the mesh can be chemically fused or bonded to the portion of the cap.

[0040] In another embodiment, the mesh of the first axial end can be held in a radial slit in a circumferential lip of the cap. In this case, the radial slit can extend axially into the lip to fit the circumference of the first axial end mesh. Again, these components can be secured either mechanically or chemically.

[0041] According to some embodiments, the cap can include one or more small openings along a contact area where the cap contacts the first axial end. The openings can be small perforations, holes, slits, or any passageway that allows fluid (e.g., air) to flow through. In one embodiment, a laminar air flow can be provided at the first axial end of the yarn storage container by gently blowing or sucking air into the interior cavity of the yarn storage container through the small openings. That is, air blown from the outside through the openings to the inside can push the yarn, while air sucked from the outside through the openings to the inside can pull the yarn. In the latter case, the container can include a means to create a sub-atmospheric pressure in the yarn storage container via the second axial end.

[0042] In some embodiments, the sub-atmospheric pressure can be created by extracting air from the second axial end to reduce the pressure within the cavity to a pressure that is lower than the ambient pressure outside of the yarn storage container. This will create a pressure gradient in the axial direction of the yarn storage container that will help the yarn end, as well as the segment of yarn blown into the container, to more easily and completely move up to the second axial end. This can also help to increase the amount of yarn that can be introduced into the container as it can compress the inserted yarn in the direction towards the second axial end.

[0043] This measure of creating a sub-atmospheric pressure in combination with a cap that includes one or more small openings along a contact area where the cap contacts the first axial end can be part of the measure to create a laminar air flow along the interior walls of the yarn storage container, or it can be the only measure to create a laminar air flow.

[0044] The laminar air flow can be used to transport the yarn into the yarn storage container and prevent the yarn from folding on itself within the container, also known as "bridging." That is, the yarn does not fold or accumulate on itself to form an obstacle in the interior portion of the container before reaching the end of the container cavity. This accumulation can cause the yarn to tangle and result in a lack of sufficient volume within the container to store sufficient yarn. The bridging problem, which can be associated with yarns based on PET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), PP (polypropylene), PA (polyamide), wool, or cotton, is mitigated using embodiments of the present disclosure.

[0045] As previously mentioned, if the yarn tangles while being loaded, knots can form when the yarn is unloaded. Any tension on the yarn can cause the knot to tighten and make it difficult or impossible for any machine consuming the yarn to consume the yarn.

[0046] In another embodiment, the yarn storage container can include a grounding system for grounding the conductive brush, grommet, container, or tube. This can be achieved by providing a conductive coating along the interior wall; either a full coating or a partial coating, such as by using a strip of conductive material along the axial length of the yarn storage container. Such a conductive coating material can be silver, gold, aluminum, pure copper, brass, bronze, tin, or similar metals or metal coatings. Since the yarn storage container forms a part of the yarn storage system, the entire system can include a grounding system.

[0047] While some embodiments of the yarn storage container described herein can be a cylinder having a circular cross-section, it is not limited to this configuration. In alternative embodiments, the yarn storage container can have other cross-sectional shapes. In some embodiments, the cross-sectional shape can be oval, square, or rectangular.

[0048] According to some embodiments, the surface area of the radial cross-sectional area of the yarn storage container can be between 0.75 square inches to 13 square inches (4.84 square centimeters to 83.87 square centimeters). More preferably, the cross-sectional area of the radial cross-section of the tubular container can be between 1.5 square inches to 13 square inches (9.68 square centimeters to 83.87 square centimeters), such as between 2 square inches to 13 square inches (12.90 square centimeters to 83.87 square centimeters).

[0049] In some embodiments, the yarn storage container disclosed and taught herein can be flexible. In some embodiments, for example, if the webbing of the yarn storage container is made of vinyl-coated polyester or fiberglass, it can deform under its own weight. The weight of the upper layers of the yarn storage container can deform the lower layers of the yarn storage container if there is no structure within the yarn storage container system to maintain the shape. Applicant has solved this problem by developing an outer sheath made of a stiffer material to surround the webbing of the yarn storage container. In one embodiment, the outer sheath can be a webbing that provides support while not interfering with the flow of the propellant fluid. Other outer sheaths that are consistent with the claimed invention will be able to be conceived by those of skill in the art and those in possession of the present disclosure.

[0050] In some embodiments, the axial length of the yarn storage container can be between 15 inches to 110 inches (38.1 centimeters to 279.4 centimeters). In more preferred embodiments, the axial length of the yarn storage container can be between 20 inches to 100 inches (50.8 centimeters to 254.0 centimeters), such as between 24 inches to 96 inches (61.0 centimeters to 243.8 centimeters).

[0051] According to a third aspect of the present application, a yarn storage system is provided. The system can comprise at least two yarn storage containers according to the first and / or second aspect of the present application. The containers can be of the same size and they can be organized in a rack.

[0052] In one embodiment, a rack can comprise from 16 to 1,024 containers. In a more preferred embodiment, a rack can comprise from 36 to 1,000 containers, which can be organized in a matrix arrangement. The matrix can comprise from 4 to 32 rows and from 4 to 32 columns, or, in a more preferred embodiment, from 6 to 30 rows and from 6 to 30 columns. In a more preferred embodiment, a rack can comprise 24 rows and 10 columns, to have 240 containers.

[0053] In one embodiment of a matrix arrangement of yarn storage containers, the containers can be positioned adjacent to each other in such a way that all yarn storage containers do not contact each other. In another embodiment, the yarn storage containers can contact each other. In some embodiments, the internal support structure can be configured to support the length of the yarn storage containers to prevent them from sagging and / or deforming under their own weight.

[0054] In one embodiment, the rack of yarn storage containers can be at least partially enclosed. In a preferred embodiment, the first axial end of each of the yarn storage containers can be surrounded by a face of the rack enclosure. In this embodiment, the contiguous sides of the rack can also be covered, leaving only the sides of the rack near the second axial end open. In this way, all of the propellant fluid injected into each of the yarn storage containers must exit the enclosure from the face of the enclosure adjacent to the second axial end of the yarn storage container. That is, propellant fluid injected into the first axial end of a yarn storage container will have to travel along the length of the yarn storage container to exit the enclosure. Directing the propellant fluid in this way will propel the end of the yarn towards the second axial end of each of the yarn storage containers. Furthermore, covering some of the sides will prevent any air flow through the yarn storage system from interfering with the propellant fluid as it propels the yarn during a loading operation. Likewise, this will also prevent air flow from interfering with an unloading.

[0055] If yarn is loaded into several or all of the yarn storage containers, propellant fluid can be injected into all of the yarn storage containers simultaneously to propel all of the yarn ends towards the second axial end of the respective yarn storage container of all of the yarn ends.

[0056] In one embodiment, the yarn storage containers can be loaded when they are in a substantially horizontal orientation. That is, the yarn storage containers can be loaded when they are inclined at an angle of about 30° or less from the horizontal. In this embodiment, it is preferred that the propellant fluid be configured to propel the end of the yarn all the way to the second axial end.

[0057] In another embodiment, the yarn storage containers can be loaded in their substantially vertical state. That is, the yarn storage containers can be within 20° of vertical. In this embodiment, the propellant fluid need not be forced to propel the yarn to the second axial end as in previous embodiments, as gravity will assist. However, the propellant fluid still helps to keep the yarn end away from the interior walls of the yarn storage system so that the yarn does not stop or fold before reaching the second axial end.

[0058] In another embodiment, each yarn storage container can be placed within a separate enclosure that is larger than the exterior of the yarn storage container. Similar to enclosing the entire gantry, each enclosure fits over the first axial end and its contiguous four sides and is open at the end proximate the second axial end. In this way, the propellant fluid injected at the first axial end will flow along the axial length of the yarn storage container to exit at the back of the gantry. As the yarn is loaded, it can block the propellant fluid from reaching the end of the yarn storage container. If this occurs, the propellant fluid will exit the yarn storage container along the length of the tube.

[0059] In some embodiments, the gantry can be movable. For example, the yarn storage system can be located on rollers, wheels, casters, skids, or any other mechanism that allows the yarn storage system to move.

[0060] In preferred embodiments, the first axial ends of the yarn storage containers can be coplanar, that is, they can all present a common face of the gantry. That is, all of them can be aligned with a plane located near a face of the gantry. Preferred embodiments are also where the yarn storage containers can have the same axial length.

[0061] According to some embodiments, the yarn storage containers can be oriented in a vertical position. According to preferred embodiments, the yarn storage containers can be oriented in a horizontal or substantially horizontal position. Preferably, the containers are oriented in a horizontal or near horizontal manner. However, according to alternative embodiments, the yarn storage containers can be oriented along a slope, where the first axial end points downward and preferably at an angle of 15° or less from horizontal. The horizontal or slightly inclined orientation of the containers can improve the withdrawal of the yarn, for example when connected to a tufting machine. Thanks to the horizontal or substantially horizontal orientation of the containers, several storage systems, for example for subsequent designs of tufting on the same tufting machine, can be placed one on top of the other and can be switched from one to the other in a fluid manner. Moreover, a more compact machine can be used to load the containers of several storage systems in a more fluid manner.

[0062] In some embodiments, the rack can be rotatable such that in one position the yarn storage containers are substantially vertical and in another position the yarn storage containers are substantially horizontal or at a desired angle of inclination. In this way, the rack can be positioned with the yarn storage containers in a vertical orientation for loading and when yarn is being withdrawn the rack can be rotated such that the yarn storage containers are horizontal or slightly horizontal.

[0063] The horizontal or substantially horizontal positioning of the yarn storage system containers forms a particular independent aspect of the invention per se, namely a yarn storage system comprising at least two yarn storage containers for storing unwound, untensioned and / or freely provided yarn, wherein the containers are elongate and comprise a first end from which yarn can be drawn and wherein the containers are oriented horizontally or substantially horizontally in the yarn storage system, wherein preferably the inclined orientation comprises the first end of the containers being oriented downwards and / or the inclined orientation comprises the containers forming an angle of 15° or less with the horizontal. It will be clear that the yarn storage system of this particular independent aspect of the invention can exhibit one or more of the features of the preferred embodiments of the third aspect of the invention without the containers necessarily having to exhibit the gas permeable mesh wall and the impermeable second end of the containers of the first aspect of the invention and / or the means for generating a laminar air flow provided in the second aspect of the invention.

[0064] In some embodiments, each yarn storage container in the yarn storage system of the invention can be provided with at least one yarn detector. The yarn detector can be, but is not limited to, an electronic, mechanical or optical yarn detector which can detect the presence of yarn at the opening at the first axial end of each yarn storage container. The yarn detector can be part of a yarn detection system which is further equipped with a processing unit to receive the signal of the yarn detector. In such embodiments, the presence or absence of yarn can be detected and a signal can be generated when at least one yarn detector fails to detect yarn. The yarn storage system can then work in conjunction with a yarn consuming machine, such as a tufting machine. In some embodiments, the yarn consuming machine can use the signal indicating the absence of yarn to interrupt its operation. The system can also sound an alarm to alert an operator or attendant to the situation.

[0065] According to some embodiments, the yarn storage system can comprise a yarn end holding device comprising a plurality of apertures or slots. In this embodiment, the number of apertures or slots can be the same as or more than the number of yarn storage containers of the yarn storage system, wherein each aperture or slot is configured to receive one yarn end from one of the containers.

[0066] The orifices or slots can all be adjacent to each other in one row, or can be organized in two or more rows, optionally in a zigzag configuration. Each slot or orifice can be provided with a ceramic tube to prevent the passing yarn from eroding or wearing the orifice or slot.

[0067] The yarn end holding device can generally be provided as a beam, for example but not limited to a rectangular block in which orifices or slots are provided. Most preferably, the yarn end holding device has a comb-like structure.

[0068] According to a fourth independent aspect of the present invention, a yarn storage system is used to supply yarn to a textile machine.

[0069] According to some embodiments, there is provided a use of a yarn storage system according to the third aspect of the present invention for supplying yarn to a textile machine, such as supplying pile yarn to a tufting machine. Preferably, for each needle of the tufting machine, at least one yarn storage container is contained. Preferably, such a yarn storage system contains a plurality of yarn storage containers, the number of which can be the same as or a multiple of the number of needles in the tufting machine.

[0070] The yarn storage system can be used to store bulked continuous filament yarn, for example which can be used by a tufting machine to supply pile yarn to a base cloth for tufting in a process of manufacturing tufted carpets or floor mats. The exemplary embodiments disclosed herein are not limited to manufacturing only tufted carpets or floor mats. A person of ordinary skill in the art will recognize that the yarn storage system can be used to supply yarn to other textile production equipment, for example warp knitting machines, carpet looms and similar devices.

[0071] According to a fifth independent aspect of the present invention, there is provided a method for storing yarn.

[0072] The yarn storage method according to the fifth aspect comprises the following steps:

[0073] a) providing a yarn storage system according to the third aspect of the present invention;

[0074] b) providing N yarn bobbins, wherein N is an integer greater than or equal to 1 ;

[0075] c) repeating the following sub-steps:

[0076] - selecting at least one yarn storage container so as to be at least partially loaded with yarn from a bobbin;

[0077] - defining a length of yarn to be loaded for the selected yarn storage container;

[0078] - selecting one of the N yarn bobbins;

[0079] - loading the defined length of yarn from the selected bobbin into the selected yarn storage container by means of a propelling fluid, for example pressurized air;

[0080] For a plurality of yarn storage containers, optionally up to all containers are at least partially loaded with yarn.

[0081] According to some embodiments, N can be larger than 1. Preferably, the number of yarns used will be between 2 and 10, more preferably between 2 and 8, for example 3, 4, 5, 6, 7 or 8 yarns.

[0082] According to some embodiments, the loading of yarns into the yarn storage containers can be carried out by a robot comprising a creel comprising N yarn bobbins. In some embodiments, the robot can comprise a storage unit capable of associating the loading data with the following information:

[0083] - an identifier of the creel,

[0084] - the position of the yarn storage container in the creel,

[0085] - an identifier of the loaded yarn, and

[0086] - the length of the loaded yarn;

[0087] The robot comprises input means for inputting the loading data to the storage unit, the robot comprising a control unit defining a loading sequence of the yarn storage containers and controlling the loading of the identified yarns into each yarn storage container while executing the loading sequence.

[0088] The robot can also comprise mechanical means to position the means for loading the yarns into each yarn storage container of the yarn storage system. This mechanical means can be various arms that can be actuated to move vertically and horizontally. The precise movement of the arms can be controlled by a controller to position the yarn loading means, which for example is an injector that can inject and propel the end of the yarn into the yarn storage container using a propellant fluid. The robot can also be configured to control a pump or a valve to cause the flow of a propellant fluid that can be used to propel the yarn. Similarly, the robot can be connected to a mechanism that measures the length of the yarn that is propelled into each yarn storage container.

[0089] According to these instructions, the robot starts loading each container with the correct yarn. The robot first makes sure that it selects the end of the yarn that is needed to load the next tubular container, brings its injection means in front of the opening at the axial end of the selected container, and loads the yarn while directly or indirectly measuring the length of the yarn.

[0090] According to some embodiments, when N > 1, the yarns on the N bobbins can all be different from one another. In these embodiments, the yarns can differ in color or shade, or can have different linear weights or compositions. Further, in some embodiments, the yarns can be made of bulk continuous filament (BCF) or staple fiber.

[0091] In preferred embodiments, the yarns used are so-called fine tufted yarns, which are finer than standard BCF yarns.

[0092] In some embodiments, the defined length of the yarns can range from 2,000 feet to 10,000 feet (609.6 to 3048.0 meters). In preferred embodiments, the length of the loaded yarns can range from 3,500 feet to 7,500 feet (1,066.8 to 2,286.0 meters).

[0093] It will be understood by those skilled in the art and having the benefit of the present disclosure that any type of yarn can be loaded and held in the yarn storage system. In one embodiment, yarns having a denier in the range of 900 to 4,000 denier can be loaded and stored. In preferred embodiments, yarns having a denier in the range of 1,100 to 3,600 denier can be loaded and stored. Yarns having these deniers are also suitable for unloading to a yarn consuming device while not exhibiting excessive tension.

[0094] According to some embodiments, the yarn storage system can include a vortex injector for loading any length of yarn into any selected yarn storage container in the yarn storage system. However, it will be understood by those skilled in the art and having the benefit of the teachings and disclosure herein that any type of injector can be used. In some preferred embodiments, the injector can utilize a Venturi effect to draw the yarn into the injector, where the yarn is further propelled by a propellant fluid into a Venturi tube.

[0095] In some cases, the propellant fluid can be air or any other gas. In some embodiments, the propellant fluid capacity of the vortex injector can be 2 to 15 cubic feet per minute (CFM) (56.6 to 424.8 liters per minute). More preferred embodiments can have a vortex injector with a capacity of 3 CFM to 8 CFM (85.0 liters per minute to 226.5 liters per minute), and even 5 CFM to 8 CFM (141.6 liters per minute to 226.5 liters per minute). In preferred embodiments, when fine tufted yarns are used, a vortex injector with a capacity of 5 CFM to 8 CFM (141.6 liters per minute to 226.5 liters per minute) can be more advantageous.

[0096] The method has the advantage that a limited number of bobbins can be used to provide a variety of organized yarn storage. Organized yarn storage means that for each yarn storage container it is known which yarn is contained and the length of the yarn contained. Thus, a plurality of yarns can be prepared for each needle of a tufting machine or similar device to provide an end of yarn, while only a limited number of bobbins need to be prepared at hand. The length of the yarn in the container can be measured precisely and can be limited. Thus, a given "small" length of carpet can be provided with little waste of yarn. The latter because the length of the yarn in the container can be calculated from the yarn consumed by the tufting machine to produce the length of the carpet.

[0097] It will be understood by those skilled in the art and having the benefit of the present disclosure that the number of bobbins need not be limited to the number of needles in the tufting machine. Each type of yarn or color of yarn needed can be loaded into a plurality of yarn storage containers in the yarn storage system. Then, the yarn in each yarn storage container can be directly connected to a tufting needle.

[0098] The possibility of moving the yarn storage system enables the loading of the yarn storage system in a dedicated location, which can include a robot. In the present disclosure, a robot refers to a mechanism that can be used to automate the loading of the yarn storage containers in the yarn storage system. This can be a mixture of mechanical components controlled by electronic devices, where the electronic components can be configured to control the mechanical components. The electronic devices can include a device for inputting configuration information, a memory for storing information, and a controller. The controller can control the mechanical components to position the devices that can be used to load the yarn into the yarn storage containers.

[0099] The yarn storage system loaded with yarn can be moved to the location of the textile machine where the yarn will be taken, while the empty yarn storage system can be moved to the reloading station. In some cases, this can require only a limited storage space compared to the spool racks that now carry the same number of bobbins of yarn in the yarn storage containers.

[0100] In some embodiments, the length of each of the required yarns can be known or calculated from the design of the textile to be produced. This can be achieved by software that is able to convert the design into a set of yarns with defined properties, such as but not limited to length, color, quality, fineness, etc. Thereby, the robot can be configured to load each yarn with defined properties into a separate yarn storage container. In a preferred embodiment, the length of the yarn to be inserted can be slightly longer than the actual length required for the production of the textile product. For example, the actual length to be inserted can be between 100% and 110% of the required length. The excess length allows for the start-up and running out of the design, as well as for the textile machine to thread the desired textile.

[0101] According to a sixth aspect of the present invention, there is provided a yarn storage container similar to the yarn storage container of the first and / or second aspect of the present invention, wherein the wall or walls of the yarn storage container are air-tight, such that they do not have openings along their axial length. In some embodiments, the yarn storage container can have a limited axial length. In preferred embodiments, the axial length can be less than or equal to 1.5 meters. In other embodiments, the axial length can be less than or equal to 1 meter, and have a circular cross-section with a diameter preferably less than 4 inches (10.16 cm).

[0102] According to a sixth aspect, there is provided a yarn storage container for storing yarn, the yarn storage container comprising a yarn storage container having an axial length, a tubular wall, and first and second axial ends, the first axial end of the tubular container having an opening for receiving an end of a yarn, the second axial end of the tubular container being air-tight, the tubular wall being air-impermeable.

[0103] All features of the yarn storage container according to the first and / or second aspect of the present invention, which features are independent of the air permeability of the wall of the yarn storage container, can be applied to the yarn storage container of this sixth aspect.

[0104] According to a seventh aspect, a yarn storage system according to the seventh aspect of the present invention can be provided with a plurality of yarn storage containers according to the sixth aspect and / or preferred embodiments thereof. All features of the yarn storage system according to the third aspect of the present invention, which features are independent of the air permeability of the tubular wall, can be applied to the yarn storage container of this seventh aspect.

[0105] According to a stand-alone eighth aspect, there is provided a yarn storage system, wherein the yarn storage system comprises at least first and second yarn storage containers, the first and second yarn storage containers being elongated, preferably tubular, and having an axial length and an elongated peripheral wall extending between first and second axial ends, the first axial end of the container having an opening for receiving an end of a yarn, characterized in that the yarn storage system is further provided with at least one of the following features, or a combination of two or more of the following features:

[0106] - the first and second containers are positioned or positionable in the storage system with their axial length directed towards the horizontal. With this feature, it is possible to obtain a stack of several yarn storage systems, while having access to the yarn at the first axial end;

[0107] - the first and second containers are positioned or positionable in the storage system with their axial length obliquely oriented relative to the horizontal plane, the obliquity being at an angle of 15° or less with the horizontal plane. With this feature, it is possible to obtain that the yarn is more or less kept in place in the respective container. The former can be preferred when loading the respective container or when moving the storage container, while the latter can be preferred when discharging or pulling out the yarn from the respective container, for example when feeding a textile machine;

[0108] - the first and second containers are positioned or positionable in the storage system with their axial length obliquely oriented relative to the horizontal plane, the obliquity being at an angle of 15° or less with the horizontal plane. With this feature, it is possible to obtain that the yarn is more or less kept in place in the respective container. The former can be preferred when loading the respective container or when moving the storage container, while the latter can be preferred when discharging or pulling out the yarn from the respective container, for example when feeding a textile machine;

[0109] - the storage system comprises a plurality of containers, including the first and second containers, wherein the plurality of containers are positioned in a matrix, wherein the matrix is preferably substantially uniform. By uniform matrix, it is meant that the axes of the respective containers are positioned equidistant from each other in horizontal and / or vertical direction;

[0110] - the storage system comprises a plurality of containers, including the first and second containers, wherein the first and second containers are positioned adjacent to a plurality of other similar containers in a matrix, wherein at least a portion of the outer wall of the first and second containers is not in contact with any of the plurality of adjacent containers; preferably, the matrix or stack of containers included in the storage system comprises voids defined by portions of the outer walls of the plurality of containers, as described above in connection with the third aspect of the application;

[0111] - at least one of the first and second containers is provided with a yarn detector and / or the storage system comprises means for detecting the yarn and / or the yarn end of at least one of the first and second containers. The signal from such a yarn detector can be used to directly or indirectly control a textile machine pulling yarn from the storage system;

[0112] - at least one of the first and second containers is provided with means for generating a laminar flow of air, preferably from the first axial end to the second axial end. Such a laminar flow of air can be beneficial for good loading and / or unloading of the first and / or second container;

[0113] - at least one of the first and second containers exhibits features of the first and / or second aspect of the application and / or features of the preferred embodiments thereof;

[0114] - the yarn storage system is directly linked to a tufting machine or a weaving machine, for example, the yarn from at least one of the first and second containers is positioned to be tufted or woven in the machine. Preferably, the yarn storage system comprises at least as many yarn storage containers as the amount of yarn necessary to feed the respective machine. Preferably, the yarn storage system comprises between 16 and 1024 yarn storage containers;

[0115] - the yarn storage system comprises yarn end holding means comprising a number of apertures or slots, the number of apertures or slots preferably being equal to or greater than the number of containers of the yarn storage system, each aperture or slot preferably being adapted to receive an end of a yarn from one of the containers. This feature minimizes the risk of yarn entanglement and / or can enable the textile machine to feed smoothly;

[0116] - at least one of the first and second containers comprises a lid substantially closing the first axial end, the lid being provided with a shaft for providing the opening for receiving the end of the yarn. Providing a lid at the first axial end can provide guidance of the end of the yarn when the yarn is discharged from the respective container, for example when feeding to a textile machine, while at the same time limiting the movement of the bulk of the yarn within the container;

[0117] - at least one of the first and second containers comprises an electrically conductive layer or an electrically conductive strip on its inner wall. As explained in connection with the first and second aspects, such an electrically conductive layer or an electrically conductive strip can minimize the risk of bridging of the yarn somewhere in the middle of the container. Thus, the axial length of the container can be made longer to increase the loading capacity, while at the same time not encountering significant difficulties when loading or unloading;

[0118] - at least one of the first and second containers is electrically grounded. This feature avoids any disturbing influence of charge accumulation on the safe and reliable operation of the yarn storage system;

[0119] - at least one of the first and second containers is configured for tensionless storage of the yarn. The yarn can be used in an unwound state in the interior void of the first and / or second container, or in other words, the yarn is freely laid in the interior void of the first and / or second container. In this way, tensional pulling when discharging the yarn from the first and / or second container can be largely avoided;

[0120] - the first and / or second containers are dimensioned to have an internal void with an axial length to diameter ratio of at least 10 or 25 or more. In case the containers are not tubular and cylindrical, the diameter refers to the diameter of the largest circle that can fit in the internal void. These elongated containers allow for a compact yarn storage system. Preferably, such elongated containers are provided with means to dissipate static electricity from the inner wall, for example means comprising a conductive coating or conductive strips on the inner wall, to avoid undesired accumulation or bridging of yarn somewhere in between the first and second axial extremities;

[0121] - the yarn storage containers are provided with a data storage for storing data about the yarns contained in the first and / or second yarn storage containers and / or possibly other containers. Such data can include one or more of a color indication, a length, a type of each yarn, their position in the yarn storage container, a design they provide in the yarn storage container, production planning data;

[0122] - the yarn storage containers are provided with a scannable data tag, for example a barcode or a QR code, for example linked to an address at which any data about the yarns contained in the plurality of yarn storage containers can be obtained, for example using a computer network or the World Wide Web. Such data can include one or more of a color indication, a length, a type of each yarn, their position in the yarn storage container, a design they provide in the yarn storage container, production planning data.

[0123] It will be understood by the person skilled in the art having mastery of the present disclosure and general technical knowledge in the field that, although the above features have been described in connection with a first and a second yarn storage container within a yarn storage system, this yarn storage system can contain a plurality of containers, for example between 10 and 10 000, preferably between 16 and 1024 containers, more preferably between 200 and 300 yarn storage containers. Preferably, at least most of the yarn storage containers, even better all of the yarn storage containers in the yarn storage system have similarities, i.e. they collectively have at least one of the above features. Preferably, they collectively have two or more of the above features.

[0124] According to a ninth aspect of the present invention, the yarn storage system according to the seventh and / or eighth aspect is used for supplying yarn to a textile machine. It will be understood that this yarn storage system can be used for providing yarn to any textile production equipment, for example but not limited to: a tufting machine, a warp knitting machine, a warp as for a loom, for example a carpet loom, etc.

[0125] According to a tenth independent aspect, the present application is also a textile production assembly, wherein the textile production assembly comprises at least a first yarn storage system and a textile production machine, wherein the textile production machine produces a textile based on a continuous yarn and / or is selected from the list consisting of a tufting machine, a weaving machine and a knitting machine, characterized in that the first yarn storage system comprises at least a first and a second yarn storage container for storing a continuous yarn, the first and the second yarn storage container are elongated, preferably tubular, and have an axial length and an elongated peripheral wall extending between a first axial end and a second axial end, the first axial end of the container has an opening for receiving an end of a yarn, wherein the first yarn storage system further comprises means for communicating with the textile production machine, in particular means for communicating that a yarn from the first and / or the second container is running short. The ability of the yarn storage system to communicate with the textile production machine provides new advantageous control possibilities for the textile production assembly and for preventing false productions.

[0126] For example, the yarn storage container can comprise a data storage comprising any data about the yarns contained in the plurality of yarn storage containers. Such data can comprise one or more of a color indication, a length, a type of each yarn, their position in the yarn storage container, a design they provide in the yarn storage container, production planning data. According to a variant, the yarn storage container can comprise a data storage containing an address at which any data about the yarns contained in the plurality of yarn storage containers can be retrieved, for example by using a computer network or the World Wide Web.

[0127] Preferably, the first yarn storage system comprises the features of any one of the third, seventh or eighth aspect of the present application and / or the preferred embodiments thereof.

[0128] Preferably, the first yarn storage system is at least provided with the following features in combination:

[0129] - at least one of the first and second containers is provided with a yarn detector and / or the first yarn storage system comprises means for detecting a yarn of at least one of the first and second containers;

[0130] - the yarn detector generates a signal to communicate with the textile machine directly or indirectly by the means for communication.

[0131] The yarn detector can provide any information about the state of the yarn to the textile machine by the means for communication. Such information can contain data about the tension in the yarn, the availability and / or lack of yarn, the remaining length and / or the consumed length of the yarn.

[0132] Preferably, said means for communication are selected from the list of electrical and electronic devices, wherein said means for communication preferably comprise a wireless link between said first yarn storage system and said textile machine. Of course, the communication can also be performed by means of magnetic, pneumatic or hydraulic devices, or by means of optical signals.

[0133] Preferably, when said textile machine receives a signal (e.g. a signal of lack of a corresponding yarn) through said means for communication, said textile machine is configured to suspend the operation, or to continue the processing with yarns from a replacement container in said first yarn storage system or from a different yarn storage system.

[0134] Preferably, said textile machine assembly further comprises means for connecting one or more yarns of said first yarn storage system to one or more yarns of a second (preferably similar) yarn storage system. Thanks to the presence of this means, it is possible to avoid a completely time-consuming rethreading of the textile machine. Preferably, said means for connecting comprise a support for positioning one or more yarns of said first yarn storage system and one or more yarns of said second yarn storage system, wherein said means for connecting further comprise an apparatus for connecting said one or more yarns of said first yarn storage system with said one or more yarns of said second yarn storage system, preferably while being positioned on said support; said support preferably comprises a set of spaced apart independent yarns respectively from said first and / or second yarn storage system. The apparatus for connecting the yarns can rely on thermal bonding and / or chemical bonding.

[0135] According to an eleventh aspect of the present application, a method for storing yarns is provided.

[0136] The method for storing yarns according to the eleventh aspect of the present application comprises the following steps:

[0137] providing a yarn storage system according to the seventh aspect of the present application;

[0138] providing N spools of yarn, wherein N is an integer greater than or equal to 1 ;

[0139] repeating the following steps

[0140] - selecting one or at least one container, e.g. tubular, to be at least partially loaded with yarns of said spools;

[0141] - defining a length of yarn to be inserted for said selected container;

[0142] - selecting one of the N yarns;

[0143] - injecting said selected yarn from said spool for said defined length into the selected container by means of a propelling fluid (e.g. pressurized air);

[0144] For multiple containers, optionally until all containers are at least partially loaded with yarn.

[0145] All features of the method according to the fifth aspect of the invention, regardless of the air permeability of the yarn storage container wall, can be applied to the methods of the eleventh aspect.

[0146] It is evident that the first to eleventh aspects described above are particularly advantageous when used for the production of small batches of textiles. That is, the first to eleventh aspects allow for the efficient production of several products of one design (first batch), followed by the production of several products of different designs (second batch).

[0147] To provide a further alternative method suitable for small-batch production, the present invention, according to its twelfth independent aspect, is a method for producing textiles having multiple designs, wherein each design is created from a set (preferably continuous) of yarns, characterized in that the method comprises:

[0148] - Provide a first set of yarns for a first design of the plurality of designs; wherein one or more of the first set of yarns are disposed in a first yarn storage system, wherein the first yarn storage system includes a first plurality of containers;

[0149] - Provide a second set of yarns for a second design of the plurality of designs; wherein one or more of the second set of yarns are disposed in a second yarn storage system, wherein the second yarn storage system includes a second plurality of containers;

[0150] - The first design is produced by pulling yarn from one or more of the first plurality of containers;

[0151] - Connect one or more yarns from the first plurality of containers to the yarns in the second plurality of containers;

[0152] - The second design is produced by pulling yarn from one or more of the second plurality of containers.

[0153] Preferably, the container is a yarn storage container having the features of the first and / or second and / or sixth aspects and / or their preferred embodiments, and / or the yarn storage system has the features of the third and / or seventh and / or eighth aspects and / or their preferred embodiments. The method of the twelfth aspect can be implemented using textile production components having the features of the tenth aspect and / or its preferred embodiments.

[0154] By connecting the yarns of the first group, preferably all of the yarns, with the yarns of the second group, preferably all of the yarns, a smooth transition from the first design to the second design of the plurality of designs can be achieved. The smooth transition can minimize waste generation between designs.

[0155] Preferably, each container from which a yarn is pulled for the first or second design comprises at most one continuous length of yarn, wherein the continuous length preferably corresponds to the length of the yarn required in the first or second design, respectively, with a margin, e.g. an excess amount of yarn, preferably less than 10% of the amount of yarn required for producing the grey product.

[0156] Preferably, the containers are tubular.

[0157] Preferably, the connecting comprises joining one or more, preferably all, of the yarns of the first group to one or more, preferably all, of the yarns of the second group. Preferably, the yarns are connected one-to-one. In a non-limiting exemplary embodiment, the yarns from the first yarn storage system can have been exhausted, thus the yarns from the first yarn storage system can be terminated and removed from the yarn consuming machine. A second yarn storage system can be positioned to supply yarn to the yarn consuming machine, and each yarn that has been terminated from the first yarn storage system can be joined to a yarn from the second yarn storage system. In a preferred embodiment, if the design of the grey product is the same, the replacement yarns from each yarn storage container of the second yarn storage system will have the same properties as the terminated yarns from each yarn storage container of the first yarn storage system.

[0158] Preferably, the connecting comprises positioning one or more of the yarns of the first plurality of containers and one or more of the yarns of the second plurality of containers on a support, and connecting the yarns while positioned on the support.

[0159] Preferably, the support comprises a set of teeth for spacing the individual yarns apart from each other.

[0160] Preferably, all of the yarns of the first group and the second group are pulled from respective containers, wherein the first group comprises at least all of the yarns required for the first design, and the second group comprises at least all of the yarns required for the second design. Preferably, the first group and the second group comprise between 100% and 110% of the yarns required for the respective design, wherein the excess length of yarn can be used in a transition zone from the first design to the second design of the plurality of designs and / or for threading a respective textile machine.

[0161] Preferably, the method further comprises the step of cutting the textile into at least two pieces, each piece of textile comprising at least one of the first design or the second design.

[0162] Preferably, the method further comprises the step of cutting the textile into at least three pieces, the at least three pieces being two pieces each comprising at least one of the first and second design and a third piece positioned between the first and second design, wherein the third piece can be considered as a transition zone or waste.

[0163] Preferably, the first set of yarns differs from the second set of yarns at least in that the number of containers loaded with yarns of a specific color, thickness and / or material in the first plurality of containers is different from the number of containers loaded with yarns of the same specific color, thickness and / or material in the second plurality of containers. Other differences between the first and second set of yarns characteristics can include differences in the twist and / or the shape and / or the entanglement of the filaments contained in the yarns.

[0164] It will be understood that according to a particular independent aspect, the application also relates to a semi-finished product obtained or obtainable by the method of the twelfth aspect and / or the method of its preferred embodiments, wherein the semi-finished product is for example a textile comprising a first design, a second design and a zone positioned between the first and second design, wherein the zone comprises two yarns from the first set of yarns and the second set of yarns.

[0165] It is noted that the first and second of the plurality of designs can themselves comprise a repetition of an individual design, for example a floral design. The application according to the twelfth aspect described above especially relates to a transition between a first design and a second design that differs in pattern, color, quality and / or relief. In other words, it relates to a transition in a design that requires different sets of yarns.

[0166] In order to provide a yarn production method that is particularly suitable for use in one or more of the other aspects of the application, according to a thirteenth independent aspect, the application is a method of producing a yarn, preferably for feeding a tufting machine, the method comprising:

[0167] - spinning a plurality of filaments;

[0168] - converting the plurality of filaments into a yarn;

[0169] - providing the yarn directly in a container; the container is preferably a yarn storage container according to the first and / or second aspect and / or their preferred embodiments and / or the container is comprised in a yarn storage system showing the features of the third, seventh and / or eighth aspect and / or their preferred embodiments;

[0170] - optionally feeding a tufting machine by pulling the yarn out of the container.

[0171] Directly providing the yarn in the container means that the method of the thirteenth aspect does not have a winding operation between spinning and providing the yarn in the container. This method avoids unnecessary winding operations and residual stresses that can accumulate in the yarn.

[0172] Preferably, the converting comprises entangling and / or twisting. The converting can comprise entangling the plurality of filaments via an air jet stream to produce the yarn, wherein the yarn is preferably adapted for tufting. The converting can comprise twisting the plurality of filaments to produce the yarn, wherein the yarn is preferably adapted for tufting and / or wherein the twisting the plurality of filaments comprises applying an S-twist or a Z-twist. Preferably, the twisting the plurality of filaments comprises adjusting the amount of twist to produce yarns of different qualities.

[0173] Preferably, the directly providing the yarn in the container comprises loading the yarn storage container with an amount of yarn corresponding to the amount of yarn needed for the textile design to be produced on a part of the textile machine, the yarn having a margin of less than 10%, such as an excess length.

[0174] Preferably, the directly providing the yarn in the container comprises loading the container with an amount of yarn, cutting the yarn, loading a subsequent container with a different amount or an equal amount of yarn.

[0175] Preferably, the method further comprises drawing yarn from the container for feeding a textile machine.

[0176] It is noted that the plurality of filaments can comprise filaments of different properties (e.g. different colors) and / or filaments of different titer.

[0177] Preferably, the method of the thirteenth aspect does comprise the step of feeding the yarn to a yarn consuming machine (e.g. a tufting machine), wherein preferably a greige product or a tufted carpet is produced.

[0178] For the same purpose as the thirteenth aspect, according to a fourteenth independent aspect, the invention is a method of producing a tufted textile, the method comprising:

[0179] - spinning a plurality of filaments;

[0180] - converting the plurality of filaments into a plurality of yarns;

[0181] - injecting at least one yarn of the plurality of yarns into at least one container; the container is preferably a yarn storage container according to the first and / or second aspect and / or their preferred embodiments, and / or the container is comprised in a yarn storage system having the features of the third, seventh and / or eighth aspect and / or their preferred embodiments; the injecting is preferably directly performed, i.e. there is no intermediate winding operation of the yarn between spinning and injecting; and

[0182] - drawing at least one yarn from at least one container to a tufting machine to produce a tufted textile. Preferably, the tufted textile comprises a tufted carpet.

[0183] Converting the plurality of filaments into a plurality of yarns can comprise entangling and / or twisting the plurality of filaments to produce the plurality of yarns.

[0184] Injecting the at least one yarn into the plurality of yarns can comprise injecting the plurality of yarns into a plurality of containers.

[0185] Said injecting at least one yarn into at least one container can comprise blowing a first yarn into a first end of a first container.

[0186] Said drawing at least one yarn from at least one container to a tufting machine can comprise drawing a first yarn from a first end of a first container to a tufting machine to produce a tufted textile. According to a variant, said drawing at least one yarn from at least one yarn storage container to a tufting machine can comprise drawing a first yarn from a second end of a first yarn storage container to a tufting machine to produce a tufted textile.

[0187] Preferably, said at least one yarn storage container is a tubular container.

[0188] For the purpose of providing a system ideally adapted to provide a yarn loaded yarn storage system as in the preceding aspects, according to an independent fourteenth aspect, the present application is a change system, said change system comprising:

[0189] - a plurality of yarn storage systems, each said yarn storage system comprising a plurality of yarn storage containers or being configured to receive one or more yarn storage containers; said containers being preferably yarn storage containers according to the first and / or second aspect and / or their preferred embodiments, and / or said containers being comprised in a yarn storage system having the features of the third, seventh and / or eighth aspect and / or their preferred embodiments;

[0190] - at least one set of injectors for injecting yarns of defined lengths into the plurality of yarn storage containers; and

[0191] - a controller comprising a memory and configured to direct the at least one set of injectors to inject yarns of defined lengths into the plurality of yarn storage containers.

[0192] Preferably, the memory comprises information for at least the plurality of yarn containers, preferably for each yarn container, in each of the plurality of yarn storage systems. Preferably, for each yarn container in the plurality of yarn storage systems, the memory comprises information of its position in the corresponding yarn storage system, the yarn to be selected for this yarn container and the length of yarn to be injected into this yarn container. Preferably, the information is at least partially transmitted to a data memory comprised in the respective yarn storage system and / or to an address accessible through a computer network or the World Wide Web. In the latter case, preferably, the address is provided to the respective yarn storage system by uploading it to the data memory of the respective yarn storage system and / or by providing a scannable label to the yarn storage system.

[0193] Obviously, any data uploaded from the memory of the change system to the yarn storage system can be transmitted to the textile machine, for example when the yarn storage system forms part of a textile production assembly having the features of the tenth aspect and / or the features of the preferred embodiments thereof.

[0194] Preferably, the plurality of injectors simultaneously inject a defined length of yarn into a plurality of yarn containers in the plurality of yarn storage systems.

[0195] Preferably, the change system is configured to receive a plurality of yarn storage systems, for example at least two or at least four. The change system preferably comprises at least one set of injectors for each of the yarn storage systems it can receive. Preferably, each injector of the set injects a single type of yarn, for example a yarn having the same characteristics, into a container of a specific yarn storage system. Preferably, each injector is able to inject yarn into containers stacked in a plurality of columns, for example because the set of injectors is configured to move horizontally, preferably by a distance at least equal to twice the horizontal distance Di between the yarn storage containers, preferably at least equal to four times. Each injector can also be configured to inject yarn into containers stacked in a plurality of rows, for example because the injectors can be configured to move vertically, preferably by a distance at least equal to four times the vertical distance D2 between the yarn storage containers. Preferably, the injectors are configured to move at least the distance they can inject yarn into all containers of a specific row.

[0196] The independent claims and the dependent claims set forth particular and preferred features of the application. Features from the dependent claims can be combined with features of the independent claims or other dependent claims and / or with features listed in the above description and / or in the following description. BRIEF DESCRIPTION OF DRAWINGS

[0197] The above and other characteristics, features and advantages of the present application will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the application. This description is given for the sake of example only, without limiting the scope of the application. The reference figures cited are referred to in order to provide a better understanding of certain concepts described herein, and reference to the accompanying drawings is made in which:

[0198] Figures 1A-1D is a schematic view of a tubular container from a yarn storage system according to the present application;

[0199] Figures 2A-2C is a schematic view of a tubular container from a yarn storage system according to the present application;

[0200] Figure 3 and Figure 4 is a schematic view of a yarn storage system according to the present application;

[0201] Figure 5 schematically represents a method for storing yarn in a yarn storage system according to the present application;

[0202] Figure 6 represents a textile production assembly according to the tenth aspect of the present application;

[0203] Figure 7 provides a front view of the yarn storage system according to Figure 6 arrow F7; Figure 6

[0204] Figure 8 a variant is represented in a similar view;

[0205] Figure 9 provides a perspective view of the support according to Figure 6 arrow F9;

[0206] Figure 10 shows a cross-section taken according to the X-X line shown in Figure 9 greater scale;

[0207] Figures 11-13 represents a variant of the yarn storage system according to Figure 6 in the view of the area indicated with F10 in Figure 6

[0208] Figure 14 represents a view according to Figure 13 arrow F14;

[0209] Figure 15 represents a method for producing yarn according to the thirteenth aspect of the present application; and

[0210] Figure 16 represents a bobbin changing system according to the fourteenth aspect of the present application;​​

[0211] Figure 17A and Figure 17B a cap with a thread retainer according to the present invention.

[0212] In the different figures, same reference numerals refer to same, similar or analogous elements. DETAILED DESCRIPTION

[0213] The present invention will be described with reference to particular embodiments.

[0214] According to a first independent aspect of the present invention, there is provided a thread storage system.

[0215] A thread storage system for storing thread will be described below with reference to the accompanying drawings. In Figure 1A In the drawings, an example of a thread storage container 101 is shown. In this example, the container 101 is tubular and cylindrical.

[0216] More particularly, an axial cross-section of such a thread storage container is provided. The exemplary tubular container 101 can have an axial length L of 96 inches (243.84 cm) in the axial direction 111 and a first axial end 113 and a second axial end 115. Each tubular container is configured to hold thread 200 having a length that is at least twice the axial length of the tubular container. The first axial end 113 has an opening 123 for receiving an end of the thread. The second axial end 115 of the tubular container can be terminated. In the present exemplary embodiment, the second axial end 115 can be terminated by an end cap 125 that is secured along the circumference of the second axial end 115. In one embodiment, the end cap 125 can be perforated by a hole 129 to allow a propellant fluid to exit the tubular container 101 through the end cap 125. In a preferred embodiment, the end cap 125 can be made of the same mesh as the tubular wall 502 of the thread storage container 101.

[0217] The tubular container 101 can have a circular cross-section and an inner diameter D of 2.78 inches (7.06 cm).

[0218] In some embodiments, the ratio of the axial length L to the inner diameter D can be greater than 10, and in such cases even greater than 25.

[0219] The tubular wall 501 can be constructed from a mesh. In a preferred embodiment, the mesh will be a continuous mesh without seams. In another embodiment, the seams on the mesh cylinder can be smoothed to remove protrusions.

[0220] The open area of the mesh wall 501 can be made up of the sum of the open areas along the wall of the yarn storage container 101 (referred to as "open area"). The average open area per unit surface of the mesh portion of the cavity can be in the range of about 70% to about 95%. In some more preferred embodiments, the range can be between about 90% and about 93%. In more preferred embodiments, the open space can be or be close to about 91%.

[0221] In one embodiment, the nominal diameter of the strands can be 0.008 inches (0.2032 mm), with 16 strands in one direction and 16 strands at a right angle to the first in each square inch (6.4516 cm2). Similarly, in a 16 x 16 strand mesh, strands of 0.004 inches (0.1016 mm) would leave approximately 88% open space. Similarly, in a 16 x 16 strand mesh, strands of 0.003 inches (0.0762 mm) would leave approximately 91.5% open space, and strands of 0.002 inches (0.0508 mm) would leave approximately 96.8% open space.

[0222] In more preferred embodiments, the strands can be 0.006 inches (0.1524 mm), which in a 16.5 x 16.5 mesh would have approximately 91% open area per square inch (6.4516 cm2) of area.

[0223] In other embodiments, the mesh can be a 16 x 18 strand or a 20 x 20 strand using any of the diameters disclosed herein.

[0224] The yarn storage container 102 is an alternate embodiment and is shown in Figure 1B The tubular container 102 can also have an axial length L of 96 inches (243.84 cm) in the axial direction 111 and have a first axial end 113 and a second axial end 115. Each tubular container is configured to hold a length of yarn 200 that is at least twice the axial length of the tubular container. The first axial end 113 has a cap 127 provided with a conductive grommet 128 configured with an opening 123 for receiving an end of the yarn. The second axial end 115 of the tubular container is closed by an end cap 126 secured to the container 102 along the circumference of the second axial end 115.

[0225] The grommet 128 can be made of copper or any other electrically conductive material. In a preferred embodiment, the grommet 128 can have an open diameter of 0.75 inches (1.91 centimeters). Both the cap 127 and the end cap 126 can be made of plastic, metal, ceramic, or any other material known to those skilled in the art. The end cap 126 can be air permeable as it is provided with a plurality of openings 129. The grommet 128 can be electrically connected to a grounding system (not shown).

[0226] In the embodiment shown here, the cap 127 and the end cap 126 can be bonded or welded to the mesh wall 502 to maintain the desired cross-sectional shape. Here, the structure of both the cap 127 and the end cap 126 can provide support to the mesh wall 502 to maintain the desired form at the first axial end 113 and the second axial end 115. In some embodiments, another structure or structures can be used to maintain the cross-sectional shape along the length L of the yarn storage container 102. The bonding or welding of the mesh wall 502 to the cap 127 and / or the end cap 126 can be achieved mechanically or chemically.

[0227] The yarn storage container 103 is an alternate embodiment and is shown as Figure 1C The tubular container 103 has an axial length L in the axial direction 111 of 96 inches (243.84 centimeters) and has a first axial end 113 and a second axial end 115. Each tubular container is configured to hold one length of yarn 200 that is at least twice the axial length of the tubular container. The first axial end 113 has a cap 130 provided with an electrically conductive tube 131 that defines an opening 123 for receiving an end of the yarn 200. The cap 130 has a plurality of small openings 136 along a contact area where the cap 130 contacts the first axial end 113. The second axial end 115 of the tubular container 103 can terminate in an end cap 137 that can slide over a mesh wall 503 along the circumference of the second axial end 115. Alternatively, the cap 130 can be configured with a slot into which the mesh of the first axial end 113 can be inserted. If desired, the end cap 137 and the mesh can be bonded together mechanically or chemically.

[0228] In one embodiment, an extension 140 can be connected to the end cap 137 and to a vacuum system or other device that can create a lower air pressure within the tubular container 103. The openings 129 allow air to be drawn from the yarn storage container 103. In a preferred embodiment, the air drawn through the yarn storage container 103 will have a laminar flow.

[0229] The cap 130 and the end cap 137 can be made of a polymer. The end cap 137 can allow air to flow through the plurality of openings 129. The cap 130 can also have openings 136 to allow air to flow.

[0230] Figure 1D Yet another alternative embodiment of a tubular yarn storage container 104 can be shown. The axial length L of the tubular container 104 along the axial direction 111 is again 96 inches (243.84 centimeters) and has a first axial end 113 and a second axial end 115. The yarn storage container 104 is configured to hold a length of yarn 200 that is at least twice the axial length of the tubular container. The first axial end 113 can have a cap 135 and, optionally, a conductive brush 150 that can define a circular opening between the bristles 151. The diameter between the two sides of the brush 150 can be 0.75 inches (1.91 centimeters). Thus, the bristles 151 can define an opening 123 for receiving an end of yarn such that the end of yarn 200 can contact the bristles 151 to discharge any electrical charge during loading and unloading. The second axial end 115 of the tubular container 104 can be closed by means of an end cap 132 that is secured to the container 104 along the circumference of the second axial end 115. In some embodiments, the end cap 132 can be perforated to allow passage of a fluid (e.g., air).

[0231] In alternative embodiments, Figures 1A-1D The radial cross-section of the tubular containers 101, 102, 103, 104 can be other than circular. That is, they can be oblong, square, oval, or other shapes that can be envisioned by one skilled in the art.

[0232] Similar to the grommet 128 of the exemplary yarn storage container 102, Figure 1B Similar to the grommet 128 of the exemplary yarn storage container 102,

[0233] Figures 2A-2C Several exemplary yarn storage containers 601, 602, 603 having tubular walls are shown that are configured to be used as part of a yarn storage system.

[0234] Figure 2AAn exemplary yarn storage container 201 is shown with an external support 604. The walls of the mesh 601 can be joined to the external support 604 that extends along the length of the yarn storage container 201 from the cap 240 to the end cap 251. The external support 604 can be removably secured to the cap 240 and the end cap 251 so that either of them can be removed from the yarn storage container 201. The external support 604 can be a lightweight rod or slat that prevents the yarn storage container 201 from deforming. In this exemplary embodiment, preventing the yarn storage container 201 from deforming can facilitate filling the yarn storage container 201 to its maximum capacity. In addition, the external support 604 can be configured so that it has a small surface area in contact with the mesh 601 so that only a small portion of the open area of the yarn storage container 201 is blocked.

[0235] Figure 2B A yarn storage container 202 is shown with an opening 223 that is nearly as large in diameter as the yarn storage container 202. In this embodiment, the cap 242 and the end cap 252 are joined to the mesh 602 to support its shape. In this illustrative embodiment, the cross-sectional shape of the yarn storage container 202 is circular. In this example figure, the external mesh is omitted for clarity, but the interior of the yarn storage container 202 is shown.

[0236] Figure 2C A yarn storage container 203 is shown with an opening 223 similar to that of the yarn storage container 202. In this illustrative embodiment, the entire mesh 603 can be embodied by an outer sleeve 605 to maintain its shape. The illustrative embodiment of the yarn storage container 203 has a circular cross-section. The sleeve 605 can or can not be joined or secured to the mesh 603. In one embodiment, securing the sleeve 605 to the mesh 603 can join these components together to enhance the rigidity of the entire yarn storage container 203. Alternatively, leaving the sleeve 605 independent of the mesh 603 will allow them to move slidably relative to each other.

[0237] In embodiments where the sleeve 605 is joined or secured to the mesh 603, the sleeve 605 and the mesh 603 can be heat staked together, chemically secured together (e.g., using epoxy or similar substances), or mechanically secured together (e.g., using snaps).

[0238] In some embodiments, the sleeve 605 can not need to be secured to the cap 243 or the end cap 253. The cap 243 and the end cap 253 will provide support to the mesh 603 so that it does not deflect or twist within a certain length away from each of the cap 243 and the end cap 253. The sleeve 605 can be configured so that it is close enough to the cap 243 and the end cap 253 so that no significant bending or twisting occurs near the cap 243 and the end cap 253.

[0239] Figure 17A / Figure 17B An embodiment of a cap 1700 with a yarn retainer is shown. Cap 1700 has a front face 1710 with a single channel 1712. Channel 1712 is an abutting opening for a bobbin 1720 and a retainer chute 1730. Although Figure 17A / Figure 17B Although shown as a circular opening in FIG. 17, other embodiments can be conceived and practiced without departing from the spirit of the invention as taught and disclosed.

[0240] In use, cap 1700 can be fitted over the end of a yarn tube such that flange 1750 is within the end of the yarn tube up to lip 1740. A ball (not shown) can be inserted into retainer chute 1730 and allowed to roll down to make contact with channel 1712. Retainer chute 1730 can be tapered such that the ball can enter retainer chute 1730 but not fall out of channel 1712. Alternatively, channel 1712 can have a circumferential lip with a diameter less than the diameter of the ball such that the ball will make contact with the circumferential lip. Other methods of allowing the ball to make a seal at channel 1712 can be conceived and practiced by those skilled in the art without departing from the spirit of the invention claimed herein.

[0241] When loading yarn into a tube, yarn propelled by an air or other fluid jet can be positioned in front of a yarn tube fitted with cap 1700 with a ball already placed in retainer chute 1730. Under the force of gravity, the ball will naturally fall toward and make a seal around channel 1712. The air jet can simultaneously push yarn into the tube and push the ball up the retainer chute 1730 and away from bobbin 1720. The yarn being propelled by the air jet will continue along bobbin 1720 into the yarn tube while the ball is held in place without interfering with retainer chute 1730.

[0242] The end of retainer chute 1730 can be fitted with a part that prevents the ball from being pushed beyond the end and into the yarn storage container. Alternatively, retainer chute 1730 can be formed such that it extends to make contact with the inner wall of the yarn storage container. In this embodiment, when the ball is pushed up by the air jet, it will make contact with the inner wall of the yarn storage container and in turn be held within retainer chute 1730.

[0243] When the desired amount of yarn has been loaded into the tube, the air jet will stop, allowing the yarn to rest and the ball to roll down toward channel 1712.

[0244] The sphere rests against the end of the yarn and the channel 1712, thus providing tension on the yarn and preventing it from moving freely. When it is desired to pull the yarn out of the tube, the yarn will slide over the sphere, which will also provide tension on the yarn.

[0245] In one proposed embodiment, the sphere may be made of a material that responds to a magnetic field, or have components within the sphere that respond to a magnetic field. In this embodiment, the magnet may be positioned near the cap 1700 to pull the sphere away from the channel 1712 before the yarn is blown in. This way, the air jet does not need to force the sphere upward toward the rear of the retainer groove 1730.

[0246] In one embodiment, the weight of the sphere can be customized according to the yarn. That is, a lighter sphere is preferred when loading and unloading low-denier yarns into the tube, while a heavier sphere is preferred when using higher-denier yarns. However, in another embodiment, a standardized sphere can be used for all types of yarn. When loading and unloading high-denier yarns from the tube, the orientation of the cap 1700 allows the retainer groove 1730 to be vertically positioned above the opening of the channel 1712. Figure 17A / Figure 17B This orientation is illustrated in the diagram. If a lighter yarn is used, the cap 1700 can be rotated so that the retainer groove 1730 is offset at an angle from the vertical. This directs a portion of the ball's mass to one side of the retainer groove 1730, preventing it from falling entirely onto the channel 1712. In other words, if the retainer groove 1730 is offset from the vertical orientation at an angle, less force is required to move the ball away from the channel 1712.

[0247] although Figure 17A / Figure 17B The illustrated embodiment of the cap 1700 is made of solid material, but is not limited thereto. The cap may have a yarn retainer and any other features disclosed and taught herein. For example, but not limited to, the cap may be breathable and / or have grommets disclosed elsewhere herein.

[0248] like Figure 3 As shown, multiple yarn storage containers 1001 can be mounted in a frame 1002 to form a yarn storage system 1000. The frame 1002 is movable due to a set of wheels 1004. All yarn storage containers 1001 are tubular and can be identical, i.e., they can have the same length. An axial cross-section such as... Figures 1A-1D The tubular yarn storage container 1001 shown.

[0249] use Figures 1A-1DThe tubes can be mounted 36 tubular yarn storage containers 1001 with respective first axial ends 113 aligned in a vertical plane 1120. The tubular yarn storage containers 1001 are mounted in a generally horizontal position. The tubular yarn storage containers can be mounted in a matrix of 6 containers per row, for a total of 6 rows. In an alternative embodiment, 10 rows of 24 containers per row can be mounted on the rack. Other geometries can also be configured.

[0250] The distance between adjacent containers can be configured to be 0.25 inches (0.635 cm). The tubes can be suspended from parallel plates provided with holes configured to support each yarn storage container 1001. To hold the yarn storage containers 1001 in place, the tubular yarn storage containers 1001 can be mounted in and supported by more than one parallel plate provided with openings, each opening for receiving one yarn storage container 1001. The diameter of the openings in the plates can be substantially equal to or slightly greater than the outer diameter of the tubes. The center distance between two such openings is equal to the diameter of the tube plus 0.25 inches (0.635 cm). A first plate can support the tubes near their first axial ends. A second plate can support the tubes near their second axial ends. If more support is desired, additional plates can be positioned between the first and second plates.

[0251] As Figure 3 and Figure 4 similarly, Figure 7 The yarn storage containers 101 are shown to be tubular and cylindrical, with the first axial end 113 including a cap 127 with an opening 123 that receives an end of the yarn 200. Figure 8 A variant is shown in which the yarn storage containers 101 can be hexagonal and also include a cap 127 with an opening 123 that receives an end of the yarn 200.

[0252] As Figure 7 and Figure 8 shown, the yarn storage containers 101 are stacked in a matrix, with the matrix being substantially uniform. A uniform matrix means that the axes of the respective containers 101 are positioned equidistant from each other in the horizontal direction H and / or the vertical direction V. In this case, the matrix of yarn storage containers 101 formed by Figure 7 and Figure 8 is uniform in both directions, with the distance D1 between the containers 101 in the horizontal direction H being equal to the distance D2 between the containers 101 in the vertical direction V in the case of Figure 7 , while in the embodiment of Figure 8 , the distances D1 and D2 are different.

[0253] Figure 7 and Figure 8Further, at least a portion of the outer wall 2008 of the container 101 is not in contact with any of the plurality of adjacent containers 101. The matrix or stack of containers 101 included in the yarn storage system 1000 includes voids 2009 substantially defined by portions of the outer walls of the plurality of containers 101.

[0254] Referring again to the exemplary embodiment of Figure 3 and Figure 4 , in front of the side 1100 providing the opening 123 of the yarn storage container 1001, a device for holding the yarn ends can be provided. In the present example, a comb creel 1005 can be provided, which includes at least as many seats as there are tubular containers in the rack 1002. The yarn 200 for each of the tubular containers is guided to one of the seats in the comb creel 1005. Such a yarn end holding device 1005 is also referred to as a comb spacer or a detachable header. The yarn end holding device can be detachably fixed to the yarn storage system 1000.

[0255] Figure 4 An alternative embodiment of a yarn storage system 2000 is shown. Identical reference numerals refer to identical or similar items. The first axial end 113 of the tubular yarn storage containers 1001 is now located in the same plane and aligned in a horizontal plane 1110. At the underside of the rack, a vacuum box 1009 is provided, which is in fluid connection with the gas-permeable second axial end. That is, when the suction pump 1008 applies a partial vacuum to the vacuum box 1009, air will be sucked from each of the second axial ends, thereby creating a small air flow in the interior volume of the tubular containers 1001.

[0256] In Figure 3 and Figure 4 , each of the yarn ends of the yarn 200 extending from the comb creel 1005 can be associated one-to-one with a needle of a tufting machine (not shown). During tufting processing of the base cloth by the tufting machine, the yarn can be taken out of the tubular yarn storage container substantially without tension or friction and can be used as pile yarn in the base cloth. Base cloths of relatively short length can be tufted (which can be made with the length of pile yarn remaining in the tubular yarn storage container). Once finished, the empty system can be replaced by a new yarn storage system. Once coupled to the tufting machine, the new yarn storage system can be used to produce new base cloths. This has the advantage that relatively small batches of base cloths can be produced without the need to maintain large beam creels and without the need to frequently change from one yarn to another for base cloths having different patterns.

[0257] Since the yarns can be loaded and unloaded without friction or tension, the length loaded into the yarn storage container will be equal to the length unloaded. In some cases, the yarn used in the machine that consumes the yarn during use will be stretched. For example, a tufting machine can stretch the yarn as it tufts the yarn onto a backing. The robot can be configured to account for the amount of stretch of each yarn as it loads each yarn into the yarn storage system.

[0258] Figure 5 An example system for performing the method of storing yarn is schematically illustrated.

[0259] A yarn storage system 5000 is provided. An example of such a system can be the system shown and described in Figure 3 or Figure 4 The tubular containers of this yarn storage system 5000 are designated 50XY, where X is an integer from 1 to N and Y is an integer from 1 to M. Where N is the number of rows in the rack and M is the number of columns in the rack. The X value can be numbered from top to bottom or from bottom to top. The Y value can be numbered from left to right or from right to left.

[0260] The robot 5110 can include a storage unit 5111 that can be configured to receive and store loading data and associate these data with other information for each yarn storage container. The other information can include, but is not limited to, the following data:

[0261] - the location of each yarn storage container (expressed in X and Y coordinates),

[0262] - the yarn to be selected (in this case, yarn A, B, or C),

[0263] - the length of yarn to be injected,

[0264] - and optionally, the configuration details of the yarn storage system, which can include whether the yarn storage system includes a yarn end holding device (e.g., a beam) and the location of the opening on the yarn end holding device.

[0265] The storage unit 5111 can also be configured to keep track of the loading status or condition of the yarn storage system. That is, the yarn storage system can be moved to an accessible location of the robot 5110 and the storage unit 5111 of the robot can be instructed that all the yarn storage containers are empty. The control unit can be configured to fill each yarn storage container with different yarns each having different lengths from the creel. The robot 5110 can keep track of the progress as it is filling each yarn storage container. If a fault occurs in the system, the storage unit can stop at a certain node until the fault is rectified, at which point the storage unit can resume loading of the yarn storage containers in the yarn storage system as per the original configuration. When all the yarn storage containers are filled as instructed, the robot 5110 can notify the operator that the yarn storage system is filled and communicate this information to the operator.

[0266] The robot can include an input device 5112 for inputting loading information about the yarns into the storage unit. The input device can be a keyboard for manually inputting data, a data reading device capable of reading data from a data carrier such as a floppy disk, a USB flash drive or any other similar data storage medium, or even a communication port for coupling the storage unit to a computer or a network.

[0267] The robot 5110 can include a control unit 5113 which can be configured with the loading sequence of the yarn storage containers 50XY. It can achieve this by selecting and controlling the injection of each selected yarn.

[0268] In the illustrative and exemplary embodiment of Figure 5 In the illustrative and exemplary embodiment of

[0269] In this illustrative embodiment, the control unit can be configured to load yarn A into the yarn storage containers with N being 1 and M being 1 to 3, wherein each yarn storage container is loaded with 600 meters of yarn. The control unit can be configured to load yarn B into the yarn storage containers with N being 2, M being 1 and loading 1000 meters of yarn; and with N being 2, M being 2 and loading 400 meters of yarn. The control unit can be configured to load yarn C into the yarn storage containers with N being 3, M being 1 and loading 800 meters of yarn.

[0270] Figure 5An exemplary loading of the yarn storage containers 50XY in the exemplary yarn storage system 5000 can be illustrated. The 3D movable arm 5124 of the hardware 5114 picks up the end of the selected yarn from the rack 5100. In the figure, this is the yarn C from the cone C. Various methods can be used to bring the end of the yarn C to the injector 5125. At least, this can be done manually by inputting into the input device 5112 of the robot 5110 by the operator the information that the end of the yarn C is ready for loading into the yarn storage system 5000. Those of ordinary skill in the art will appreciate that other methods can be used to achieve automation of this task. In a preferred embodiment, the robot 5110 can control multiple injectors, where each of the injectors has been loaded with a known yarn. That is, a first injector can be attached to the end of the yarn A from the cone A; a second injector can be attached to the end of the yarn B from the cone B; a third injector can be attached to the end of the yarn C from the cone C. The robot can move each of these injectors simultaneously to the selected yarn storage container to speed up the loading. This can be done in the exemplary embodiment of Figure 16 .

[0271] When the end of the yarn is ready to be loaded into the yarn storage container 50XY, the injector 5125 is positioned in front of the opening 123 of the selected yarn storage container 50XY and pushes the defined length of the yarn into the yarn storage container via the opening 123. The injector 5125 can include a vortex injector 5126 that can use compressed air from a reservoir 5127 via a valve 5128 as a propellant.

[0272] Once the defined length of the yarn has been loaded, the yarn needs to be separated from the cone. Referring back to Figure 3 and Figure 4 , the robot 5110 guides the injector that still contains the yarn to the predetermined opening 1006 of the beam 1005. That is, the control unit 5113 will know that the defined length of the yarn A has been loaded into the yarn storage container 50XY where X=l and Y=l and has laid out the still connected portion of the yarn A into the opening 1006 of the beam 1005, where the opening 1006 is the designated opening of the beam 1005. The yarn can be cut so that it stays in the opening 1006 across the beam 1005.

[0273] After the yarn is cut, the same yarn can be brought in front of the next selected yarn storage container 50XY or it can be moved back to the rack 5100 while the injector 5125 selects another yarn for loading the next yarn storage container.

[0274] This sequence of actions is repeated until all necessary tubular containers are loaded as required. Thus, many tubular containers can be loaded with a given length of yarn, while only a limited number of yarns are available on a limited number of spools. That is, in the example shown, three yarns A, B and C can be loaded into the twenty-five storage containers. When the yarn storage system 5000 is moved to a yarn consuming device, yarns A, B and C will be available from twenty-five sources, instead of just three bobbins on the creel 5100. Figure 5

[0275] It is noted that the beam 1005 shown in Figs. 1 1 and 12 can include means for connecting the yarn and means for detecting whether a yarn is present in each opening 1006. These means for connecting the yarn and / or the yarn detector can also be provided separately from the beam 1005. Figure 3 Figure 4

[0276] After loading and cutting off all yarn ends, the yarn storage system 5000 can be moved away from the robot 5110 and the creel 5100. The yarn storage system 5000 can be left aside until it is needed. The amount of yarn stored in each storage container and all other information will be saved in a data storage unit (not shown in Fig. 10) which can be included in the yarn storage system 5000. Figure 5

[0277] When needed, the yarn storage system can be moved to be connected with a yarn consuming device, where the yarn can be withdrawn from the storage containers and used for manufacturing a textile product.

[0278] Figure 6 A textile production assembly 2000 is shown. The textile production assembly 2000 comprises a yarn storage system 1000 and a textile production machine 2001. In this case, the textile production machine 2001 consumes yarn and produces a textile product from the yarn 200. In the present illustrative embodiment, the textile production machine 2001 can be a tufting machine, where the yarn 200 is used to form the pile 2002 of a tufted carpet. As shown, the tufting machine comprises needles 2003 which tuft the pile yarn 200 into a base material 2004. In this case, the base material 2004 is provided from a roll 2005 and can be a woven or non-woven textile, such as but not limited to a layer of fiberglass or a layer of PET fibers. The greige 2006 leaves the tufting machine, in this case with its face 2007 turned downwards. That is, the pile is tufted with its face downwards, while the backstitching is upwards. The greige 2006 can be further finished into a carpet product, for example by applying a second base cloth and / or applying a material containing latex or co-polyester to fix the backstitching.

[0279] In​​​​Figure 6 In an exemplary embodiment, the yarn storage system 1000 includes a plurality of yarn storage containers 101, each storing a certain amount of continuous yarn 200, such as yarn 200 formed from bulky continuous filaments. The yarn 200 can be pulled out from each of the first axial ends 113 of the containers 101. In an illustrative embodiment, the containers 101 are positioned in the yarn storage system 1000, wherein their axial orientation is set substantially horizontal.

[0280] The yarn storage system 1000 also includes a device 2010 for communicating with the textile production machine 2001. For example... Figure 6 As shown, the yarn storage system 1000 includes a data storage device 2011 and a means 2010 for transmitting information from the data storage device 2011 to the textile production machine 2001. Furthermore, in this exemplary embodiment, the yarn storage system 1000 includes a means 2012 for detecting the presence of yarn from the container, wherein the yarn detector 2012 sends a signal indicating the presence or absence of yarn to the textile production machine 2001. The means 2010 for communication can be a wired or wireless electronic connection between the yarn storage system 1000 and the textile production machine 2001.

[0281] Figure 6 The textile production assembly 2000 shown includes a yarn end holding device, which is in the form of a comb-shaped warp beam 1005, such as Figure 3 and Figure 4 As shown.

[0282] Figure 9 An exemplary warp beam 1005 with a plurality of slots 2013 is shown. Each slot 2013 is configured to receive a yarn end 200 from each of the containers 101. In this illustrative embodiment, the slots 2013 are arranged in a row, all adjacent to each other. In order to be able to receive a yarn end 200 from each of the yarn storage containers in the yarn storage system, there is at least one slot 2013 for each yarn storage container in the yarn storage system.

[0283] In a preferred embodiment, the warp shaft 1005 may be made of metal and have a set of teeth.

[0284] 2014 or raised, used to space the individual yarns 200 apart from each other.

[0285] like Figure 9 As shown, a support is formed by a shaft 1005 for positioning the yarn 200 of the yarn storage system. Different yarns 200 fed from the yarn storage container can be shown as a first yarn 2015 and a second yarn 2016. The first yarn 2015 can be continuously fed to the yarn consumption device. Figure 6This is the case when the yarn consuming device is consuming yarn 200 to manufacture a textile product, as illustrated. However, when the yarn storage system 1000 is moved into interaction with the yarn consuming device, the end of the yarn 200 does not connect to the yarn that has already been fed to the needle 2003. This is illustrated by the second yarn 2016, where one end is the tag of the previously travelled yarn and the other end is the new supply of the second yarn 2016. The two ends can be fused together to continue the operation of feeding yarn to the yarn consuming device.

[0286] The second yarn 2016 is shown as two yarn ends that can be positioned in the slot 2013. This facilitates the connection of the yarn ends. In the illustrated example, the two yarn ends are presented end to end. However, this is not always the case. In a preferred embodiment, the two yarn ends can be presented side by side or placed on top of each other on the support and preferably in the shared slot 2013.

[0287] Figure 10 It is shown that the heating and / or pressing element 2017 can be in contact with the yarn ends 2016 to be connected. The heating and / or pressing element 2017 together with the support forms a device 2018 for connecting the two ends of the second yarn 2016. In a preferred embodiment, the ends can be fused together by the heat of the heating and / or pressing element 2017.

[0288] In a preferred embodiment, the yarn storage system can be moved into interaction with the yarn consuming device. The yarn in the yarn storage system can be arranged on the beam in the manner disclosed herein, where each yarn end from each yarn storage container occupies a slot in the beam. The yarn end from the yarn consuming device can be laid onto the beam such that each yarn end associated with each needle will be connected with the yarn to be delivered from the specified yarn storage container in the yarn storage system. When these yarn ends are laid together on the beam, a heating and / or pressing element can fuse each of the ends together such that continuity is maintained between the yarn end being consumed and the new yarn end being supplied. In a preferred embodiment, multiple heating and / or pressing elements can be used simultaneously to fuse all the old yarn ends and new yarn ends together in one operation.

[0289] By using such a fusion operation and with reference to Figure 6 a smooth switch from one yarn storage system 1000 to another system can be achieved and the textile production machine 2001 can be smoothly switched from a first design to a second design, where the first yarn storage system 1000 contains the supply of yarn 200 required for the first design and the second yarn storage system includes the supply of yarn 200 required for the second design. In this way, a textile production method according to the twelfth aspect can be obtained.

[0290] Figure 6 It is shown that the textile production assembly 2000 can be provided with one or more yarn detectors 2019, alternatively or in combination with the yarn end detector 2012 positioned in the vicinity of the yarn storage system 1000, positioned more downstream, preferably downstream of the support or beam. The yarn detector 2019 can also communicate with the textile production machine 2001 through the communication means 2010.

[0291] Figure 11 and Figure 12 It is shown that the yarn storage system 1000, wherein the containers 101 are positioned or can be positioned in the yarn storage system 1000, wherein their axial direction 111 is directed obliquely with respect to the horizontal plane. In this exemplary embodiment, the angle G of the obliquity with the horizontal plane is 15° or less. In this case, the containers 101 are oriented with their first axial end 113 pointing downwards. In Figure 11 In the shown embodiment, the containers 101 are obliquely mounted in the yarn storage system 1000, whereas in Figure 12 In the shown embodiment, the containers 101 are obliquely mounted in the yarn storage system 1000, whereas in

[0292] Figure 13 and Figure 14 It is shown that an alternative embodiment of the yarn end holding device of Figure 9 In this embodiment, the through-holes are arranged in a matrix. Each aperture 2022 is provided with a ceramic tube 2024 to prevent the passing yarn 200 from eroding the aperture 2022. Preferably, the yarn 200 passes through the apertures 2022 in the yarn end holding plate 2023 corresponding to the matrix arrangement of the respective yarn storage containers 101 in the yarn storage system 1001. Thus, the apertures 2022 are preferably provided at a distance da-db in the horizontal direction H and / or the vertical direction V, which distance is equal to or corresponds to the distance D1 and / or D2 defined by the matrix of containers 101. In case the corresponding distances are not equal, the distances d1-d2 can be uniformly scaled down or up from the distances D1 and / or D2, for example, the distances da-db can each be scaled down to half of the respective distances D1-D2.

[0293] Figure 15Several steps in a method for producing yarn 200 suitable for feeding a tufting machine 2001 are illustrated. The method comprises a step S0 of melting and extruding a polymer such as PET or PTT or PA, in this case using an extruder 2025 with one or more rotating screws to achieve the extrusion. The method further comprises a step S1 of spinning the polymer melt into a plurality of filaments 2026. In this case several spinning stations 2027 are fed from the same polymer melt. Each spinning station 2027 delivers a filament 2026 for a yarn 200. The method further comprises a step S2 of converting said plurality of filaments 2026 into a yarn 200. The conversion can comprise twisting and / or entangling the filaments 2026. After the conversion the yarn 200 is directly injected into a storage container 101, in this case said storage container 101 is comprised in a storage system 1000. For the injection pressurized air can be used to propel the yarn 200, for example using a vortex injector 2028. The partly or fully loaded storage system 1000 can then be used for feeding the tufting machine 2001, for example as Figure 6 illustrated in Fig. 1 by pulling yarn from the respective containers 101.

[0294] Figure 16 An exemplary embodiment of a change system 2029 according to the invention as disclosed and taught herein is shown. The change system 2029 is configured to receive a plurality of storage systems 1000. In the present exemplary embodiment four storage systems 1000 can be received at the same time. The change system 2029 further comprises several groups of injectors 2028 for injecting yarn 200 into the plurality of storage containers 101 comprised in each of the storage systems 1000. Preferably each injector 2028 injects a single type of yarn 200 (same color, type, quality and material) into the containers 101 of a specific storage system 1000. As shown here each injector 2028 is able to inject yarn 200 into a plurality of columns or stacks of containers 101 of a rack 1002, since the groups of injectors 2028 are configured to move, in this case typically horizontally, preferably by a distance at least equal to twice the horizontal distance D1 between the storage containers 101, more preferably at least equal to four times. In this case each injector 2028 is also able to inject yarn 200 into a plurality of rows of stacks of containers 101, since the injectors 2028 are configured to move, in this case individually vertically, preferably by a distance at least equal to four times the vertical distance D2 between the storage containers 101. In this case the injectors are configured to move at least a distance such that they can inject yarn into all containers of a specific row.

[0295] The change system 2029 can further include a memory configured or comprising the necessary data to direct at least one set of injectors 2028 for injecting a desired length of yarn 200 into each of the yarn storage containers.

[0296] It should be understood that, even though a few embodiments of the present application have been discussed, various modifications or changes can be made by those skilled in the art without departing from the scope and spirit of the present application.

Claims

1. A yarn storage container (101) for storing yarn (200), the yarn storage container (101) comprising a tubular container having: an axial length (L); a tubular wall (501) including a breathable mesh along the axial length (L) of the tubular container (101); a first axial end and a second axial end (113-115), characterized in that, The first axial end (113) of the tubular container (101) has an opening (123) for receiving the end of the yarn (200), and the second axial end (115) of the tubular container (101) is either open or closed.

2. The yarn storage container according to claim 1, wherein, The breathable mesh is composed of strands.

3. The yarn storage container according to any one of claims 1 to 2, wherein, The strands are arranged in a pattern in which at least a first plurality of strands are perpendicular to a second plurality of strands.

4. The yarn storage container according to any of the preceding claims, wherein, The mesh consists of a single layer.

5. The yarn storage container according to any of the preceding claims, wherein, The proportion of the open area of ​​the mesh is between 70% and 95%; preferably between 90% and 93%; more preferably 91%.

6. The yarn storage container according to claim 5, wherein, The breathable mesh is selected from the group consisting of polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, metal and glass fiber.

7. The yarn storage container according to any one of the preceding claims, wherein, The first axial end (113) of the tubular container includes a cap or lid (127) that substantially closes the first axial end (113), the cap having a hole for providing the opening (123) for receiving the end of the yarn (200).

8. The yarn storage container according to claim 7, wherein, The first axial end (113) of the tubular container (101) includes a loop (128) for receiving the end of the yarn (200), the loop (128) being mechanically coupled to the first axial end (113) of the tubular container (101).

9. The yarn storage container according to claim 8, wherein, The cable loop (128) is conductive.

10. The yarn storage container according to any one of claims 7 to 9, wherein, The cover includes one or more small openings along the contact area where the cover contacts the first axial end (113).

11. The yarn storage container according to any one of the preceding claims, wherein, The first axial end (113) of the tubular container (101) includes a brush for contacting the end of the yarn (200).

12. The yarn storage container according to any one of the preceding claims, wherein, The container includes means for providing laminar airflow in the axial direction from the first axial end (113) to the second axial end (115) at least along the tubular wall of the tubular container (101).

13. The yarn storage container according to any one of the preceding claims, wherein, The container (101) includes a means for generating a pressure below atmospheric pressure within the tubular container via the second axial end (115).

14. The yarn storage container according to any one of the preceding claims, wherein, The radial cross-section of the tubular container (101) is circular, elliptical, square, or rectangular.

15. The yarn storage container according to any one of the preceding claims, wherein, The cross-sectional area of ​​the tubular container (101) is between 0.75 square inches and 13 square inches, or between 4.84 square centimeters and 83.87 square centimeters.

16. The yarn storage container according to any one of the preceding claims, wherein, The cap or hood (127) includes a radial slot, and the mesh of the first axial end (115) is configured to engage within the slot.

17. The yarn storage container according to any one of the preceding claims, wherein, The mesh at the first axial end (115) is fixed in the slot of the cover or cap (127) by mechanical or chemical means.

18. The yarn storage container according to any one of the preceding claims, wherein, The axial length (L) of the tubular container (101) is between 15 inches and 110 inches, or between 38.1 cm and 279.4 cm.

19. The yarn storage container according to any one of the preceding claims, characterized in that, The container (101) is not tubular or cylindrical, but elongated and has a cross-section that is different from a circle, preferably selected from a list of free hexagons, rectangles, squares and triangles.

20. A yarn storage container, whether or not according to any of the preceding claims, characterized in that, The yarn storage container (100) includes a tubular and / or elongated container having an axial length (L), a tubular and / or elongated peripheral wall (501), and a first axial end and a second axial end (113-115). The first axial end of the container (101) has an opening (123) for receiving the end of a yarn (200). The container (101) also includes means for providing a laminar airflow along the wall of the container (101) in the axial direction, preferably from the first axial end (113) to the second axial end (115).

21. A yarn storage container for storing yarn, characterized in that, The yarn storage container (101) includes, for example, a tubular container having an axial length (L), a tubular wall, and a first axial end and a second axial end (113-115). The first axial end of the tubular container (101) has an opening (123) for receiving the end of the yarn (200). The second axial end (115) of the tubular container (101) is either open or closed and the tubular wall (501) is a breathable mesh.

22. A yarn storage system comprising at least two yarn storage containers (101) according to any one of claims 1 to 21.

23. The yarn storage system according to claim 22, wherein, All yarn storage containers (101) have the same dimensions.

24. The yarn storage system according to any one of claims 22 or 23, wherein, The tubular container (101) is organized in a frame (1002).

25. The yarn storage system according to any one of claims 22 to 24, wherein, The first axial ends (113) of all tubular containers are coplanar.

26. The yarn storage system according to any one of claims 22 to 25, wherein, The tubular container (113) is oriented in a generally vertical position.

27. The yarn storage system according to any one of claims 22 to 26, wherein, The tubular container (113) is oriented in a generally horizontal position.

28. The yarn storage system according to any one of claims 22 to 27, wherein, The yarn storage system (1000) further includes a yarn end holding device comprising a number of orifices (2022) or slots (2013), the number of orifices or slots being equal to or greater than the number of tubular containers (101) of the yarn storage system (1000), each orifice (2022) or slot (2013) being adapted to receive at least one yarn end from one of the tubular containers (101).

29. A yarn storage system comprising at least a first yarn storage container and a second yarn storage container (101), the first and second yarn storage containers (101) being elongated, preferably tubular, and having an axial length (L) and an elongated peripheral wall (501) extending between a first axial end and a second axial end (113-115), the first axial end (113) of the container (101) having an opening (123) for receiving an end of yarn (200), characterized in that, The yarn storage system (1000) also has at least one of the following features, or a combination of two or more of the following features: - The first container and the second container (101) are positioned or can be positioned in the yarn storage system (1000), wherein the axial length (L) of the container points to the horizontal plane; - The first container and the second container (101) are positioned or can be positioned in the yarn storage system (1000), wherein the axial length (L) of the container is inclined relative to the generally horizontal plane, and the angle (G) between the inclination and the generally horizontal plane is 15° or less. - The first container and the second container (101) are positioned or can be positioned in the yarn storage system (1000), wherein the axial length (L) of the container is oriented at an angle relative to the generally horizontal plane, wherein the first axial end (113) points downward; - The yarn storage system (1000) includes a plurality of containers (101), the plurality of containers including the first container and the second container (101), wherein the plurality of containers (101) are positioned in a matrix manner, wherein the matrix is ​​preferably approximately uniform; - At least one of the first container and the second container (101) is provided with a yarn detector (2012-2019), and / or the yarn storage system (1000) includes means for detecting the yarn (200) in at least one of the first container and the second container (100); - At least one of the first container and the second container (100) is provided with means for generating laminar airflow, which preferably flows from the first axial end (113) to the second axial end (115). - At least one of the first container and the second container (101) exhibits the features of any one of claims 1 to 20; - The yarn storage system (1000) is directly connected to a tufting machine (2001) or a loom, for example, yarn (200) from at least one of the first container and the second container (101) is positioned to be tufted or woven in the tufting machine or loom; - The yarn storage system (1000) includes a yarn end holding device, which includes a number of orifices (2022) or slots (2013), the number of orifices (2022) or slots (2013) preferably being equal to or greater than the number of containers (101) of the yarn storage system (1000), and each orifice (2022) or slot (2013) preferably being adapted to receive at least one yarn end from one of the containers (101); - At least one of the first container and the second container (101) includes a lid that substantially closes the first axial end (113) and the lid is provided with a shaft to provide the opening (123) for receiving the end of the yarn. - At least one of the first container and the second container (101) includes a conductive layer or conductive strip on its inner wall; - At least one of the first container and the second container (101) is grounded; - At least one of the first container and the second container (101) is configured to store yarn (200) without tension.

30. Use of the yarn storage system according to any one of claims 22 to 29 for supplying pile yarn to a tufting machine (2001).

31. A textile production component, wherein, The textile production assembly (2000) includes at least a first yarn storage system (1000) and a textile production machine (2001), wherein the machine produces textiles based on continuous yarn (200) and / or the machine is selected from a list consisting of a tufting machine (2001), a loom, and a knitting machine. The first yarn storage system (1000) includes at least a first yarn storage container and a second yarn storage container (101) for storing continuous yarn (200), the first and second yarn storage containers (101) being elongated, preferably tubular. The container (1000) has an axial length (L) and an elongated peripheral wall (501) extending between a first axial end and a second axial end (113-115). The first axial end (115) of the container (101) has an opening (123) for receiving the end of yarn (200). The first yarn storage system (1000) also includes means (2010) for communicating with the textile production machine, particularly for communicating a shortage of yarn (200) from the first container and / or the second container (101).

32. The textile production component according to claim 31, characterized in that, The first yarn storage system (1000) includes the features of claim 29.

33. The textile production component according to claim 31 or 32, characterized in that, The first yarn storage system (1000) is provided with a combination of at least the following features: - At least one of the first container and the second container (101) is provided with a yarn detector (2012-2019), and / or the first yarn storage system (1000) includes means for detecting yarn (200) in at least one of the first container and the second container (100); The signal generated by the yarn detector (2012-2019) is transmitted directly or indirectly to the textile machine via the communication device (2010).

34. The textile production component according to any one of claims 31 to 33, characterized in that, The communication device (2010) is selected from a list of electrical and electronic devices, wherein the communication device preferably includes a wireless link between the first storage system (1000) and the textile machine.

35. The textile production component according to any one of claims 31 to 34, characterized in that, The textile machine (1000) is configured to either suspend operation or continue processing yarn (200) from a substitute container (101) in the first yarn storage system (1000) when it receives a signal via the means (2010) for communication.

36. The textile production component according to any one of claims 31 to 35, characterized in that, The textile production assembly (2000) further includes means (2018) for connecting one or more yarns of the yarn (200) of the first yarn storage system (1000) to one or more yarns (200) of a preferably similar second yarn storage system (1000).

37. The textile production component according to claim 36, characterized in that, The connecting device (2018) includes a support for positioning one or more yarns (200) of the first yarn storage system (1000) and one or more yarns (200) of the second yarn storage system (1000), wherein the connecting device (2018) further includes a welding element for connecting one or more yarns (200) of the first yarn storage system (1000) to one or more yarns (200) of the second yarn storage system (1000), preferably, the connection is made when the yarns are positioned on the support; the support preferably includes a set of teeth (2014) for separating the yarns (200) from the first yarn storage system (1000) and / or the second yarn storage system (1000), respectively.

38. A method for storing yarn, the method comprising the following steps: - Provide at least one yarn storage system (1000) according to any one of claims 22 to 29. - Provide N spools of yarn (200), where N is an integer greater than or equal to 1; Repeat the following steps ■ Select at least one container (101), preferably tubular, to at least partially load the yarn (200) of the spool. ■ Define the length of the yarn to be inserted into the selected at least one container (101); ■ Select one of the N yarns (200); ■The selected yarn (200) of the defined length is injected from the spool into the selected at least one container (101) by means of a fluid, such as pressurized air; For multiple containers (101), this can be optionally repeated until all containers (101) are at least partially loaded with yarn (200).

39. The method according to claim 38, wherein, N is greater than 1, preferably between 2 and 10, and even more preferably between 2 and 8, for example, 3, 4, 5, 6, 7 or 8 yarns.

40. The method according to claim 38 or 39, wherein, The injection of the yarn into the container (101) is performed by a robot (5110), the robot comprising a spool holder having the N yarns (200).

41. The method according to claim 40, wherein, The robot (5110) includes a storage unit (5111) for storing loading data, storing data for each tubular container: -The location of the tubular container - Yarns to be selected, and - The length of the yarn to be injected; The robot (5110) includes an input device (5112) for inputting the loading data into the storage unit. The robot also includes a control unit that defines the loading sequence of the tubular container and controls the injection of the yarn into the tubular container while executing the loading sequence.

42. The method according to any one of claims 38 to 41, wherein, N>1, and the yarns on the N yarn spools are all different yarns (200).

43. The method according to any one of claims 38 to 42, wherein, The yarn (200) is a bulky continuous filament yarn.

44. The method according to any one of claims 38 to 43, wherein, The defined length of yarn (200) ranges from 2,000 feet to 10,000 feet, or from 609.6 meters to 3,048 meters.

45. The method according to any one of claims 38 to 44, wherein, The system includes a vortex injector (2028) for injecting a selected yarn (200) of a defined length into a selected, preferably tubular, container (101).

46. ​​A yarn storage container (101) for storing yarn (200), the yarn storage container (101) comprising a preferably tubular container (101) having an axial length (L), a preferably tubular wall (501), and a first axial end and a second axial end, the first axial end (113) of the container (101) having an opening (123) for receiving the end of the yarn (200), the second axial end (115) of the container (101) being either ventilated and open or closed, the wall (501) being a ventilated mesh.

47. A method for producing textiles having multiple designs, wherein, Each design is generated from a set of yarns (200), characterized in that the method comprises: - Provide a first set of yarns for a first design of the plurality of designs; wherein one or more of the first set of yarns are disposed in a first yarn storage system (1000), wherein the first yarn storage system (1000) includes a first plurality of containers (101). - Provide a second set of yarns for the second design of the plurality of designs; wherein one or more of the second set of yarns are disposed in a second yarn storage system (1000), wherein the second yarn storage system (1000) includes a second plurality of containers (101). -The first design is produced at least by pulling yarn (200) from one or more of the first plurality of containers (101); - Connect one or more yarns of the yarns (200) of the first plurality of containers (101) to the yarns of the second plurality of containers (101); - The second design is produced by at least pulling yarn (200) from one or more of the second plurality of containers (101).

48. The method according to claim 47, characterized in that, Each container (101) from which yarn (200) is drawn for either the first design or the second design includes at most one continuous length of yarn, wherein the continuous length preferably corresponds to the length of the yarn required in either the first design or the second design, having a margin preferably less than 10%.

49. The method according to claim 48, wherein, The container (101) is tubular.

50. The method according to any one of claims 47 to 49, characterized in that, The container is a yarn storage container (100) according to any one of claims 1 to 21, and / or is characterized by One of the first yarn storage system and the second yarn storage system (1000) presents the features of any one of claims 22 to 29.

51. The method according to any one of claims 47 to 50, characterized in that, The connection includes fusion welding.

52. The method according to any one of claims 47 to 51, characterized in that, The connection includes positioning one or more yarns of the yarns (200) of the first plurality of containers (101) and one or more yarns of the yarns (200) of the second plurality of containers on a support, and connecting the yarns (200) while they are positioned on the support.

53. The method according to claim 52, characterized in that, The support includes a set of teeth (2014) for spacing individual yarns (200).

54. The method according to any one of claims 47 to 53, characterized in that, All the yarns (200) of the first group of yarns and the second group of yarns are pulled out from the respective containers (101), wherein the first group of yarns includes at least all the yarns (200) required for the first design, and the second group of yarns includes at least all the yarns (200) required for the second design.

55. The method according to any one of claims 47 to 54, characterized in that, The method further includes the step of cutting the textile into at least two pieces, each piece comprising at least one of the first design and the second design.

56. The method according to any one of claims 47 to 55, characterized in that, The method further includes the step of cutting the textile into at least three pieces, wherein each of two pieces includes at least one of the first design and the second design, and the third piece is positioned between the first design and the second design.

57. The method according to any one of claims 47 to 56, characterized in that, The difference between the first group of yarns and the second group of yarns is at least that the number of containers (101) of a specific color loaded in the first plurality of containers is different from the number of containers (101) of the same specific color loaded in the second plurality of containers.

58. A grey fabric product obtained or obtainable by the method according to any one of claims 47 to 57, wherein, The greige fabric product is a textile comprising the first design, the second design, and a region between the first design and the second design, wherein the region contains yarns from both the first group of yarns and the second group of yarns.

59. A method for producing yarn, wherein the yarn is preferably fed into a tufting machine (2001), the method comprising: - Spinning multiple filaments (2026); - Convert the multiple filaments (2026) into yarn (200); - The yarn (200) is provided directly in a container (101); the container is preferably a yarn storage container (101) according to any one of claims 1 to 21 and / or the container is included in a yarn storage system (1000) exhibiting the features of any one of claims 22 to 29; - Optionally, the yarn (200) is fed into the tufting machine (2001) by pulling it out of the container (101).

60. The method according to claim 59, characterized in that, The conversion includes tangling and / or twisting.

61. The method according to claim 59 or 60, characterized in that, The conversion includes entanglement of the multiple filaments (2026) via an air jet to produce the yarn (200), wherein the yarn is preferably adapted for tufting.

62. The method according to any one of claims 59 to 61, characterized in that, The conversion includes twisting the plurality of filaments (2026) to produce the yarn (200), wherein the yarn is preferably adapted for tufting and / or wherein twisting the plurality of filaments (2026) includes applying an S-twist or a Z-twist.

63. The method according to claim 62, characterized in that, Twisting the multiple filaments (2026) includes adjusting the amount of twisting to produce yarns (200) of different textures.

64. The method according to any one of claims 59 to 63, characterized in that, The yarn (200) is directly supplied in the container (101) including a quantity of yarn (200) corresponding to the amount required for the design of the textile to be produced on a part of the textile machine, the quantity having a margin of less than 10%.

65. The method according to any one of claims 59 to 64, characterized in that, Directly providing the yarn (200) into the container (101) includes loading the container (101) with a certain amount of yarn (200), cutting the yarn, and loading subsequent containers (101) with different or the same amount of yarn (200).

66. The method according to any one of claims 59 to 65, characterized in that, The method also includes pulling yarn (200) from the container (101) for feeding into a textile machine.

67. The method according to any one of claims 59 to 66, characterized in that, The multiple filaments (2026) include filaments of different colors and / or filaments of different fineness.

68. A method for producing tufted textiles, the method comprising: - Spinning multiple filaments (2026); - Convert the multiple filaments (2026) into multiple yarns (200); - Injecting at least one of the plurality of yarns (200) into at least one container (101); said container is preferably a yarn storage container (101) according to any one of claims 1 to 21, and / or said container is included in a yarn storage system (1000) exhibiting the features of any one of claims 22 to 29, and - The at least one yarn (200) is pulled from the at least one container (101) to the tufting machine (2001) to produce tufted textiles.

69. The method according to claim 68, characterized in that, The tufted textiles include tufted carpets.

70. The method according to claim 68 or 69, characterized in that, Converting the multiple filaments (2026) into multiple yarns (200) includes tangling and / or twisting the multiple filaments (2026) to produce the multiple yarns (200).

71. The method according to any one of claims 68 to 70, characterized in that, Injecting at least one of the plurality of yarns (200) includes injecting the plurality of yarns (200) into a plurality of containers (101).

72. The method according to any one of claims 68 to 71, characterized in that, Injecting at least one yarn (200) into at least one container (101) includes blowing the first yarn (200) into the first end (113) of the first container (101).

73. The method according to any one of claims 68 to 72, characterized in that, Pulling at least one yarn (200) from the at least one container (101) to the tufting machine (2001) includes pulling a first yarn (200) from the first end (113) of the first container (101) into the tufting machine (2001) to produce tufted textiles.

74. The method according to any one of claims 68 to 72, characterized in that, Pulling at least one yarn (200) from the at least one container (101) to the tufting machine (2001) includes pulling a first yarn (200) from the second end (115) of the first container (101) into the tufting machine (2001) to produce tufted textiles.

75. The method according to any one of claims 68 to 74, characterized in that, The at least one container (101) is a tubular container.

76. A drum changing system, the drum changing system comprising: - One or more yarn storage systems (1000), each yarn storage system comprising a plurality of yarn storage containers (101) or configured to receive one or more yarn storage containers (1000); the containers are preferably yarn storage containers (101) according to any one of claims 1 to 21 and / or included in a yarn storage system (1000) exhibiting the features of any one of claims 22 to 29; - At least one set of multiple injectors (2028) for injecting yarn (200) of a defined length into the multiple yarn storage containers (101); as well as - A controller, the controller including a memory and configured to direct the at least one set of multiple injectors (2028) to inject the defined length of yarn (200) into the multiple yarn storage containers (101).

77. The drum changing system according to claim 76, characterized in that, The memory includes information for at least a plurality of yarn storage containers (101) in each of the plurality of yarn storage systems (1000), preferably including information for each yarn storage container.

78. The drum changing system according to claim 76 or 77, characterized in that, For each yarn storage container (101) in the plurality of yarn storage systems, the memory includes information on the position of each yarn storage container in the corresponding yarn storage system (1000), the yarn (200) to be selected for the yarn storage container (101), and the length of the yarn (200) to be injected into the yarn storage container (101).

79. The drum changing system according to any one of claims 76 to 78, wherein, The plurality of injectors (2028) simultaneously inject the defined length of yarn (200) into the plurality of yarn storage containers (101) in the plurality of storage systems (1000).

80. The drum changing system according to any one of claims 76 to 79, characterized in that, The yarn changing system preferably includes at least one set of multiple injectors (2028) for each of the yarn storage systems (1000) that it can receive.

81. The drum changing system according to any one of claims 76 to 80, characterized in that, Each injector (2028) in the group injects a single type of yarn (200), i.e., yarn of the same color, type, quality and material, into the container of the specific yarn storage system.

82. The drum changing system according to any one of claims 76 to 81, characterized in that, One or more injectors in the group, preferably each injector (2028) is capable of injecting yarn (200) into multiple columns of the stack of containers (101) and / or capable of injecting yarn (200) into multiple rows of the stack of containers (101).

83. A yarn storage container for storing yarn, the yarn storage container comprising: A tubular container with an axial length; A tubular wall comprising a breathable mesh along the axial length of the tubular container and having a first axial end and a second axial end; The first axial end of the tubular container includes an opening for receiving the end of the yarn; and The second axial end of the tubular container includes a ventilated end cap.

84. The yarn storage container according to claim 83, wherein, The breathable mesh is composed of strands.

85. The yarn storage container according to claim 84, wherein, The strands are arranged in a pattern in which at least a first plurality of strands are perpendicular to a second plurality of strands.

86. The yarn storage container according to claim 85, wherein, The mesh consists of a single layer.

87. The yarn storage container according to claim 86, wherein, The first plurality of strands and the second plurality of strands are woven together.

88. The yarn storage container according to claim 86, wherein, The proportion of the open area of ​​the mesh element is between 70% and 95%.

89. The yarn storage container according to claim 86, wherein, The proportion of the open area of ​​the mesh is between 90% and 93%.

90. The yarn storage container according to claim 86, wherein, The proportion of the open area of ​​the mesh is 91%.

91. The yarn storage container according to claim 88, wherein, The breathable mesh is made of a material selected from the group consisting of polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, metal and glass fiber.

92. The yarn storage container according to claim 88, wherein, The first shaft end includes a cap configured to substantially close the first shaft end, wherein the cap is configured with a shaft for receiving the end of a yarn.

93. The yarn storage container according to claim 92, wherein, The shaft includes a loop and a yarn retainer.

94. The yarn storage container according to claim 93, wherein, The cable loop is conductive.

95. A yarn storage system for storing yarn, the yarn storage system comprising: Multiple cylindrical bodies made of mesh fabric; Each cylinder has a first axial end and a second axial end; The mesh fabric is composed of multiple intersecting strands; The first shaft end of each of the plurality of cylindrical bodies is configured as an end for receiving yarn; and The yarn storage system includes wheels configured to move the yarn storage system.

96. The yarn storage system according to claim 95, wherein, The mesh fabric is breathable and is composed of strands.

97. The yarn storage container according to claim 96, wherein, The strands are arranged in a pattern in which at least a first plurality of strands are perpendicular to a second plurality of strands.

98. The yarn storage container according to claim 97, wherein, The first plurality of strands and the second plurality of strands are woven together.

99. The yarn storage container according to claim 86, wherein, The proportion of the open area of ​​the mesh element is between 70% and 95%.

100. The yarn storage container according to claim 86, wherein, The proportion of the open area of ​​the mesh is between 90% and 93%.

101. The yarn storage container according to claim 99, wherein, The mesh fabric is made of a material selected from the group consisting of polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, metal, and glass fiber.

102. The yarn storage container according to claim 101, wherein, The first axial end includes a cap configured to substantially close the first axial end, the cap being configured with a yarn retainer and a shaft for receiving the end of the yarn.

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