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

Abstract

A yam storage container for storing a yam, said storage container (101) comprising a, preferably tubular, container (101), having an axial length (L), a, preferably tubular, wall (501) and a first and second axial extremity (113-115), the first axial extremity (113) of said container (101) having an opening (123) for receiving an end of a yarn (200), said second axial extremity (115) of said container (101) being air-permeably open or closed, said wall (501) is an air permeable mesh present along the axial length of said container (101). The invention further relates to a yarn storage system (1000) comprising a plurality of containers (101), to a textile production assembly (2000) and to methods of producing yam (200) and textiles.

Description

[0001] Yarn storage system and method for producing textiles using such yam storage system

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to yam storage containers and yam storage systems, in particular to yarn storage systems for a plurality of yarns, such as yam storage systems for yams used as pile yarn in tufting processes. The present invention also relates to creeling systems.

[0004] The invention further relates to methods for producing textiles having a plurality of designs, methods for producing a tufted textile, and methods for producing yarn.

[0005] BACKGROUND OF THE INVENTION

[0006] Tufting machines are known in the art. A large number of yams, even up to or more than 1000 yams, may be simultaneously tufted into a primary backing to provide a greige product. Previously, a yarn cone would be held in a rack of yarns for each yarn tufted.

[0007] At certain times in a tufting process, the color or design of the greige fabric may be changed. This may occur when the same design is to be tufted in a different color palette or scheme. This may require the replacement of a large number of yarn cones in a rack feeding the tufting machine. This is labor intensive and time consuming to rethread all of the yarns to the tufting machine.

[0008] EP 2 885 235 Bl discloses a yarn packaging system comprising metered quantities of yam for small lot size production of tufted or woven textiles. The packaging system comprises a plurality of vertical yam containers. The yarns may be routed from the packaging system to a loom or tufting machine. A change-over between different packaging systems may be time consuming. In some prior art yarn storage systems that store yam in a tube, the injected yam may fold upon itself during the loading process. In some cases, the unloading process will cause the folded yam to form a knot, which may be detrimental to the machine consuming the yarn. For example, a tufting machine may not be able to tuft a yam with a knot in it through a primary backing.

[0009] SUMMARY OF THE INVENTION

[0010] The present invention in the first place aims at an alternative yam storage system, wherein, in accordance with preferred embodiments, solutions are obtained for the problem with the yam storage systems of the prior art.

[0011] It is, amongst others, an object of the present invention to provide a yarn storage system, which reduces the change over time for changing the greige product from one set of yarns to another. It is also the object of the invention to provide yam storage containers being part of such yam storage system, and methods to store yam in such yam storage systems. The invention further relates to a creeling system for loading such yarn storage systems.

[0012] It is a further object of the present invention to provide alternative methods for producing textiles having a plurality of designs, wherein, in accordance with preferred embodiments the change-over time between designs is reduced. Further alternative methods for producing a tufted textile, and methods for producing yarn are aimed at advantages over prior art methods.

[0013] It is a further objective of the present invention to reduce the number of knots formed within a yam storage container during loading and unloading.

[0014] According to a first independent aspect of the invention, a yam storage container and a yarn storage system are provided.

[0015] In an embodiment of this aspect, the yam storage containers disclosed and taught herein may be used to store wound yam and non-wound yarn. Yams which are nonwound may be yarns which are not wound or coiled on a spool or bobbin. In this embodiment, the yam may be laid down freely and unguided within the void inside the tubular container.

[0016] In a preferred embodiment the internal cavity of a yam storage container may be a void. That is to say that there will be no obstacles disturbing the yam in the container as it is being loaded and unloaded. In this way loading the container with yam may be executed in a uniform manner so that any tension variations in the yarn may be avoided while feeding a tufter or loom with the yam from the container. In an alternative embodiment, the container may comprise internal means for guiding the yam in a desired path. For example, the container may comprise a centrally located cone or frustum. In such case, the yam may be guided to lay freely about the perimeter of the cone or frustrum as it is loaded. This exemplary embodiment may reduce or even eliminate undue tension. Any such exemplary internal means may be air permeable or impermeable.

[0017] In a preferred embodiment, the wall of the yarn container may be air permeable to allow air to pass radially outwards through the internal wall of the yam container.

[0018] In one embodiment, each yam container may be configured to hold only one yarn, wherein the yarn has a length being at least double, or at least 10 times the axial length of the container and / or a length being at least twenty, or at least hundred times the internal circumference of the cross-section of the yarn container. Preferably the yarn may have a length of at least 5 or at least 10 meters. Preferably, the length is shorter than 2 kilometers, or shorter than 750 meters, or shorter than 500 meters or shorter than 250 meters. Preferably, the length is at least 5 meters, and preferably in the range of 500 to 2500 meters. A minimum length of 5 meters is desirable to allow threading of the loom or tufter. Preferably a length of yam is used which is at least 1.5 meters more than what is needed in accordance with the design to be created in the textile.

[0019] In a preferred embodiment of a yarn storage container, the opening of the first axial extremity of the yarn container may be configured to receive an end of a yarn. This may be provided by leaving the first axial extremity of the yam container uncovered or open. In one embodiment, this may be that the tubular extends all the way to the first axial extremity. In other embodiments, the first axial extremity may be terminated with a cap, flange, or lid that will still leave the first axial extremity open to receive an end of yarn.

[0020] The second axial extremity of the yarn storage container may be configured with an air permeable closing cap, such as, but not limited to, a perforated cap, which is configured to close the second axial extremity of the yarn storage container. Alternatively, the second axial extremity of the tubular container may be closed with a grid, which may be removably secured to the second axial extremity. The open area of this air permeable closing cap may be in the range of 30 to 90% of the total cross-sectional area of the yam storage container. In other embodiments, the open area may be in the range of 40 to 80%. In preferred embodiments, the open area may be the same as the open area of the walls of the yarn storage container.

[0021] In another embodiment, the second axial extremity of the yam storage container may be configured with a fluid impermeable cap. In this embodiment, the end of the yarn loading the yarn storage container would be stopped by the cap and the propulsion fluid would have to exit the yarn storage container through other openings.

[0022] A yam storage system according to a second aspect of the invention may comprise a plurality of yarn storage containers according to the first aspect of the invention. In one embodiment, a plurality of yam storage containers in the yam storage system may be loaded with yarn by blowing the yam into each tube. This may be done by entraining the yarn within a propulsion fluid, such as blowing air, via the opening at the first axial extremity of each of the containers. The yarn end blown into a yam storage container will be blown through the length of the yarn storage container to meet the closure of the second axial extremity. Once the end of the yarn is stopped there, additional yarn may be blown in to gradually load the container as the yam is laid freely in the volume of the tubular container. The fluid blown in will escape the cavity of the yarn storage container via the air permeable closure of the second extremity, and / or the openings in the wall. In other words, the yarn end stuffs and loads the container at least partially. Once required lengths of yams are provided in the yarn storage containers, the yam storage system may be moved to the apparatus which will consume the yarns and convert them into a desired textile product. As a non-limiting example, the yarns may be used by a tufting machine as pile yarn. During consumption of the yams, the yarns may be gently pulled from the yam storage containers via the opening of the first axial extremity, hence in the opposite direction from which it was blown in. The yarn unloaded from the container will exhibit very little to no variation of tension, which facilitates the tension control of the yam during conversion into a textile fabric. The apparatus which is to consume the yams and convert them into a desired textile product may be a tufting machine, a weaving loom, a warp or weft knitting loom, a sewing machine, an embroidering machine, and similar machines.

[0023] In a preferred embodiment, a yarn storage container may comprise a mesh. A seamless cylinder of a mesh will provide a boundary for the loading of yarn and an effective means for allowing propulsion fluids, such as air, ingress and egress. In another embodiment, a mesh cylinder with a smoothed seam will provide a boundary for the loading of yam and an effective means for allowing propulsion fluids, such as air, ingress and egress.

[0024] As the yarn is blown or sucked into the yarn storage container, the yam will travel to the second axial extremity and be stopped there by the cap. The propulsion fluid will exit the yarn storage container through the mesh between the first and second axial extremities and through the cap.

[0025] In a preferred embodiment, the mesh will be a continuous mesh with no seams. A seam may offer projections in an otherwise smooth interior face of the yarn storage container and projections may be points where the travelling yarn may catch and hang on. In another embodiment, a seam in a mesh cylinder may be smoothed over to remove projections.

[0026] One method of smoothing over seams may be to cover the seam with a strip that offers smooth edges. A sufficiently thin strip may cover the seam without substantially reducing the overall permeability of the mesh. Another method of smoothing over seams may be to apply a coating over the seam that offers smooth edges. This may be done by spraying the coating on the mesh at the seam. In a preferred embodiment, the spray would only smooth the seam and not fill the openings of the mesh.

[0027] The openings define a total sum of open area along the wall of the yam storage container, hereinafter referred to as “open area”. The average open area per surface unit of the mesh portion of the cavity may be in the range of about 70% to about 95%. In some more preferred embodiments, the range may be between about 90% and about 93%. In a more preferred embodiment, the open space may be at or about 91%. This may be accomplished by having a mesh with connecting strands laid out at right angles to each other. In one view, these may be termed as horizontal and vertical strands. However, the actual orientation of the strands in forming the cylinder need not have the strands oriented vertically and horizontally or at right angles to each other.

[0028] In one embodiment, the strands may have a nominal diameter of 0.008 inches (0.2032 millimeters) with 16 strands in one direction and 16 strands at right angles to the first set per square inch (6.4516 square centimeters). Similarly, strands of 0.004 inches (0.1016 mm) would have approximately 88% open space in a 16 by 16 strand mesh. Similarly, strands of 0.003 inches (0.0762 mm) would have approximately 91.5% open space, and strands of 0.002 inches (0.0508 mm) would have approximately 96.8% open space in a 16 by 16 strand mesh.

[0029] In more preferred embodiments, the strands may be 0.006 inches (0.1524 mm), which, in a 16.5 by 16.5 mesh in a one square inch (6.4516 square centimeters) area would have approximately 91% open area.

[0030] In other embodiments, the mesh may be 16 by 18 strands or 20 by 20 strands using any of the diameters disclosed herein.

[0031] In one embodiment, the horizontal strands may be woven with the vertical strands to create the mesh. This may be done with 32-gauge wire that has a diameter of 0.008 inches (0.2032 millimeters). More preferably, this may be done with a wire that is between 34-gauge and 35-gauge wire, where 34-gauge wire has a diameter of 0.0063 inches (0.16002 millimeters) and a 35-gauge wire has a dimeter of 0.0056 inches (0.14224 millimeters). This will leave a surface with wires that pass over and under each other. These intersections of wires may be sprayed or coated as disclosed herein to smooth those junctures so they do not project any areas that may catch filaments of yarn.

[0032] In a preferred embodiment, the mesh may be fabricated in a single layer. This may be done using any material that dries, hardens, or cures to form a smooth surface that will not have projections that may catch filaments of yarn. Alternatively, the mesh may be fabricated from a material that may leave projections, which may be smoothed by abrasive smoothing and / or coated as disclosed herein to yield a smooth interior.

[0033] The mesh may be made of any suitable material, including, but not limited to: polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, other polymers or combinations of polymers, metals, fiberglass, and other fibers.

[0034] According to some embodiments, the first axial extremity of a yarn storage container may comprise a lid proximal the first axial extremity. In a preferred embodiment, the lid may be configured with an opening, such as a shaft or hole, for receiving an end of the yarn. Such a lid may provide for a further minimization of the risk of the yarn becoming entangled and / or tensioned by having a smooth bore. Furthermore, the lid may be configured to prevent the yam from being removed from the container unintentionally, for example while moving the container in an orientation that is not level. The lid may be configured to fit in and / or over the axial extremity of the yam storage container. The lid may be a plug or a cap. The lid may be removably secured to the first axial extremity. It may be attached by clips, clamps, magnets, or may be retained through a friction or interference fit.

[0035] In some embodiment, the second axial extremity of the yam storage container may comprise an endcap proximal to the second axial extremity. In a preferred embodiment, the endcap may be made of the same mesh material as the walls of the yam storage container. The endcap may be chemically bonded or mechanically secured to the walls of the second axial extremity. In some embodiments, the first axial extremity of the yam storage container may comprise a grommet for receiving an end of the yam. The grommet may be part of the lid, thereby providing the opening to the lid. In one non-limiting exemplary embodiment, the grommet may fit into the shaft of a lid substantially closing the first axial extremity.

[0036] In other embodiments, the grommet may be configured to mechanically couple to the first axial extremity of said container.

[0037] In some embodiments, the grommet may be a tube, typically of relative short length, such as 0.5- to 2-inches (1.27- to 5.08-centimeters). The inner diameter of the tube opening may vary, such as between 0.25- and 2-inches (0.635- and 5.08-centimers), or such as between 0.5- and 1-inches (0.635- and 2.54-centimers). The grommet may be electrically conductive.

[0038] The grommet may be made from metal, such as iron, steel, copper, aluminum, bronze, messing, or any alternative metal alloy, or may be made from electrically conductive polymers, like carbon fiber or carbon powder filled polymer, such as carbon powder filled polypropylene, polyethylene, polyamide, polyvinylchloride or alike. In the alternative, the grommet may be porcelain.

[0039] In some embodiments of the yarn storage container, the first axial extremity of the container may comprise a brush for contacting the end of the yarn. The brush may be proximal an opening provided in a lid which substantially closes the first axial extremity. In a non-limiting exemplary embodiment, the bristles of the brush may close the opening or shaft. The bristles contacting the yam in or passing through the opening may be configured to exert a minimum tension when the yam is drawn out of the container. The brush may be a straight brush with bristles all being substantially parallel, or a circular brush with bristles oriented towards a central point. For a circular brush, the bristles may overlap at the central point, but preferably leave an opening of about 0.25- to 1-inches (0.635- and 2.54-centimers), such as about 0.75-inches (1.905-centimeters). In some embodiments, a lid may be affixed to the first axial extremity. This may be configured such that the lid has a portion that fits within the first axial extremity for a distance. That is to say that a portion of the lid may be configured to slide within the mesh at the first axial extremity. This may expand the diameter of the mesh as the portion of the lid is slid within the first axial extremity. In embodiments where there will be little force exerted on the area where the portion of the lid contacts the mesh of the first axial extremity, the tension fit formed there may be sufficient to removably secure the lid to the mesh of the yam storage container. However, if a more permanent configuration is required or desired, the mesh at the first axial extremity may be mechanically secured to the portion of the lid. Alternatively, the mesh may be chemically welded or bonded to a portion of the lid.

[0040] In another embodiment, the mesh of the first axial extremity may be retained within a radial slit within a circumferential lip of the lid. In this, the radial slit may extend axially into the lip to fit the circumference of the mesh of the first axial extremity. Again, the parts may be mechanically or chemically secured.

[0041] According to some embodiments the lid may comprise one or a plurality of small openings along the contact zone where said lid contacts the first axial extremity. The openings may be small perforations, holes, slits, or any passage that permits the flow of a fluid such as air. In one embodiment, a laminar air stream may be provided at the first axial extremity of the yam storage container by gently blowing or sucking air through the small openings into the inner cavity of the container. That is to say that air blown through the openings from the outside to the inside may push yam, while air sucked from the outside to the inside through the openings may pull the yarn. In the latter, the container may comprise means to create a sub- atmospheric pressure in the yam storage container via the second axial extremity.

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

[0043] This means to create sub-atmospheric pressure in combination with lids comprising one or a plurality of small openings along the contact zone where the lid contacts the first axial extremity may be part of the means to create a laminar stream along the inner wall of the yam storage container, or it may be the only means for creating the laminar stream.

[0044] The laminar air stream may be used to transport the yam into the yam storage container and to prevent the yam from folding, which is also known as bridging, inside the container. That is to say that the yarn will not fold or self-accumulate on itself to form an obstruction in the inner part of the container before having reached the end of the cavity of the container. Such an accumulation may lead to the yam becoming entangled, and to a lack of volume to store sufficient yam inside the container. Using this disclosed embodiment alleviates the problem of bridging, which may be associated with yarns that are based on PET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), PP (polypropylene), PA (polyamide), wool or cotton.

[0045] As noted, if the yarn becomes entangled while loading, it may form a knot while it is being unloaded. Any tension on the yam may cinch the knot and make it difficult or impossible to be consumed by any machine that consumes yam.

[0046] In another embodiment, the yarn storage container may comprise a grounding system for grounding the electrically conductive brush, grommet, container or tube. This may be obtained by providing an electrically conductive coating along the inner wall; either entirely, or partially such as by using a strip of electroconductive material along the axial length of the yam storage container. Such electroconductive coating materials may be silver, gold, aluminum, copper, brass, bronze, tin or similar metal or metallic coatings. As the yarn storage containers form part of a storage system, the entire system may comprise a grounding system. While some embodiment of the yarn storage container may be described herein as a cylinder with a circular cross-section, it is not limited to that topology. In alternative embodiments, the yam storage container may have other cross-sectional shapes. In some embodiments, the cross-sectional shape may be oval, square, or rectangular.

[0047] According to some embodiments, the surface of a radial cross-sectional area of the yarn storage container may be between 0.75- and 13-inch2(4.84- and 83.87-cm2). More preferably, the cross-sectional area of a radial cross-section of the tubular container may be between 1.5- and 13-inch2(9.68- and 83.87-cm2), such as between 2- and 13-inch2(12.90- and 83.87-cm2).

[0048] In some embodiments, a yarn storage container as disclosed and taught herein may be flexible. In some embodiments, such as if the mesh of the yarn storage container is made from vinyl-coated polyester or fiberglass, it may deform under its own weight. If there is no structure to maintain a shape within a yarn storage container system, then the weight of the upper layers of yam storage containers may deform lower layers of yam storage containers. Applicant has addressed this by developing an outer sheath of a more rigid material to encircle the mesh of the yarn storage container. In one embodiment, the outer sheath may be a mesh that provides support without interfering with the flow of the propulsion fluid. Those of skill in the art and in possession of this disclosure will be able to envision other outer sheaths that adhere to the inventions claimed.

[0049] In some embodiments, the axial length of the yam storage container may be between 15 and 110 inches (38.1 and 279.4 cm). In a more preferred embodiment, the axial length of the yarn storage containers may be between 20 and 100 inches (50.8 and 254.0 cm), such as between 24 and 96 inches (61.0 and 243.8 cm).

[0050] According to a third aspect of the invention, a yam storage system is provided. The system may comprise at least two yam storage containers according to the first and / or second aspect of the invention. These containers may have identical dimensions and they may be organized in a rack. In one embodiment, one rack may comprise 16 to 1,024 containers. In a more preferred embodiment, the rack may comprise 36 to 1,000 containers, which may be organized in a matrix arrangement. The matrix may comprise 4 to 32 rows and 4 to 32 columns, or, in a more preferred embodiment, 6 to 30 rows and 6 to 30 columns. In a more preferred embodiment, the rack may comprise 24 rows and 10 columns to have 240 containers.

[0051] In one embodiment of a matrix arrangement of yarn storage containers, a plurality of containers may be positioned adjacent others in a way that none of the yarn storage containers touch each other. In another embodiment, the yam storage containers may contact each other. In some embodiments, internal support structures may be configured to support the lengths of the yam storage containers to prevent them from sagging and / or deforming under their own weight.

[0052] In one embodiment, the rack of yarn storage containers may be at least partially enclosed. In a preferred embodiment, the first axial extremities of the yam storage containers may each be encircled by a face of the rack enclosure. In this embodiment, the adjoining sides of the rack may also be covered, leaving only the side of the rack proximal the second axial extremity open. In this way, all propulsion fluids injected into each of the yarn storage containers would have to exit the enclosure at the face of the enclosure near the second axial extremities of the yarn storage containers. That is to say that propulsion fluids injected into the first axial extremities of the yarn storage containers will have to traverse the lengths of the yarn storage containers to exit the enclosure. Directing the propulsion fluids in this way will propel the ends of yarn towards the second axial extremities of each of the yarn storage containers. Additionally, having some of the sides covered will prevent any drafts flowing across the yam storage system from interfering with the propulsion fluid as it propels the yarn during a loading operation. Similarly, it will prevent drafts from interfering with unloading.

[0053] If several or all of the yarn storage containers are to be loaded with yarn, then the propulsion fluid may be simultaneously injected into all of the yam storage containers to propel all of the ends of yam towards the second axial extremities of their respective yarn storage containers.

[0054] In one embodiment, the yam storage containers may be loaded with yam while the yam storage containers are in a somewhat horizontal orientation. That is to say that they may be loaded while they are inclined at an angle of around or less than about 30° from horizontal. In this embodiment, it may be preferred that the propulsion fluid would be configured to propel the end of the yam all the way to the second axial extremity.

[0055] In another embodiment, the yarn storage containers may be loaded while the yarn storage containers are substantially vertical. That is to say that they may be within 20° of being vertical. In this embodiment, the propulsion fluid would not need to be as forceful in propelling the yarn to the second axial extremity since gravity will aid in that. However, the propulsion fluid will still contribute towards keeping the end of the yarn away from the internal wall of the yam storage system so that it does not stop or fold before it reaches the second axial extremity.

[0056] In another embodiment, each yarn storage container may be in an individual enclosure that is larger than the exterior of the yarn storage container. Similar to enclosing the entire rack, each enclosure will fit the first axial extremity and the four adjoining sides, and be open at the end proximal to the second axial extremity. In that way, the propulsion fluid injected at the first axial extremity will flow along the axial length of the yarn storage container to exit at the back of the rack. As the yarn is loaded, it may block the passage of the propulsion fluid from reaching the end of the yarn storage container. If that happens, the propulsion fluid will exit the yarn storage container along the length of the tube.

[0057] In some embodiments, the racks may be mobile. For example, the yam storage system may be on rollers, wheels, castors, skids, or any other mechanism that allows the yam storage system to be moved.

[0058] In a preferred embodiment, the first axial extremities of the yam storage containers may be coplanar in that they may all present a common face of the rack. That is to say that all of them may algin with a plane proximal the face of the rack. It is also a preferred embodiment that the yam storage containers may have identical axial lengths.

[0059] According to some embodiments, the yam storage containers may be oriented in a vertical position. According to a preferred embodiment, the yarn storage containers may be oriented in a horizontal or substantially horizontal position. Preferably the containers are oriented in a level or near-level manner. However, in accordance with an alternative embodiment, they may be oriented along a slope with the first axial extremity downwardly directed, and preferably at an angle of 15° or less from the horizontal plane. The horizontal or slightly sloping orientation of the containers may improve the taking out of the yam, for example when connected with a tufting machine. Due to the horizontal orientation or the substantially horizontal orientation of the containers, several storage systems, for example for subsequent designs to be tufted on the same tufting machine, can be placed on top of each other, and the change-over from one storage system to the other can be made fluently. Also, the loading of the containers of several storage systems can be carried out with a more compact machine in a more fluent manner.

[0060] In some embodiments, the rack may be rotatable such that in one position the yarn storage containers are substantially vertical, and in another position the yam storage containers are substantially horizontal or at a desired slope. In this way, the rack may be positioned with the yam storage containers in a vertical orientation for loading, and rotated so the that yarn storage containers are horizontal or somewhat horizontal for when yarn is being withdrawn.

[0061] The horizontal or substantially horizontal positioning of the containers within the storage system forms in itself a particular independent aspect of the present invention, being a yarn storage system comprising at least two yam storage containers for storing unwound, untensioned and / or freely provided yarn, wherein said containers are elongated and comprise a first extremity from which yam can be drawn, an wherein said containers are oriented horizontally or substantially horizontally in said yarn storage system, wherein, preferably, a sloping orientation comprises a first extremity of said containers being oriented downwardly and / or a sloping orientation comprises said containers making an angle with the horizontal plane of 15° or less. It is clear that the storage system of the present particular independent aspect of the invention may show the features of one or more of the preferred embodiments of the third aspect of the invention, without the containers necessarily having to show the air permeable mesh wall and impermeable second extremity of the containers of the first aspect of the invention and / or the means for creating a laminar air stream as provided for in the second aspect of the invention.

[0062] In some embodiments, each yam storage container in the storage system of the invention may be provided with at least one yam detector. The yarn detector may be, but is not limited to: an electronical, mechanical or optical yam detector, which may detect the presence of a yarn at the opening of the first axial extremity of each yarn storage container. The yarn detectors may be part of a yarn detecting system, further equipped with a processing unit to receive signals of the yam detectors. In such an embodiment, the presence or absence of the yam may be detected, and a signal generated when at least one yarn detector fails to detect a yarn. Then the yam storage system cooperates with the machinery consuming yam, such as a tufting machine. In some embodiments, the yarn consuming machine may use the signal indicating an absence of a yam to intermpt its operation. The system may also generate an alarm to an operator or attendant to alert the operations staff of this condition.

[0063] According to some embodiments, the yam storage system may comprise a yam end holding means comprising a number of apertures or slots. In this embodiment, the number of apertures or slots may be identical or more than the number of yam storage containers of the yarn storage system, where each aperture or slot is configured to receive one yarn end from one of the containers.

[0064] The apertures or slots may all be adjacent to each other in a row, or may be organized in two or more rows, optionally in a zig-zag configuration. Each slot or aperture may be provided with a ceramic tube to prevent the passing yarn to erode or abrade the aperture or slot. The yarn end holding means typically may be provided as a beam, such as, but not limited to a rectangular, balk-like piece in which the apertures or slots are provided. Most preferably the yam end holding means has a comb-like structure.

[0065] According to a fourth independent aspect of the invention, a yarn storage system is used to supply textile machinery with yam.

[0066] According to some embodiments, the use of a yam storage system according to the third aspect of the invention is provided, for providing yam to a textile machine, such as to provide pile yam to a tufting machine. Preferably, such yarn storage system contains at least one yam storage container per needle of the tufting machine. Preferably, such yarn storage system contains a number of yarn storage containers which may be the same number as or a multiple of the number of needles in the tufting machine.

[0067] The yarn storage system may be used to store bulked continuous filament yams, such as may be used by tufting machines to provide pile yam to a tufted greige in the process of making a tufted carpet or mg. The exemplary embodiments disclosed herein are not limited to only making a tufted carpet or mg. Those of ordinary skill in the art will recognize that the yarn storage system may be used to provide yams to other textile producing equipment, such as warp knitting machines, carpet weaving looms, and similar devices.

[0068] According to a fifth independent aspect of the invention, a method to store yams in provided.

[0069] The method to store yam according to this fifth aspect comprises the steps of a) Providing a yam storage system according to the third aspect of the invention; b) Providing N spools of yarn, N being an integer equal to or more than 1; c) Repeating the following sub-steps selecting at least one yam storage container to at least be partially loaded with yam from a spool; defining for the selected yarn storage container a length of yarn to be loaded; selecting one of the N spools of yams;

[0070] - loading the defined length of the yarn from the selected spool by means of a propulsion fluid, such as pressured air, to the selected yam storage container; for a plurality of yam storage containers, optionally until all containers are at least partially loaded with yarn.

[0071] According to some embodiments, the N may be more than 1. Preferably, the number of yams used will be between 2 and 10, even more preferably between 2 and 8, such as 3, 4, 5, 6, 7 or 8 yams.

[0072] According to some embodiments, the loading of a yam into a yam storage container may be performed by a robot, comprising a spool rack comprising the N spools of yarn. In some embodiments, the robot may comprise a memory unit capable of associating a loading data with: an identifier of the rack,

[0073] - the position of the yarn storage container in the rack, an identification of the yarn loaded, and

[0074] - the length of yarn loaded; the robot comprising an input means for inputting the loading data into a memory 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 yam storage container while executing the loading sequence.

[0075] The robot may also comprise mechanical means to position a device for loading yarn into each yarn storage container in a yarn storage system. The mechanical means may be an assortment of arms that may be activated to move vertically and horizontally. The precise movement of the arms may be controlled by the controller to position a yarn loading device, such as an injector that may use a propulsion fluid to inject and propel an end of yam into a yam storage container. The robot may also be configured to control a pump or valve to flow a propulsion fluid that may be used to propel yam. Similarly, the robot may be connected to a mechanism that measures the length of the yarn that is propelled into each yarn storage container.

[0076] With these instructions, the robot proceeds to load each container with the correct yarn. It first ensures it selects the yam end needed to load the next tubular container, brings its injection instrument in front of the opening at the axial extremity of the selected container, and loads the yarn while measuring the length of yarn, either directly or indirectly.

[0077] According to some embodiments, when N>1, the yarns of the N spools of yarn all may be mutually different yams. In these embodiments, the yams may be different in color or color tone, or may have a different linear weight or composition. Also, in some embodiments, the yams may be made of bulked continuous filaments (BCF), or of staple fibers.

[0078] In preferred embodiments, the yarns used are known as delicate tuft yarn, which are yams that may be more delicate than standard BCF yam.

[0079] In some embodiments, the defined lengths of yams may be in the range of 2,000 to 10,000 feet (609.6 to 3048.0 meters). In preferred embodiments, the loaded lengths of yarn may be in the range of 3,500 to 7,500 feet (1,066.8 to 2,286.0 meters) of yarn.

[0080] Those in possession of this disclosure and of ordinary skill in the art will understand that any type of yam may be loaded into and held in the yarn storage system. In one embodiment, yams with a titer in the range of 900 to 4,000 denier may be loaded and stored. In a preferred embodiment, yarns with a titer in the range of 1,100 to 3,600 denier may be loaded and stored. Yams with these titers are also suitable for unloading to a yarn consuming device without presenting undue tensions.

[0081] According to some embodiments, the yam storage system may comprise a vortex injector for loading any length of yam into any selected yam storage container in the yarn storage system. However, those of ordinary skill in the art and in possession of the teachings and disclosures disclosed herein will understand that any type of injector may be used. In some preferred embodiments, an injector may use the Venturi-effect to suck the yarn into the injector, where it is further propelled by the propulsion fluid, flowing into the Venturi tube.

[0082] In some cases, the propulsion fluid may be air or any other gas. In some embodiments, a vortex injector may have a capacity of 2 to 15 cubic feet per minute (CFM) (56.6 to 424.8 liters per minute) of the propulsion fluid. A more preferred embodiment may have a vortex injector with a capacity of 3 to 8 CFM (85.0 to 226.5 1 / m), or even 5 to 8 CFM (141.6 to 226.5 1 / m). In a preferred embodiment, a vortex injector with a capacity of 5 to 8 CFM (141.6 to 226.5 1 / m) may be advantageous when delicate tuft yam is used.

[0083] The method has the advantage that with a limited number of spools of yams, a wide variety of organized yarn storage may be provided. The yam storage being organized meaning that it is known for each yam storage container, which yam is contained and at what length. As such a plurality of yarns can be made ready for use providing one yarn end for each needle of a tufting machine or similar, while only a limited number of spools need to be at hand. The lengths of the yarns in the containers can be measured accurately and may be limited. As such a given “minor” length of a tufted greige carpet can be provided with little yam waste being created. The latter because the yam length in the containers may be calculated according to the yarn which will be consumed by the tufting machine to make the length of greige.

[0084] A person of skill in the art and in possession of this disclosure will understand that the number of spools of yarn need not be a limit to the number of needles in the tufting machine. Each kind of yarn or yam color needed may be loaded into a number of yarn storage containers in a yarn storage system. Then the yam in each yarn storage container may be directly linked to one tufting needle.

[0085] The possibility to move the yam storage system enables loading the yarn storage system at a dedicated location which may contain a robot. In this disclosure, a robot denotes the mechanisms that may be used to automate the loading of the yam storage containers in a yarn storage system. This may be a mixture of mechanical parts controlled by electronics where the electronic components may be configured to control the mechanical parts. The electronics may comprise a means for inputting configuration information, a memory for storing information, and a controller. The controller may control the mechanical parts to position an apparatus that may be used to load yarn into the yarn storage containers.

[0086] A loaded yam storage systems may move to the position where the textile machine will take out the yarn, while an empty yarn storage system may move to the reloading station. In some situations, this may require only limited storage place being needed as compared with yarn creels carrying the same number of spools as are now in the yam storage containers.

[0087] In some embodiments, the lengths of each of the yarns needed may be known or calculated from the design of the textile to be produced. This may be done by software capable of converting a design into a set of yarns with defined properties such as, but not limited to, length, color, quality, titer, etc. From this, the robot may be configured to load each yarn of defined properties into separate yam storage containers. In a preferred embodiment, the length of yam to be inserted may be slightly longer than the actual length needed to produce the textile product. For example, the actual length to be inserted may be between 100% and 110% of the needed length. The surplus length allows for start-up and running out of the design, as well as for threading the textile machine producing the desired textile.

[0088] According to a further, sixth aspect of the invention, a yam storage container is provided, similar to the yarn storage container of the first aspect and / or second aspect of the invention, where the wall or walls of the yam storage container are airtight, such that they do not have openings along their axial length. In some embodiments, yam storage containers may have a limited axial length. In preferred embodiments, the axial length may be less than or equal to 1.5 meters. In other embodiments, the axial length may 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). According to this sixth aspect, a yarn storage container for storing a yam is provided, said storage container comprising a yarn storage container having an axial length, a tubular wall and a first and second axial extremity, the first axial extremity of said tubular container having an opening for receiving an end of a yam, said second axial extremity of said tubular container being air-permeably closed, said tubular wall is air impermeable.

[0089] All features of the yarn storage containers according to the first and / or second aspect of the invention, which features are not related to the air permeability of the wall of the yam storage container may be applied for the yam storage containers of this sixth aspect.

[0090] According to a seventh aspect, a plurality of yarn storage containers in accordance with the sixth aspect and / or the preferred embodiments thereof, can be used to provide a yam storage system according to this seventh aspect of the invention. All features of the yarn storage system according to the third aspect of the invention, which features are not related to the air permeability of the tubular wall, can be applied for the yarn storage containers of this seventh aspect.

[0091] According to an independent eighth aspect, a yarn storage system is provided, wherein said yarn storage system comprises at least a first and a second yam storage container, said first and second storage containers being elongated, preferably tubular, and having an axial length and an elongated perimetral wall extending between a first and second axial extremity, the first axial extremity of said container having an opening for receiving an end of a yarn, with as a characteristic that said yarn storage system further is provided with at least one of the following features, or with a combination of two or more of the following features:

[0092] - the feature that said first and second containers are positioned, or positionable, in said storage system with their axial length directed in a horizontal plane. With this feature it is obtained that several yarn storage systems can be placed on top of each other while the yams are accessible at the first axial extremity; - the feature that said first and second containers are positioned, or are positionable, in said storage system with their axial length directed slopingly with respect to said horizontal plane, said slope being at an angle of 15° or less with said horizonal plane. With this feature it can be obtained that the yarn is slightly more or slightly less kept in position in the respective container. The former may be preferred while loading the respective containers or when moving the yarn storage container, and the latter may be preferred while discharging or drawing the yam form the respective containers for example when feeding a textile machine;

[0093] - the feature that said first and second containers are positioned, or are positionable, in said yarn storage system with their axial length directed slopingly with respect to said horizontal plane, with said first axial extremity being directed downwardly. With this feature the discharging or drawing of the yarn out of the respective container from the first axial extremity is enhanced. This positioning may be useful when feeding a textile machine with the respective yam;

[0094] - the feature that said yam storage system comprises a plurality of containers, including said first and second containers, wherein said plurality of containers is positioned in a matrix, wherein said matrix is preferably substantially uniform. With a uniform matrix it is meant that the axes of the respective containers are positioned equidistantly from each other in a horizontal and / or vertical direction;

[0095] - the feature that said yam storage system comprises a plurality of containers, including said 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 part of the outer wall of said first and second container is free from contact with any of said plurality of adjacent containers; Preferably, the matrix or stack of containers comprised in said yarn storage system comprises voids defined by the outer wall portions of a plurality of containers as described above in connection to the third aspect of the invention;

[0096] - the feature that at least one of said first and second containers, is provided with a yarn detector and / or the feature that said yarn storage system comprises means for detecting the yarn and / or yam end of at least one of said first and second containers. The signal from such yarn detector may be used to directly or indirectly control a textile machine that draws yam from said yam storage system;

[0097] - the feature that at least one of said first and second containers, is provided with means for creating a laminar air stream, preferably from the first axial extremity to the second axial extremity. Such laminar air stream may be advantageous for a good loading and / or discharging of the first and / or second container;

[0098] - the feature that at least one of said first and second containers show the features of the first and / or second aspect of the invention and / or the preferred embodiments thereof;

[0099] - the feature that said yarn storage system is directly linked to a tufting or weaving machine, for example in that yarns from at least one of said first and second container are positioned to be tufted or woven in said machine. Preferably, the yam storage system comprises at least as many yarn storage containers as the number of yarns necessary for feeding the respective machine. Preferably, the yam storage system comprises between 16 and 1024 yarn storage containers;

[0100] - the feature that said yarn storage system comprises a yarn end holding means comprising a number of apertures or slots, said number of apertures or slots being preferably identical or more than the number of containers of the yarn storage system, each aperture or slot preferably being fit to receive one yarn end from one of the containers. This feature minimizes the risk of the yams becoming entangled and / or may enable a fluent feeding of a textile machine;

[0101] - the feature that at least one of said first and second container comprises a lid substantially closing said first axial extremity, said lid being provided with a shaft for providing said opening for receiving an end of the yarn. The provision of a lid at the first axial extremity may provide for a guiding of the yarn end upon discharging the yam from the respective container for example when feeding a textile machine, while restricting the movement of the bulk of the yam inside the container;

[0102] - the feature that at least one of said first and second container comprises an electrical conductive layer or strips on the inner wall thereof. As explained in connection to the first and second aspect, such layer or strips may minimize the risk of bridging of the yam somewhere midway the container. As such, the axial length of the containers may be made longer for enlarging the loading capacity without significant difficulties upon loading or discharging;

[0103] - the feature that at least one of said first and second container is electrically grounded. This feature avoids any disturbing effects from build-up of electrical charges to the safe and trustworthy operation of said yam storage system;

[0104] - the feature that at least one of said first and second container is configured for tensionless storage of yarn. The yam is available in the internal void of said first and / or second container in an unwound condition, or, in other words, the yarn freely lays in the internal void of said first and / or second container. In this way tension plucks while discharging the yam from the first and / or second container can be largely avoided;

[0105] - the feature that said first and / or second container are dimensioned to have an internal void with a ratio axial length over diameter that is at least ten, or 25 and larger. In the cases where the container is not tubular and cylindrical, the diameter is that of the largest circle that can be fit in the internal void. These slender containers allow for a compact yarn storage system. Preferably, such slender containers are provided with a means to dissipate static electricity from the inner walls, such as a means comprising an electrically conductive coating or strips on the inner wall, to avoid undesired build up or bridging of the yarn somewhere midway the first and second axial extremity;

[0106] - the feature that said yarn storage container is provided with a data storage for storing data concerning the yams contained in said first and / or second yarn storage containers and / or possible further containers. Such data may comprise one or more of color indications, length, type of individual yams, their location in the yarn storage container, the design for which they had been provided in the yarn storage container, production planning data;

[0107] - the feature that said yam storage container is provided with a scannable data tag, e.g. a barcode or QR code, for example linking to an address where any data about the yams contained in the plurality of yarn storage containers can be obtained, e.g. using a computer network or the world wide web. Such data may comprise one or more of color indications, length, type of individual yarns, their location in the yarn storage container, the design for which they had been provided in the yarn storage container, production planning data.

[0108] Those in possession of this disclosure and of ordinary skill in the art will understand that, although the above features have been described in connection to a first and second yarn storage container within the yarn storage system, that the yarn storage system may contain a plurality of containers, such as between 10 and 10,000, preferably from 16 to 1,024 containers, and more preferably from 200 to 300 yarn storage containers. Preferably, at least a majority of the number of yam storage containers, and even better all yam storage containers in a yarn storage system are similar in that they have at least one of the above-mentioned features in common. Preferably they have two or more of the above-mentioned features in common. According to a ninth aspect of the invention, a yam storage system according to the seventh and / or eighth aspect is used to supply textile machinery with yarn. It may be understood that this yarn storage system may be used to provide yarns to any textile producing equipment, such as, but not limited to: tufting looms, warp knitting machines, as warp yam for weaving looms, such as carpet weaving looms, and similar.

[0109] According to an independent tenth aspect, the present invention also is a textile production assembly, wherein said textile production assembly at least contains a first yarn storage system and a textile producing machine, wherein said textile producing machine produces textile on the basis of continuous yarn and / or is chosen from the list consisting of a tufting machine, a weaving machine, and a knitting machine, with as a characteristic that said first yarn storage system comprises at least a first and a second yam storage container for storing continuous yarns, said first and second storage containers being elongated, preferably tubular, and having an axial length and an elongated perimetral wall extending between a first and second axial extremity, the first axial extremity of said container having an opening for receiving an end of a yam, wherein said first yam storage system further comprises means for communicating with said textile producing machine, in particular for communicating the lack of a yarn from said first and / or said second container. The ability of the yam storage system to communicate with the textile producing machine gives way for new advantageous control possibilities of the textile production assembly and prevention of erroneous production.

[0110] For example, the yarn storage container may comprise a data storage comprising any data about the yams that are contained in the plurality of yam storage containers. Such data may comprise one or more of color indications, length, type of individual yams, their location in the yam storage container, the design for which they had been provided in the yam storage container, the production planning data. According to a variant the yarn storage container may comprise a data storage containing an address where any data about the yams contained in the plurality of 1 yarn storage containers can be obtained, such as by using a computer network or the world wide web.

[0111] Preferably, said first yam storage system comprises the features of any of the third, seventh, or eighth aspect of the invention, and / or the preferred embodiments thereof.

[0112] Preferably, said first yarn storage system is provided with at least the following features in combination:

[0113] - the feature that at least one of said first and second containers, is provided with a yarn detector and / or the feature that said first yarn storage system comprises means for detecting the yarn of at least one of said first and second containers;

[0114] - the feature that said yarn detector creates a signal to be directly or indirectly communicated to said textile machine through said means for communication.

[0115] Any information about the status of the yam may be provided by the yarn detector to said textile machine through said means for communicating. Such information may contain data about the tension in the yam, the availability and / or lack of a yarn, the remaining and / or consumed length of the yam.

[0116] Preferably, said means for communicating are chosen from the list of electric and electronic means, wherein said means for communicating preferably comprise a wireless link between said first storage system and said textile machine. It is of course not excluded that the communication would be executed by means of magnetic, pneumatic or hydraulic means, or by means of optical signals.

[0117] Preferably, said textile machine is configured to pause the operation, or to proceed with yarn from an alternative container in said first yarn storage system, or from a different yarn storage system, when it receives a signal through said means for communication, for example the signal that the respective yarn is lacking.

[0118] Preferably, said textile machine assembly further comprises means for connecting one or more of the yarns of said first yarn storage system to one or more yarns of a second, preferably similar, yam storage system. Due to the presence of such means, rethreading of the textile machine, which is entirely time consuming, can be avoided. Preferably, said means for connecting comprise a support for positioning one or more yarns of said first yam storage system and one or more yarns of said second yarn storage system, wherein said mean for connecting further comprises equipment for connecting said one or more yarns of said first yam storage system with said one or more yarns of said second yarn storage system, preferably while being positioned on said support; said support preferably comprising a set of spacing individual yams from said first yam storage system and / or second yarn storage system respectively. The equipment for connecting the yarns may be by thermal and / or chemical bonding.

[0119] According to a further eleventh aspect of the invention, a method to store yarns in provided.

[0120] The method to store yam according to this eleventh aspect comprises the steps of

[0121] Providing a yarn storage system according to the seventh aspect of the invention;

[0122] Providing N spools of yam, N being an integer equal or more than 1;

[0123] Repeating selecting one or at least one, e.g. tubular, container to at least partially be loaded with yam of said spool; defining for said selected container the length of yam to be inserted; selecting one of the N yarns;

[0124] - injecting said defined length of said selected yarn from said spool by means of a propulsion fluid, such as pressured air, in the selected container; for a plurality of containers, optionally until all containers are at least partially loaded with yarn. All features of the method according to the fifth aspect of the invention, which features are not related to the air permeability of the wall of the yarn storage container, can be applied to these methods of this eleventh aspect.

[0125] It is clear that the above first till eleventh aspect are particularly advantageous when used for producing textile of small lot sizes. That is to say that aspects one to eleven may be effective in producing a few articles of one design, a first lot, then a few articles of a different design, a second lot.

[0126] With the aim of providing further alternative methods that are suitable for small lot size production, the present invention in accordance with its twelfth independent aspect is a method for producing textiles with a plurality of designs, wherein each design is created from a set of, preferably continuous, yams, with as a characteristic that the method comprises

[0127] - providing a first set of yams for a first of said plurality of designs; wherein one or more of said first set of yarns is provided in a first yarn storage system, wherein said first yam storage system comprises a first plurality of containers;

[0128] - providing a second set of yams for a second of said plurality of designs; wherein one or more of said second set of yams is provided in a second yam storage system, wherein said second yam storage system comprises a second plurality of containers;

[0129] - producing said first design at least by drawing yam from one or more of said first plurality of containers;

[0130] - connecting one or more of the yarns of said first plurality of containers to yarns of said second plurality of containers;

[0131] - producing said second design at least by drawing yarn from one or more of said second plurality of containers.

[0132] Preferably said containers are yarn storage containers having the features of the first and / or second and / or sixth aspect and / or the preferred embodiments thereof and / or said yam storage systems have the features of the third and / or seventh and / or eighth aspect and / or the preferred embodiments thereof. The method of the twelfth aspect may be performed using a textile production assembly having the features of the tenth aspect and / or the preferred embodiments thereof.

[0133] By connecting the yarns, preferably all yams, of said first set to the yarns, preferably all yams, of said second set, a fluent changeover from the first to the second of said plurality of designs can be attained. A fluent changeover may lead to a minimized waste production in between the designs.

[0134] Preferably, each yarn storage container from which yam is drawn for said first, respectively second design, comprises at most one continuous length of a yarn, wherein said continuous length preferably corresponds to the length of said yarn needed in the first or second design respectively, with a margin, such as a surplus amount of yarn, of preferably less than 10% of the amount of yam needed to produce the griege product.

[0135] Preferably, said containers are tubular.

[0136] Preferably, said connecting comprises bonding one or more, preferably all, of the yarns of the first set to one or more, preferably all, yams of the second set. Preferably the yams are connected one to one. In a non-limiting exemplary embodiment, the yams from a first yarn storage system may be exhausted so the yarns from that first yarn storage system may be terminated and removed from the yarn consuming machine. A second yarn storage system may be positioned to feed the yarn consuming machine and each yarn that had been terminated from the first yam storage system may be bonded to a yarn from the second yarn storage system. In a preferred embodiment, if the design of the griege product is the same then the replacing yarn from each yarn storage container of the second yam storage system will have the same properties as the terminated yarn from each yam storage container of the first yarn storage system.

[0137] Preferably, said connecting comprises positioning one or more of the yarns of said first plurality of containers and one or more of the yams of said second plurality of containers on a support, and connecting said yarns while being on the support. Preferably, said support comprises a set of teeth for spacing individual yarns apart from each other.

[0138] Preferably, all of the yams of said first set and said second set are drawn from respective containers, wherein said first set comprises at least all the yam needed for the first design and said second set comprises at least all the yam needed for said second design. Preferably, said first set and said second set comprises between 100% and 110% of the yarn needed for the respective design, wherein a surplus length of the yarn may be used in a change-over zone from the first to the second of said plurality of designs and / or for threading the respective textile machine.

[0139] Preferably, said method further comprises the step of cutting the textile in at least two pieces, each comprising at least one of the first and second designs.

[0140] Preferably, said method further comprises the step of cutting the textile in at least three pieces being two pieces each comprising at least one of the first and second designs, and a third piece positioned in between a first and a second design, wherein said third piece may be considered a change-over zone or waste.

[0141] Preferably, said first set of yams is different from said second set of yams at least in that the number of containers being loaded with yam of a particular color, thickness, and / or material in said first plurality of containers is different from the number of containers being loading with yam of the same particular color, thickness and / or material respectively in said second plurality of containers. Other differences between the properties of the first and second sets of yams may include a difference in entanglement and / or twist and / or shape of the filaments contained in the yarns.

[0142] It may be understood that in accordance with a particular independent aspect, the present invention also relates to a semi-product obtained or obtainable with the method of the twelfth aspect and / or the preferred embodiments thereof, wherein said semi-product is, for example, a textile comprising the first design, the second design and a zone in between a first and second design, wherein said zone contains both yarns from said first and from said second set. It may be noted that the first and second of the plurality of designs may in themselves contain repetitions of an individual design, such as a floral design. The invention in accordance with the above twelfth aspect in particular concerns the change-over between a first and second design that are different in pattern, color, quality, and / or relief. In other words, it concerns a change-over in the design that requires a different set of yarns.

[0143] With the aim of providing a yam production method which is particularly suitable to be applied with one or more of the other aspects of the invention, the present invention, in accordance with a thirteenth independent aspect, is a method of producing yarn preferably for feeding a tufting machine, comprising

[0144] - spinning a plurality of filaments;

[0145] - converting said plurality of filaments to a yam;

[0146] - directly providing said yam in a container; said containers preferably being yarn storage containers according to the first and / or second aspect and / or the preferred embodiments thereof and / or being comprised in a yarn storage systems showing the features of the third, seventh and / or eighth aspect and / or the preferred embodiments thereof;

[0147] - optionally feeding a tufting machine by drawing said yarn from said container.

[0148] With directly providing said yarn in a container, it is meant that the method of the thirteenth aspect is free from winding operation in between the spinning and the provision of the yarn in said container. Such method avoids an unnecessary winding operation and possible build-up of residual stresses in the yarn.

[0149] Preferably, said converting comprises entangling and / or twisting. Said converting may comprise entangling the plurality of filaments via air jets to produce the said yarn, wherein said yarn is preferably suitable for tufting. Said converting may comprise twisting the plurality of filaments to produce the said yarn, wherein said yarn is preferably suitable for tufting and / or wherein said twisting the plurality of filaments comprises applying a S-twist or a Z-twist. Preferably, said twisting the plurality of filaments comprises adjusting an amount of twist to produce yams of different texture.

[0150] Preferably, said directly providing said yarn in a container comprises loading said yam storage container with an amount of yam corresponding to the amount of yam needed for a textile design to be produced on a portion of a textile machine, with a margin, such as a surplus length, of less than 10%.

[0151] Preferably, said directly providing said yarn in a container comprises loading said container with an amount of yam, cutting the yam, loading a subsequent container with a different or equal amount of yarn.

[0152] Preferably, said method further comprises drawing out yarn from said container for feeding a textile machine.

[0153] It is noted that said plurality of filaments may comprise filaments of different properties, such as different colors and / or filaments of different titers.

[0154] Preferably, the method of said thirteenth aspect does comprise said step of feeding a yam consuming machines, such as a tufting machine, wherein preferably a griege product or a tufted carpet is produced.

[0155] With the same aim as in the thirteenth aspect, the present invention, in accordance with a fourteenth independent aspect, is a method of producing a tufted textile, comprising: spinning a plurality of filaments; converting said plurality of filaments to a plurality of yarns;

[0156] - injecting at least one yam of the plurality of yams into at least one container; said containers preferably being yarn storage containers according to the first and / or second aspect and / or the preferred embodiments thereof and / or being comprised in a yarn storage systems showing the features of the third, seventh and / or eighth aspect and / or the preferred embodiments thereof; said injecting is preferably executed directly, i.e. without intermediate winding operations of the yarn between the spinning and the injecting; and drawing the at least one yam from the at least one container to a tufting machine to produce a tufted textile. Preferably, the tufted textile comprises a tufted carpet.

[0157] Said converting said plurality of filaments to a plurality of yarns may comprise entangling and / or twisting the plurality of filaments to produce the plurality of yams.

[0158] Said injecting at least one yarn of the plurality of yams may comprise injecting multiple yarns into multiple containers.

[0159] Said injecting at least one yarn into at least one container may comprise blowing a first yarn into a first extremity of a first container.

[0160] Said drawing at least one yarn from the at least one container to a tufting machine may comprise drawing the first yarn from the first extremity of the first container into a tufting machine to produce tufted textile. According to a variant, said drawing at least one yarn from the at least one yam storage container to a tufting machine may comprise drawing the first yarn from a second extremity of the first yam storage container into a tufting machine to produce tufted textile.

[0161] Preferably said at least one yam storage container is a tubular container.

[0162] With the aim of providing a system ideally suitable for providing a yam storage system as in the previous aspects, loading with yarn, the present invention in accordance with a fourteenth independent aspect, is a creeling system, comprising: a plurality of yarn storage systems each comprising a plurality of yam storage containers or being configured to receive one or more yarn storage containers; said containers preferably being yam storage containers according to the first and / or second aspect and / or the preferred embodiments thereof and / or being comprised in a yam storage systems showing the features of the third, seventh and / or eighth aspect and / or the preferred embodiments thereof; at least one set of a plurality of injectors for injecting defined lengths of yarn into the plurality of yarn storage containers; and a controller comprising a memory and configured to direct the at least one set of plurality of injectors to inject the defined length of yarn into the plurality of yarn storage containers.

[0163] Preferably, said memory comprises information for at least a plurality of yam storage containers, preferably each yam storage container, in each of said plurality of yam storage systems. Preferably, for each yam storage container of 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 the yarn storage container, and the length of the yarn to be injected in the yam storage container. Preferably said information is at least partially transferred to a data storage comprises in the respective yam storage system and / or to an address accessible over a computer network or the world wide web. In the latter case, said address is preferably provided to the respective yarn storage system by uploading it to its data storage and / or by providing a scannable tag to said yam storage system.

[0164] It is clear that any data uploaded from the memory of said creeling system to said yarn storage system may be communicated to a textile machine, for example when the yam storage systems forms part of a textile production assembly having the features of the tenth aspect and / or the preferred embodiments thereof.

[0165] Preferably, the plurality of injectors inject the defined lengths of yam into the plurality of yarn storage containers in the plurality of storage systems simultaneously.

[0166] Preferably, the creeling system is configured to receive a plurality of yam storage systems, for example at least two or at least four. The creeling system preferably comprises at least one set of a plurality of injectors for each of the yarn storage systems that it can receive. Preferably each injector of said set injects a single type of yarn, such as a yarn having the same properties, into the containers of a particular yarn storage system. Preferably, each injector is able to inject yarn in a plurality of columns of the stack of containers, for example because the sets of injectors are configured to move horizontally, preferably at least over a distance equal to twice, and preferably at least four times, the horizontal distance DI between the yarn storage containers. Each injector may also be configured to inject yam in a plurality of rows of the stack of containers, as the injectors may be configured to move vertically, preferably at least over a distance equal to four times the vertical distance D2 between the yarn storage containers. Preferably, the injectors are configured to move at least such a distance that they can inject yam in all containers of a particular row.

[0167] The independent and dependent claims set out particular and preferred features of the invention. Features from the dependent claims may be combined with features of the independent or other dependent claims, and / or with features set out in the description above and / or hereinafter as appropriate.

[0168] BRIEF DESCRIPTION OF THE DRAWINGS

[0169] The above and other characteristics, features and advantages of the present invention 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 invention. This description is given for the sake of example only, without limiting the scope of the invention. The reference Figures quoted below refer to the attached drawings, wherein:

[0170] Figures 1A to ID are schematic views of tubular containers from a yarn storage system according to the invention;

[0171] Figures 2A to 2C are schematic views of tubular containers from a yarn storage system according to the invention;

[0172] Figures 3 and 4 are schematic views of yam storage systems according to the invention;

[0173] Figure 5 schematically represents a method to store yam in a yam storage system according to the invention;

[0174] Figure 6 represents a textile production assembly in accordance with the tenth aspect of the invention; Figure 7 provides a front view on the yarn storage system of Figure 6 in accordance with arrow F7 of Figure 6;

[0175] Figure 8 in a similar view represents a variant;

[0176] Figure 9 provides a perspective view on the support of Figure 6 in accordance with arrow F9;

[0177] Figure 10 on a larger scale shows a cross-section according to the line X-X shown in Figure 9;

[0178] Figures 11 to 13 represent variants for the yarn storage system of Figure 6 in a view on the area indicated with F 10 in Figure 6;

[0179] Figure 14 represent a view in accordance with the arrow F14 of Figure 13;

[0180] Figure 15 represents a method for producing yam in accordance with the thirteenth aspect of the invention; and

[0181] Figure 16 represents a creeling system in accordance with the fourteenth aspect of the invention;

[0182] Figures 17A and 17B represent a cap with a yarn retainer according to the invention.

[0183] The same reference signs refer to the same, similar or analogous elements in the different Figures.

[0184] DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0185] The present invention will be described with respect to particular embodiments.

[0186] According to a first independent aspect of the invention, a yarn storage system is provided.

[0187] A yarn storage system for storing yams will be described hereinafter by making use of the Figures. In Figure 1 A, an example of a yarn storage container 101 is shown. In the example the container 101 is tubular and cylindrical.

[0188] More in particular, an axial cross-section of such yam storage container is provided. The exemplary tubular container 101 may have an axial length L of 96 inches (243.84 centimeters) in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is configured to hold a yam 200 having a length of at least double the axial length of the tubular container. The first axial extremity 113 has an opening 123 for receiving an end of a yarn. The second axial extremity 115 of the tubular container may be terminated. In this exemplary embodiment, the second axial extremity 115 may be terminated with an endcap 125 secured along the circumference of the second axial extremity 115. In one embodiment, the endcap 125 may be perforated with holes 129 to allow a propulsion fluid to exit the tubular container 101 through the endcap 125. In a preferred embodiment, the endcap 125 may be made of the same mesh as the tubular wall 502 of the yam storage container 101.

[0189] The tubular container 101 may have a circular cross-section and an inner diameter D of 2.78 inches (7.06 cm).

[0190] In some embodiments, the ratio of the axial length L to the inner diameter D may be larger than 10, and in this case even larger than 25.

[0191] The tubular wall 501 may be comprised of a mesh. In a preferred embodiment, the mesh will be a continuous mesh with no seams. In another embodiment, a seam in a mesh cylinder may be smoothed over to remove projections.

[0192] The openings of the mesh wall 501 may be comprised of a total sum of open area along the wall of the yarn storage container 101, referred to as “open area”. The average open area per surface unit of the mesh portion of the cavity may be in the range of about 70% to about 95%. In some more preferred embodiments, the range may be between about 90% and about 93%. In a more preferred embodiment, the open space may be at or about 91%.

[0193] In one embodiment, the strands may have a nominal diameter of 0.008 inches (0.2032 millimeters) with 16 strands in one direction and 16 strands at right angles to the first set per square inch (6.4516 square centimeters). Similarly, strands of 0.004 inches (0.1016 mm) would have approximately 88% open space in a 16 by 16 strand mesh. Similarly, strands of 0.003 inches (0.0762 mm) would have approximately 91.5% open space, and strands of 0.002 inches (0.0508 mm) would have approximately 96.8% open space in a 16 by 16 strand mesh. In more preferred embodiments, the strands may be 0.006 inches (0.1524 mm), which, in a 16.5 by 16.5 mesh in a one square inch (6.4516 square centimeters) area would have approximately 91% open area.

[0194] In other embodiments, the mesh may be 16 by 18 strands or 20 by 20 strands using any of the diameters disclosed herein.

[0195] Yarn storage container 102 is an alternative embodiment and is shown in Figure IB. The tubular container 102 again may have an axial length L of 96 inches (243.84 centimeters) in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is configured to contain a yam 200 having a length of at least double the axial length of the tubular container. The first axial extremity 113 has a cap 127 provided with an electrically conductive grommet 128 which is configured with an opening 123 for receiving an end of a yarn. The second axial extremity 115 of the tubular container is closed with an endcap 126 being secured to the container 102 along the circumference of the second axial extremity 115.

[0196] The grommet 128 may be made of copper or any other electrically conductive material. In a preferred embodiment, the grommet 128 may have an opening diameter of 0.75 inches (1.91 cm). Both the cap 127 and the endcap 126 may be made of a plastic, a metal, a ceramic, or any other material known to those skilled in the art. The endcap 126 may be air permeable as it is provided with a plurality of openings 129. The grommet 128 may be electrically connected to a grounding system (not shown in the figure).

[0197] In this illustrated embodiment, the cap 127 and the endcap 126 may be bonded or fused to the mesh wall 502 to maintain a desired cross-sectional shape. In this, the structure of the cap 127 and the endcap 126 may provide support to the mesh wall 502 to keep it in a desired form at the first and second axial extremities 113, 115. In some embodiments, another structure, or structures, may be used to maintain a cross-sectional shape along the length L of the yarn storage container 102. Bonding or fusing the mesh wall 502 to the cap 127 and / or endcap 126 may be done with mechanical means or through chemical means. Yarn storage container 103 is an alternative embodiment and is shown in Figure 1C. The tubular container 103 again may have an axial length L of 96 inches (243.84 centimeters) in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. Each tubular container is configured for holding one yam 200 having a length at least double of the axial length of the tubular container. The first axial extremity 113 has a cap 130 provided with an electrically conductive tube 131 which on its term defines the opening 123 for receiving an end of the yam. The cap 130 may have a plurality of small openings 136 along the contact zone where the cap 130 contacts the first axial extremity 113. The second axial extremity 115 of the tubular container 103 may be terminated with an endcap 137, which may be slid on the mesh wall 503 along the circumference of the second axial extremity 115. Alternatively, the cap 130 may be configured with a slot within which the mesh of the first axial extremity 113 may be inserted. The endcap 137 and the mesh may be mechanically or chemically bonded to secure them together if desired.

[0198] In one embodiment, an extension 140 may be connected to the endcap 137 and connected to a vacuum system or other means that may create a lower air pressure in the tubular container 103. The openings 129 allow air to be drawn from the yam storage container 103. In a preferred embodiment, the air drawn through the yarn storage container 103 will have a laminar flow.

[0199] The cap 130 and the endcap 137 may be made of polymer. The endcap 137 may allow air to flow through a plurality of openings 129. The lid 130 may also have openings 136 to allow air to flow.

[0200] Still another alternative embodiment of a tubular yam storage container 104 may be illustrated in Figure ID. The tubular container 104 again may have an axial length L of 96 inches (243.84 centimeters) in the axial direction 111 and a first axial extremity 113 and a second axial extremity 115. The yam storage container 104 is configured for holding a yarn 200 having a length at least double of the axial length of the tubular container. The first axial extremity 113 may have a cap 135 and, optionally, an electrically conductive, brush 150 which may define a circular opening between the bristles 151. The diameter between the brush 150 sides may be 0.75 inches (1.91 cm). As such an opening 123 for receiving an end of yam may be defined by the bristles 151 such that the yarn end 200 may contact the bristles 151 during loading and unloading to discharge any electrical charge. The second axial extremity 115 of the tubular container 104 may be closed by means of an endcap 132 being secured to the container 104 along the circumference of the second axial extremity 115. In some embodiments, the endcap 132 may be perforated to allow the passage of fluids such as air.

[0201] In alternative embodiments, the tubular containers 101, 102, 103, 104 of Figures 1A to ID may have radial cross-sections of shapes other than circular. That is to say that they may be rectangular, square, oval, or of other shapes that may be envisioned by those skilled in the art.

[0202] Similar to the grommet 128 of the exemplary yarn storage container 102 of Figure IB, the entire yarn storage container 501, 502, 503, 504 and / or the circumference of the first axial extremity 113 may be electrically conductive and may be grounded.

[0203] Figures 2A to 2C illustrate several exemplary yam storage containers 601, 602, 603 with tubular walls, configured for being used as part of the yarn storage system.

[0204] Figure 2A illustrates an exemplary yam storage container 201 having external supports 604. The mesh 601 walls may be bonded to the external supports 604 that run the length of the yarn storage container 201 from the cap 240 to the endcap 251. The external supports 604 may be removably secured to the cap 240 and endcap 251 so that either may be removed from the yarn storage contain 201. The external supports 604 may be lightweight rods or slats that prevent the yarn storage container 201 from deforming. In this exemplary embodiment, preventing the yam storage container 201 from deforming may aid in filling the yam storage container 201 to a maximum capacity. Also, the external supports 604 may be configured to have little surface area in contact with the mesh 601 so that only a small amount of the open area of the yam storage container 201 is blocked.

[0205] Figure 2B illustrates a yarn storage container 202 with an opening 223 that has a diameter that is nearly as large as the diameter of the yam storage container 202. In this embodiment, the cap 242 and the endcap 252 connected to the mesh 602 to support its shape. In this illustrative embodiment, the cross-sectional shape of the yam storage container 202 is circular. In this exemplary illustration, the mesh of the exterior has been omitted for clarity but is illustrated on the inside of the yarn storage container 202.

[0206] Figure 2C illustrates a yarn storage container 203 with an opening 223 that is similar to that of the yam storage container 202. In this illustrative embodiment, the entire mesh 603 may be embodied by an outer sleeve 605 to maintain a shape. This illustrative embodiment of a yarn storage container 203 has a circular cross-section. The sleeve 605 may, or may not, be bonded or secured to the mesh 603. In one embodiment, securing the sleeve 605 to the mesh 603 would sister the components to enforce a rigidity of the entire yam storage container 203. Alternatively, leaving the sleeve 605 independent of the mesh 603 would allow each to move slidably to each other.

[0207] In an embodiment where the sleeve 605 is bonded or secured to the mesh 603, the sleeve 605 and the mesh 603 may be thermally melted together, chemically secured together such as with epoxy or similar, or mechanically secured together such as with clasps.

[0208] In some embodiments, the sleeve 605 may not need to be secured to the cap 243 or to the endcap 253. The cap 243 and the endcap 253 will provide support to the mesh 603 so that it will not deflect or distort for some length away from each of those. The sleeve 605 may be configured to be near enough to the cap 243 and the endcap 253 so that no substantial flexing or distortion takes place near the cap 243 and the endcap 253.

[0209] An embodiment of a cap 1700 with a yarn retainer is illustrated in Figures 17A / B. The cap 1700 has a front face 1710 with a single passageway 1712. The passageway 1712 is a coterminous opening for a yarn shaft 1720 and a retainer chute 1730. While it is illustrated in Figure 17A / B as a circular opening, other embodiments may be envisioned and practiced without departing from the spirit of the inventions taught and disclosed herein. In use, a cap 1700 may be fitted over the end of a yarn tube as such that the flange 1750 is within an end of a yam tube up to the lip 1740. A ball (not illustrated here) may be inserted into the retainer chute 1730 and allowed to roll down to meet the passageway 1712. The retainer chute 1730 may be tapered such that the ball may enter the retainer chute 1730 but will not fall out of the passageway 1712. Alternatively, the passageway 1712 may have a circumferential lip that is of a smaller diameter than the ball such that the ball will meet the circumferential lip. Those of skill in the art will be able to envision and put into practice other means for allowing the ball to form a seal at the passageway 1712 without departing from the spirit of the inventions claimed herein.

[0210] When a tube is to be loaded with yam, a yam that may be propelled with a jet of air or other fluid may be positioned in front of a yarn tube fitted with a cap 1700 wherein a ball has been placed in the retainer chute 1730. Due to gravity, the ball will naturally fall towards and form a seal around the passageway 1712. A jet of air may simultaneously propel the yarn into the tube and push the ball upwards along the retainer chute 1730 and out of the way of the yarn shaft 1720. The yarn, being propelled by the jet of air will continue into the yam tube along the yam shaft 1720 while the ball is held out of the way in the retainer chute 1730.

[0211] The end of the retainer chute 1730 may be fitted with a part that prevents the ball from being pushed beyond the end and into the yam storage container. Alternatively, the retainer chute 1730 may be formed such that it extends to meet the inner wall of a yarn storage container. In that embodiment, when the ball is pushed upwards by the jet of air, it will meet the inner wall of the yarn storage container and will thusly be retained within the retainer chute 1730.

[0212] When the tube has been loaded with a desired amount of yarn, the jet of air will stop, thereby allowing the yarn to rest and the ball to roll downwards towards the passageway 1712.

[0213] The ball will rest against the end of the yam and the passageway 1712 thereby providing some tension on the yam so that the yarn cannot be freely moved. When it is desired to withdraw the yarn from the tube, the yam will glide past the ball, which will offer some tension on the yam.

[0214] In an envisioned embodiment, the ball may be made of, or have a component within it, that reacts to a magnetic field. In that embodiment, a magnet may be positioned near the cap 1700 to draw the ball away from the passageway 1712 before yam is blown in. In that way, the jet of air will not need to force the ball upwards towards the back of the retainer chute 1730.

[0215] In one embodiment, the weight of the ball may be tailored to the yarn. That is to say that a low weight ball may be preferred when loading and unloading a tube with a low denier yam, while a heavier ball may be preferred when using a higher denier yarn. However, in another embodiment, a standardized ball may be used for all types of yarn. When a high denier yarn is being loaded and unloaded from a tube, the orientation of the cap 1700 may be such that the retainer chute 1730 is vertically above the opening of the passageway 1712. This is the orientation represented in Figures 17A / B. If a lighter weight yarn is to be used, the cap 1700 may be rotated such that the retainer chute 1730 is offset at an angle from the vertical. In this way, a portion of the mass of the ball will be directed to a side of the retainer chute 1730 and will not fall entirely upon the passageway 1712. That is to say that less force will be required to move the ball away from the passageway 1712 if the retainer chute 1730 is angled away from a vertical orientation.

[0216] While the embodiment of a cap 1700 as illustrated in Figures 17A / B is that of a solid material, it is not limited to that. The cap may have a yam retainer along with any other feature disclosed and taught herein. For example, and without limitation, a cap may be air permeable and / or have a grommet as is disclosed elsewhere herein.

[0217] As shown in Figure 3, a plurality of yam storage containers 1001 may be mounted in a rack 1002 to form a yarn storage system 1000. The rack 1002 is moveable as it is provided with a set of wheels 1004. All yarn storage containers 1001 are tubular and may be identical in that they may have the same length. Tubular yarn storage containers 1001 of which the axial cross-sections are shown in Figures 1A to ID may be used. Using the tubes as shown in Figures 1 A to ID, 36 tubular yam storage containers 1001 may be mounted with their respective first axial extremities 113 being aligned in the vertical plane 1120. The tubular yarn storage containers 1001 are mounted in a substantially horizontal position. They may be mounted matrix-wise with 6 rows of 6 storage containers per row. In an alternative embodiment, 10 rows of 24 storage containers may be mounted in a rack. Other geometries may also be configured.

[0218] Between adjacent containers, a distance of 0.25-inches (0.635-cm) may be configured. The tubes may be suspended by parallel plates provided with holes configured to support each yarn storage container 1001. To hold the yam storage containers 1001 in place, the tube-like yam storage containers 1001 may be mounted in and supported by more than one parallel plates, which are provided with openings, each opening to receive one yam storage container 1001. The openings in the plates may have a diameter substantially equal to or slightly greater than the outer diameter of the tubes. The distance center-to-center between two such openings is equal to the diameter of the tube plus 0.25-inch (0.635-cm). A first plate may support the tubes near their first axial extremities. A second plate may support the tubes near their second axial extremities. Additional plates may be positioned between the first and second plates if more support is desired.

[0219] Similar to Figures 3 and 4, Figure 7 illustrates that yarn storage containers 101 may be tubular and cylindrical, wherein the first axial extremity 113 comprises a cap 127 with an opening 123 that receives the end of the yam 200. Figure 8 shows a variant wherein the yarn storage containers 101 may be hexagonal and also comprise a cap 127 with an opening 123 that receives the end of the yarn 200.

[0220] The yam storage containers 101, as illustrated in Figures 7 and 8, are stacked in a matrix, wherein said matrix is substantially uniform. With a uniform matrix it is meant that the axes of the respective containers 101 are positioned equidistantly from each other in a horizontal direction H and / or in a vertical direction V. In this case, the matrix formed by the yam storage containers 101 of Figure 7 and 8 is uniform in both directions, wherein the distance DI between the containers 101 in horizontal direction H is equal to the distance D2 between the containers 101 in vertical direction V in the case of Figure 7, while the distance DI and D2 are different in the embodiment of Figure 8.

[0221] Figures 7 and 8 further illustrate that at least a part of the outer wall 2008 of the containers 101 is free from contact with any of a plurality of adjacent containers 101. The matrix or stack of containers 101 comprised in said yarn storage system 1000 comprises voids 2009 substantially defined by the outer wall portions of a plurality of containers 101.

[0222] Referring again to the illustrative embodiments of Figures 3 and 4, in front of the side 1100 providing the openings 123 of the yarn storage containers 1001, a means to hold an end of a yarn may be provided. In this exemplary illustration, a comblike beam 1005 may be provided, which comprises at least as many seats as there are tubular containers in the rack 1002. The yams 200 for each of the tubular containers are guided to one of the seats in the beam 1005. Such yam end holding means 1005 is also referred to as comb-spacer or detachable header. The yam end holding means may be detachably secured to the yarn storage system 1000.

[0223] An alternative embodiment of a yam storage system 2000 is shown in Figure 4. The same reference signs refer to the same or similar items. The first axial extremities 113 of the tubular yarn storage containers 1001 are now coplanar and aligned in a horizontal plane 1110. At the lower side of the rack, a vacuum box 1009 is provided, with which the air permeable second axial extremities are in fluidal connection. That is to say that when a partial vacuum is applied to the box 1009 by suction pump 1008, there will be air drawn from each of the second axial extremities, thereby creating a small air flow in the inner volume of the tubular containers 1001.

[0224] In Figures 3 and 4, each of the yarn ends from the yarns 200, extending from the beam 1005, may be coupled in a one-to-one association to a needle of a tufting machine (not shown). During tufting of the greige by the tufting machine, the yams may be taken substantially without tension or friction from the tubular yarn storage containers, and may be used as pile yam in the greige. A greige with a relatively short length (the length which can be made with the length of pile yams residing in the tubular yarn storage containers) of greige may be tufted. Once finished, a new yarn storage system may replace the emptied one. After the new yam storage system is coupled to the tufting machine and a new greige may be made. The advantage is that relatively short runs of greige may be made without an extensive creel maintained with frequent changeovers from one yam to another for grieges that have different patterns.

[0225] Since the yarn may be loaded and unloaded without friction or tension, then the length loaded into the yarn storage container will be the length that is unloaded. In some cases, the yarn that is used in a yarn consuming machine will be stretched as it is used. For example, a tufting machine may stretch a yam as it tufts it into a backing. A robot may be configured to take that amount of stretch of each yam into account when loading each yam into a yam storage system.

[0226] An exemplary system to execute a method to store yam may be schematically illustrated in Figure 5.

[0227] A yam storage system 5000 is provided. Examples of such system may be the ones shown and described in Figures 3 or 4. The tubular containers of this yarn storage system 5000 are named 50XY, where X is an integer varying from 1 to N, and Y an integer varying from 1 to M. In this, N is the number of rows in the rack and M is the number of columns in the rack. The X value may be numbered from top to bottom, or bottom to top. The Y value may be numbered from left to right, or right to left

[0228] A robot 5110 may comprise a memory unit 5111 that is capable of being configured to receive and store a loading data and associating that with other information for each yarn storage container. The other information may comprise data such as, but not limited to:

[0229] - the position of each yarn storage container (expressed as X and Y coordinates),

[0230] - the yam (in this case yarn A, B, or C) to be selected,

[0231] - the length of yarn to be injected, and optionally, details of the configuration of the yarn storage system, which may include if the yam storage system comprises a yarn end holding means, like a beam, and a position of the opening in the yam end holding means.

[0232] The memory unit 5111 may also be configured to maintain the loading status, or state, of the yarn storage system. That is to say that a yam storage system may be moved to a location that is accessible to the robot 5110 and the memory unit 5111 of the robot may be instructed that all of the yam storage containers are empty. The control unit may be configured to fill each yam storage container with different yarns each of a different length from a creel. As the robot 5110 is filling each yarn storage container, it may keep an ongoing ledger of progress. If there is a fault in the system, the memory unit may stop at some point until the fault is cleared, at which time it may resume loading the yarn storage containers in the yam storage system as it was configured to do. When all of the yarn storage containers are filled as per the instructions, the robot 5110 may alert an operator that the yam storage system is filled and relay that information to the operator.

[0233] The robot may comprise an input means 5112 for inputting the loading information, about the yarn into the memory unit. This input means may be a keyboard to manually put in the data, or a data reading device capable of reading the data from a data carrier (such as a floppy disk, a USB key, or any other similar data storage medium), or may even be a communication port for coupling the memory unit to a computer or to a network.

[0234] The robot 5110 may comprise a control unit 5113 that may be configured with a loading sequence of the yarn storage containers 50XY. It may do this by selecting and controlling the injection of each selected yam.

[0235] In the illustrative and exemplary embodiment of Figure 5, three yam spools each comprising a BCF yarn (A, B, and C) are stored in a rack 5100. In some embodiments only one or two yarns may be used. In other embodiments more than 3 yams may be used.

[0236] In this illustrative embodiment, the control unit may be configured to load yam A into yarn storage containers where N is 1 and M is from 1 to 3, where each yarn storage container is to be loaded with 600 meters of the yarn. The control unit may be configured to load yarn B into yam storage container where N is 2 and M is 1 with 1000 meters of yarn; and where N is 2 and M is 2 with 400 meters of yam. The control unit may be configured to load yam C into yam storage container where N is 3 and M is 1 with 800 meters of yarn.

[0237] Figure 5 may be used to illustrate an exemplary loading of yarn storage containers 50XY in an exemplary yarn storage system 5000. The 3D moveable arm 5124 of the hardware 5114, will pick up the end of the selected yam from the rack 5100. In the illustration, this is yarn C which comes from cone C. Various means may be used to bring an end of yarn C to the injector 5125. At the very least, this may be done manually with an operator entering information describing that an end of yarn C is ready for loading into the yarn storage system 5000 by entering that information into the input means 5112 of the robot 5110. Those of ordinary skill in the art will understand that other means may be used to automate this task. In a preferred embodiment, a robot 5110 may control multiple injectors where each injector has been loaded with a known yam. That is to say that a first injector may be attached to an end of yarn A from cone A; a second injector may be attached to an end of yarn B from cone B; and a third injector may be attached to an end of yarn C from cone C. The robot may move each of these injectors to selected yarn storage containers simultaneously to expedite loading. This may be illustrated in the exemplary embodiment of Figure 16.

[0238] When an end of a yam is ready to be loaded into the yarn storage containers 50XY, the injector 5125 will be positioned in front of the opening 123 of the selected yarn storage container 50XY and will propel a defined length of yam into the yam storage container via opening 123. The injector 5125 may comprise a vortex injector 5126 which may use compressed air from storage 5127 via valve 5128 as the propellant.

[0239] Once a configured length of yam has loaded, the yam will need to be separated from the cone. Referring back to Figures 3 and 4, the robot 5110 will direct the injector, which is still containing the yam, to a predetermined opening 1006 of the beam 1005. That is to say that the control unit 5113 will know that a determined length of yarn A has been loaded into yarn storage container 50XY with X=1 and Y=1 and has laid the still connected portion of yarn A into opening 1006 of the beam 1005, where opening 1006 is an identified opening of the beam 1005. The yarn may be cut such that it remains in the opening 1006 across the beam 1005.

[0240] After the yarn is cut, either the same yam is brought in front of the next selected yam storage container 50XY, or is brought back to the rack 5100, while the injector 5125 selects another yarn to be used to load the next yam storage container.

[0241] This sequence of actions is repeated until all necessary tubular containers are loaded as required. As such, numerous tubular containers may be loading with a given length of yarn, while only a limited number of yarns on a limited number of spools are available. That is to say that in this illustrative example of Figure 5, the twenty- five yam storage containers may be loaded with the three yarns A, B, and C. When the yam storage system 5000 is moved to a yam consuming device, yams A, B, and C will be available from twenty -five sources rather than just the three cones on the rack 5100.

[0242] It may be noted that the beam 1005, represented in Figures 3 and 4, may comprise means for connecting yams and means for detecting the presence or absence of a yarn in each opening 1006. Such means for connecting yams and / or yam detectors may also be provided separately from the beam 1005

[0243] Once loaded and all yarn ends cut, the yam storage system 5000 may be moved away from the robot 5110 and the rack 5100. The yam storage system 5000 may be parked until it is needed. The amounts and all other information of the yarns stored in each yam storage containers will be maintained in a data storage unit (not shown in Figure 5) that may be contained within the yam storage system 5000.

[0244] When it is needed, a yarn storage system may be moved to connect with a yam consuming device where the yams may be withdrawn from the yarn storage containers and used to make textile products.

[0245] Figure 6 represents a textile production assembly 2000. The textile production assembly 2000 comprises a yam storage system 1000 and a textile producing machine 2001. In this case, the textile production machine 2001 consumes yam and produces textile from yam 200. In this illustrative embodiment, the textile production machine 2001 may be a tufting machine wherein the yam 200 is used to form the pile 2002 of a tufted carpet. As illustrated, the tufting machine comprises needles 2003 that tuft the pile yam 200 into a backing material 2004. In this case, the backing material 2004 is provided from a roll 2005 and may be a woven or nonwoven textile, such as, but not limited to a glass fiber layer or a PET fiber layer. A greige 2006 leaves the tufting machine, in this case, with its face 2007 turned downward. That is to say that the pile is being tufted such that it is facing downwards with the backstitching facing upwards. The greige 2006 may be further finished into a carpet product for example by applying a second backing and / or by applying a latex or coPET containing material to secure the backstitching.

[0246] In the illustrative embodiment of Figure 6, the yarn storage system 1000 comprises several yarn storage containers 101 that each store an amount of continuous yam 200, such as a yarn 200 formed from bulked continuous filament. The yam 200 may be drawn from each of the first axial extremities 113 of the containers 101. In the illustrative embodiment, the containers 101 are positioned in the storage system 1000 with their axial direction disposed substantially horizontal.

[0247] The yarn storage system 1000 further comprises means 2010 for communicating with said textile producing machine 2001. As illustrated in Figure 6, the yarn storage system 1000 comprises a data storage 2011 and said means 2010 for transferring information from data storage 2011 to the textile producing machine 2001. Further, in this illustrative embodiment, the yam storage system 1000 comprises means 2012 for detecting the presence or absence of yarn from the containers, wherein the yarn detectors 2012 signal the presence or absence of yarn to the textile production machine 2001. Said means 2010 for communicating may be wired or wireless electronic connections between the yarn storage system 1000 and the textile production machine 2001. The illustrated textile production assembly 2000 in Figure 6 comprises a yam end holding means, in the form of a comb-like beam 1005 as was also illustrated in Figures 3 and 4.

[0248] Figure 9 illustrates an exemplary beam 1005 with a number of slots 2013. Each slot

[0249] 2013 is configured to receive one yarn end 200 from each of the containers 101. In this illustrative embodiment, the slots 2013 are all adjacent one next to the other in a row. To be able to accept one yarn end 200 from each of the yarn storage containers of the yarn storage system, there will be at least one slot 2013 for each yarn storage container in the yam storage system.

[0250] In a preferred embodiment, the beam 1005 may be made of metal, with a set of teeth

[0251] 2014 or protrusions for spacing individual yams 200 apart from each other.

[0252] As illustrated in Figure 9, the beam 1005 forms a support for positioning the yarns 200 of said yarn storage system. Different yarns 200 being fed from the yarn storage containers may be illustrated as a first yam 2015 and a second yam 2016. First yam

[0253] 2015 may be continuously fed to the yarn consuming device. This would be the case while the yarn consuming device is consuming yam 200 to make a textile product as illustrated in Figure 6. However, when a yam storage system 1000 is moved to interact with a yarn consuming device, the ends of the yarn 200 will not be connected to the yarns already being fed to the needles 2003. This is illustrated by second yarn 2016 where one end is the tag of a previous run of yarn and the other end is a fresh supply of the second yarn 2016. The two ends may be fused together to continue the operation of feeding yarn to the yam consuming device.

[0254] Second yarn 2016 is illustrated as two yam ends that may be positioned in a slot 2013. This is advantageous for connecting the said yam ends. In the represented example the two yarn ends are presented end-to-end. This is not necessarily always the case. In preferred embodiments, the two yarn ends may be presented alongside each other or on top of each other on the support and preferably in a common slot 2013. Figure 10 illustrates that a heating and / or pressing element 2017 may be put in contact with the yarn ends 2016 to be connected. The heating and / or pressing element 2017 together with the support form a means 2018 for connecting the two ends of second yam 2016. In a preferred embodiment the ends may be fused by the heat from heating and / or pressing element 2017.

[0255] In a preferred embodiment, a yarn storage system may be moved to interact with a yarn consuming device. The yarns of the yarn storage system may be arrayed on the beam as disclosed herein where each yarn end from each yam storage container occupies one slot in the beam. The ends of the yarns from the yam consuming device may be laid onto the beam such that each yam end associated with each needle will be associated with a yarn to be delivered from a designated yarn storage container in the yarn storage system. When these are laid together on the beam, a heating and / or pressing element may fuse each of the ends together so that there is continuity from the yarn end being consumed and the new yam ends being supplied. In a preferred embodiment, a plurality of heating and / or pressing elements may be simultaneously used to fuse all of the old and fresh yam ends together in one operation.

[0256] By using such a fusing operation and referring to Figure 6, a fluent change-over from one yam storage system 1000 to another may be attained, and the textile production machine 2001 may fluently change-over from a first design to a second design, wherein a first yarn storage system 1000 contains a supply yam 200 required for a first design, and the second yam storage system comprises s supply of yarn 200 required for a second design. In this way a method for producing textile in accordance with the twelfth aspect can be obtained.

[0257] Figure 6 illustrates that textile production assembly 2000 may alternatively, or in combination with the yarn end detectors 2012 positioned proximate the yarn storage system 1000, be provided with one or more yam detectors 2019 positioned further downstream, preferably downstream of said support or the beam. The yam detectors 2019 may also communicate through the communicating means 2010 with the textile production machine 2001. Figures 11 and 12 show a yam storage system 1000 where the containers 101 are positioned, or are positionable, in said storage system 1000 with their axial direction 111 directed slopingly with respect to said horizontal plane. In this exemplary embodiment, the slope being at an angle G of 15° or less with said horizonal plane. In this case the containers 101 are directed with their first axial extremity 113 being directed downwardly. In the embodiment of Figure 11 the containers 101 are slopingly mounted in the yam storage system 1000, while in the embodiment of Figure 12 the containers 101 are horizontally mounted in the yam storage system 1000. However, the yarn storage system 1000 may be tilted, for example by lifting the side 2020 of the yam storage system 1000 proximate the second axial extremity 115 of the containers 101, as indicated by means of the arrow 2021.

[0258] Figures 13 and 14 illustrate an alternative embodiment of the yam end holding means of Figure 9. In this alternative embodiment, a yam end holding plate 2023 may be provided that comprises a number of apertures 2022, with through bore holes, preferably organized in two or more rows. In this embodiment, the through bore holes are arranged in a matrix. Each aperture 2022 is provided with a ceramic tube 2024 to prevent the passing yam 200 from eroding the aperture 2022. Preferably, the yams 200 pass through the apertures 2022 in the yam end holding plate 2023 that corresponds to the matrix arrangement of the respective yam storage containers 101 in the yarn storage system 1001. Preferably therefore the apertures 2022 are provided at distances da-db in the horizontal direction H and / or vertical direction V equal to or corresponding to the distances DI and / or D2 defined by the matrix of the containers 101. In the case of a corresponding distance not being equal, the distance dl-d2 may be uniformly scaled down or up from the distances DI and / or D2, for example, the distances da-db may each be scaled down to half of the distance D1-D2 respectively.

[0259] Figure 15 illustrates a few steps in a method for producing yarn 200 suitable for feeding a tufting machine 2001. The method comprises the step SO 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. The method further comprises the step SI of spinning the polymer melt into a plurality of filaments 2026. In this case several spinning stations 2027 are fed by the same polymer melt. Each spinning stations

[0260] 2027 delivers the filaments 2026 for a yam 200. The method further comprises the step S2 of converting said plurality of filaments 2026 to yams 200. The conversion may comprise twisting and / or entangling of the filaments 2026. After the conversion the yarns 200 are directly injected into a yarn storage container 101, in this case comprised in a yarn storage system 1000. For the injection pressurized air can be used to propel the yams 200, for example using vortex injectors 2028. The wholly or partially loading yarn storage system 1000 can then be used for feeding a tufting machine 2001, for example as in Figure 6 by drawing yarn from the respective containers 101.

[0261] Figure 16 illustrates an exemplary embodiment of a creeling system 2029 in accordance with the inventions disclosed and taught herein. The creeling system 2029 is configured to receive a plurality of yarn storage systems 1000. In this exemplary embodiment, four yarn storage systems 1000 may be received simultaneously. The creeling system 2029 further comprises several sets of injectors 2028 for injecting yam 200 into the plurality of yam storage containers 101 comprised in each of the yarn storage systems 1000. Preferably each injector

[0262] 2028 injects a single type of yam 200 (the same color, type, quality and material) into the containers 101 of a particular yarn storage system 1000. As illustrated here, each injector 2028 may be able to inject yam 200 in a plurality of columns of the rack 1002 or stack of containers 101, as the sets of injectors 2028 are configured to move, in this case commonly, horizontally, preferably at least over a distance equal to twice, and preferably at least four times, the horizontal distance DI between the yarn storage containers 101. Each injector 2028 is, in this case, also able to inject yarn 200 in a plurality of rows of the stack of containers 101, as the injectors 2028 are configured to move, in this case individually, vertically, preferably at least over a distance equal to four times the vertical distance D2 between the yarn storage containers 101. In this case, the injectors are configured to move at least such a distance that they can inject yam in all containers of a particular row. The creeling system 2029 may further comprise a memory configured to or comprising the necessary data to direct the at least one set of injectors 2028 for injection of the required length of yam 200 in each of the yam storage containers.

[0263] It is to be understood that although preferred embodiments and / or materials have been discussed for providing embodiments according to the present invention, various modifications or changes may be made without departing from the scope and spirit of this invention.

Claims

Claims1.- A yam storage container for storing a yam (200), said storage container (101) comprising a tubular container, having an axial length (L), a tubular wall (501) comprising an air permeable mesh present along the axial length (L) of said tubular container (101), and a first and second axial extremity (113-115), characterized in that the first axial extremity (113) of said tubular container (101) having an opening (123) for receiving an end of a yarn (200), said second axial extremity (115) of said tubular container (101) being air-permeably open or closed.2.- The yarn storage container as in claim 1, wherein the air permeable mesh is comprised of strands.3.- The yarn storage container according to any one of the claims 1 to 2, wherein the strands are arranged in a pattern where at least a first plurality of strands are at right angles to a second plurality of strands.4.- The yam storage container according to any preceding claim, wherein the mesh comprises a single layer.5.- The yarn storage container according to any preceding claim, wherein the amount of 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 air permeable mesh is chosen from the group consisting of polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, metals, and fiberglass.7.- The yarn storage container according to any one of the preceding claims, wherein said first axial extremity (113) of said tubular container comprises a lid orcap (127) substantially closing said first axial extremity (113), said lid is provided with a hole for providing said opening (123) for receiving an end of the yam (200).8.- The yarn storage container according to claim 7, wherein said first axial extremity (113) of said tubular container (101) comprises a grommet (128) for receiving said end of yarn (200), said grommet (128) being mechanically coupled to the first axial extremity (113) of said tubular container (101).9.- The yam storage container according to claim 8, wherein said grommet (128) is electrically conductive.10.- The yarn storage container according to any one of the claims 7 to 9, wherein the lid comprises one or a plurality of small openings along a contact zone where said lid contacts said first axial extremity (113).11.- The yam storage container as in any one of the preceding claims, wherein said first axial extremity (113) of said tubular container (101) comprises a brush for contacting said end of said yam (200).12.- The yarn storage container according to any one of the preceding claims, wherein said container comprises means for providing a laminar air stream in an axial direction from the first axial extremity (113) to the second axial extremity (115) at least along the walls of the tubular container (101).13.- The yarn storage container according to any one of the preceding claims, wherein said container (101) comprises means to create a sub-atmospheric pressure in the tubular container via the second axial extremity (115).14.- The yarn storage container according to any one of the preceding claims, wherein the tubular container (101) has, in radial cross-section, a circular, oval, square or rectangular cross-section profile.15.- The yarn storage container according to any one of the preceding claims, wherein the area of a cross-section of the tubular container (101) is between 0.75 and 13 inch2(4.84- and 83.87-cm2).16.- The yarn storage container according to any one of the preceding claims, wherein the lid or cap (127) comprises a radial slot within which the mesh of the first axial extremity (115) is configured fit.17.- The yarn storage container according to any one of the preceding claims, wherein the mesh of the first axial extremity (115) is mechanically or chemically secured within the slot of the lid or cap (127).18.- A yarn storage container according to any one of the preceding claims, wherein the axial length (L) of the tubular container (101) is between 15 and 110 inches (38.1 and 279.4 cm).19.- A yarn storage container according to any one of the preceding claims, characterized in that said container (101) instead of being tubular and cylindrical, is elongated and has a cross-section different from circular, preferably chosen from the list consisting of hexagonal, rectangular, square, and triangular.20.- A yam storage container for storing a yarn, whether or not in accordance with any of the preceding claims, characterized in that said storage container (100) comprises a tubular and / or elongated container, having an axial length (L), a tubular, and / or elongated perimetral wall (501) and a first and second axial extremity (113-115), the first axial extremity of said container (101) having an opening (123) for receiving an end of a yam (200), said container (101) further comprising means for providing a laminar air stream in axial direction, preferably from the first axial extremity (113) to the second axial extremity (115), along the walls of the container (101).21.- A yarn storage container for storing a yarn, characterized in that said storage container (101) comprising a, e.g. tubular, container, having an axial length (L), a tubular wall and a first and second axial extremity (113-115), the first axial extremity of said tubular container (101) having an opening (123) for receiving an end of a yarn (200), said second axial extremity ( 115) of said tubular container (101) being air-permeably open or closed, said tubular wall (501) is an air permeable mesh.

22. -A yarn storage system comprising at least two yam storage containers (101) according to any one of the claims 1 to 21.23.- A yarn storage system according to claim 22, wherein all yam storage containers (101) have identical dimensions.24.- A yarn storage system according to any one of the claims 22 or 23, wherein said tubular containers (101) are organized in a rack (1002).25.- A yam storage system according to any one of the claims 22 to 24, wherein the first axial extremities (113) of all tubular containers are coplanar.26.- A yarn storage system according to any one of the claims 22 to 25, wherein said tubular containers (113) are oriented in a substantially vertical position.27.- A yarn storage system according to any one of the claims 22 to 26, wherein said tubular containers (113) are oriented in a substantially horizontal position.28.- A yarn storage system according to any one of the claims 22 to 27, wherein said yarn storage system (1000) further comprises a yam end holding means comprising a number of apertures (2022) or slots (2013), said number being identical to or more than the number of tubular containers (101) of the yam storagesystem (1000), each aperture (2022) or slot (2013) being fit to receive at least one yarn end from one of the tubular containers (101).29.- A yarn storage system comprising at least a first and a second yarn storage containers (101), said first and second storage containers (101) being elongated, preferably tubular, and having an axial length (L) and an elongated perimetral wall (501) extending between a first and second axial extremity (113-115), the first axial extremity (113) of said container (101) having an opening (123) for receiving an end of a yarn (200), characterized in that said yarn storage system (1000) further being provided with at least one of the following features, or with a combination of two or more of the following features:- the feature that said first and second containers (101) are positioned, or positionable, in said storage system (1000) with their axial length (L) directed in a substantially horizontal plane;- the feature that said first and second containers (101) are positioned, or are posti enable, in said storage system (1000) with their axial length (L) directed slopingly with respect to said substantially horizontal plane, said slope being at an angle (G) of 15° or less with said substantially horizonal plane;- the feature that said first and second containers (101) are positioned, or are posti enable, in said yam storage system (1000) with their axial length (L) directed slopingly with respect to said substantially horizontal plane, with said first axial extremity (113) being directed downwardly;- the feature that said yarn storage system (1000) comprises a plurality of containers (101), including said first and second containers (101), wherein said plurality of containers (101) is positioned in a matrix, wherein said matrix is preferably substantially uniform;- the feature that at least one of said first and second containers (101), is provided with a yarn detector (2012-2019) and / or the feature that said yarn storage system (1000) comprises means for detecting the yarn (200) of at least one of said first and second containers (100);- the feature that at least one of said first and second containers (100), is provided with means for creating a laminar air stream, preferably from the first axial extremity (113) to the second axial extremity (115);- the feature that at least one of said first and second containers (101) shows the features of any of claims 1 to 20;- the feature that said yam storage system (1000) is directly linked to a tufting machine (2001) or weaving machine, for example in that yams (200) from at least one of said first and second container (101) are positioned to be tufted or woven in said machine;- the feature that said yarn storage system (1000) comprises a yam end holding means comprising a number of apertures (2022) or slots (2013), said number of apertures (2022) or slots (2013) being preferably identical to or more than the number of containers (101) of the yarn storage system (1000), each aperture (2022) or slot (2013) preferably being fit to receive at least one yam end from one of the containers (101);- the feature that at least one of said first and second container (101) comprises a lid substantially closing said first axial extremity (113), said lid being provided with a shaft for providing said opening (123) for receiving an end of the yam;- the feature that at least one of said first and second container (101) comprises an electrically conductive layer or strips on the inner wall thereof;- the feature that at least one of said first and second container (101) is grounded;- the feature that at least one of said first and second container (101) is configured for tensionless storage of yam (200).30.- The use of a yarn storage system according to any one of the claims 22 to 29 to provide pile yarn to a tufting machine (2001).31.- Textile production assembly, wherein said textile production assembly (2000) at least contains a first yam storage system (1000) and a textile producing machine(2001), wherein said machine produces textile on the basis of continuous yam (200) and / or is chosen from the list consisting of a tufting machine (2001), a weaving machine and a knitting machine, characterized in that said first yarn storage system (1000) comprises at least a first and a second yarn storage container (101) for storing continuous yarns (200), said first and second storage containers (101) being elongated, preferably tubular, and having an axial length (L) and an elongated perimetral wall (501) extending between a first and second axial extremity (113- 115), the first axial extremity (115) of said container (101) having an opening (123) for receiving an end of a yam (200), and wherein said first yarn storage system (1000) further comprises means (2010) for communicating with said textile producing machine, in particular for communicating the lack of a yarn (200) from said first and / or said second container (101).32.- Textile production assembly according to claim 31, characterized in that said first yam storage system (1000) comprises the features of claim 29.33.- Textile production assembly according to claim 31 or 32, characterized in that said first yarn storage system (1000) is provided with at least the following features in combination:- the feature that at least one of said first and second containers (101), is provided with a yarn detector (2012-2019) and / or the feature that said first yam storage system (1000) comprises means for detecting the yam (200) of at least one of said first and second containers (100);- the feature that said yarn detector (2012-2019) creates a signal to be directly or indirectly communicated to said textile machine through said means (2010) for communication.34.- Textile production assembly in accordance with any of claims 31 to 33, characterized in that said means (2010) for communicating are chosen from the list of electric and electronic means, wherein said means for communicating preferablycomprise a wireless link between said first storage system (1000) and said textile machine.35.- Textile production assembly in accordance with any of claims 31 to 34, characterized in that said textile machine (1000) is configured to pause the operation, or to proceed with yarn (200) from an alternative container (101) in said first yarn storage system (1000), when it receives a signal through said means (2010) for communication.36.- Textile production assembly in accordance with any of claims 31 to 35, characterized in that said textile production assembly (2000) further comprises means (2018) for connecting one or more of the yams (200) of said first yarn storage system (1000) to one or more yams (200) of a second, preferably similar, yam storage system (1000).37.- Textile production assembly according to claim 36, characterized in that said means (2018) for connecting comprise a support for positioning one or more yams (200) of said first yarn storage system (1000) and one or more yarns (200) of said second yarn storage system (1000), wherein said means (2018) for connecting further comprises a fusing element for connecting said one or more yarns (200) of said first yarn storage system (1000) with said one or more yarns (200) of said second yarn storage system (1000), preferably while being positioned on said support; said support preferably comprising a set of teeth (2014) for spacing individual yams (200) from said firstyam storage system (1000) and / or second yarn storage system (1000) respectively.38.- A method to store yam, said method comprises the steps ofProviding at least one yarn storage system (1000) according to any one of the claims 22 to 29;Providing N spools of yam (200), N being an integer equal or more than 1;Repeating■ selecting at least one, preferably tubular, container (101) to at least partially be filed with yam (200) of said spool;■ defining for said selected at least one container (101) the length of yam to be inserted;■ selecting one of the N yams (200);■ injecting said defined length of said selected yarn (200) from said spool by means of a fluid, such as pressured air, in the selected at least one container (101); for a plurality of containers (101), optionally until all containers (101) are at least partially loading with yam (200).39.- A method according to claim 38, wherein N is more than 1, preferably between 2 and 10, even more preferably between 2 and 8, such as 3, 4, 5, 6, 7 or 8 yarns.40.- A method according to claim 38 or 39, wherein injecting said yarn in said containers (101) is performed by a robot (5110), comprising a spool rack comprising said N spools of yam (200).41.- A method according to claim 40, wherein the robot (5110) comprises a memory unit (5111) memorizing loading data, being for each tubular container memorizing- its position,- the yarn to be selected and- the length of yarn to be injected; the robot (5110) comprising an input means (5112) for inputting said loading data in said memory unit, said robot comprising a control unit defining the loading sequence of said tubular containers and controlling the injection of said yarns in said tubular containers while executing said loading sequence.42.- A method according to any of claims 38 to 41, wherein N>1, the yarns of said N spools of yarn all are mutually different yams (200).43.- A method according to any one of the claims 38 to 42, wherein said yams (200) are bulked continuous filament yarns.44.- A method according to any one of the claims 38 to 43, wherein said defined lengths of yarns (200) are in the range of 2000 to 10000 ft, or in the range of 609.6 meters to 3048 meters.45.- A method according to any one of the claims 38 to 44, wherein said system comprises a vortex injector (2028) for injecting said defined length of said selected yarn (200) in the selected, preferably tubular, container (101).46.- A yarn storage container for storing a yam (200) is provided, said storage container (101) comprising a, preferably tubular, container (101), having an axial length (L), a, preferably tubular, wall (501) and a first and second axial extremity, the first axial extremity (113) of said container (101) having an opening (123) for receiving an end of a yarn (200), said second axial extremity (115) of said container (101) being air-permeably open or closed, said wall (501) being an air permeable mesh.47.- Method for producing textiles with a plurality of designs, wherein each design is created from a set of yams (200), characterized in that the method comprises- providing a first set of yams for a first of said plurality of designs; wherein one or more of said first set of yams is provided in a first yarn storage system (1000), wherein said first yarn storage system (1000) comprises a first plurality of containers (101);- providing a second set of yams for a second of said plurality of designs; wherein one or more of said second set of yams is provided in a second yam storage system (1000), wherein said second yam storage system (1000) comprises a second plurality of containers (101);- producing said first design at least by drawing yam (200) from one or more of said first plurality of containers (101);- connecting one or more of the yarns (200) of said first plurality of containers (101) to yams of said second plurality of containers (101);- producing said second design at least by drawing yarn (200) from one or more of said second plurality of containers (101).48.- Method according to claim 47, characterized in that each container (101) from which yarn (200) is drawn for said first, respectively second design, comprises at most one continuous length of a yam, wherein said continuous length preferably corresponds to the length of said yarn needed in the first or second design respectively, with a margin of preferably less than 10%.49.- Method according to claim 48, wherein said containers (101) are tubular.50.- Method according to any of claims 47 to 49, characterized in that said containers are yam storage containers (100) according to any of the claims 1 to 21 and / or in that said one of said first and second yarn storage systems (1000) show the features of any of the claims 22 to 29.51.- Method according to any of claims 47 to 50, characterized in that said connecting comprises fusing.52.- Method according to any of claims 47 to 51, characterized in that said connecting comprises positioning one or more of the yarns (200) of said first plurality of containers (101) and one or more of the yarns (200) of said second plurality of containers on a support, and connecting said yams (200) while being on the support.53.- Method according to claim 52, characterized in that said support comprises a set of teeth (2014) for spacing individual yams (200).54.- Method according to any of claims 47 to 53, characterized in that all of the yams (200) of said first set and said second set are drawn from a respective container (101), wherein said first set comprises at least all the yarn (200) needed for the first design and said second set comprises at least all the yam (200) needed for said second design.55.- Method according to any of claims 47 to 54, characterized in that said method further comprises the step of cutting the textile in at least two pieces, each comprising at least one of the first and second designs.56.- Method according to any of claims 47 to 55, characterized in that said method further comprises the step of cutting the textile in at least three pieces being two pieces each comprising at least one of the first and second designs, and a third piece positioned in between a first and a second design.57.- Method according to any of claims 47 to 56, characterized in that first set of yams is different from said second set of yams at least in that the number of containers (101) being loading with a particular color in said first plurality of containers is different from the number of containers (101) being loading with the same particular color in said second plurality of containers.58.- A griege product obtained or obtainable with the method of any of claims 47 to 57, wherein said griege product is a textile comprising the first design, the second design and a zone in between a first and second design, wherein said zone contains both yarns from said first and from said second set.59.- A method of producing yam preferably for feeding a tufting machine (2001), comprising- spinning a plurality of filaments (2026);- converting said plurality of filaments (2026) to a yam (200);- directly providing said yarn (200) in a container (101); said containers preferably being yarn storage containers (101) according to any of the claims 1 to 21 and / or being comprised in a yam storage systems (1000) showing the features of any of the claims 22 to 29;- optionally feeding a tufting machine (2001) by drawing said yam (200) from said container (101).60.- The method of claim 59, characterized in that said converting comprises entangling and / or twisting.61.- The method of claim 59 or 60, characterized in that said converting comprises entangling the plurality of filaments (2026) via air jets to produce the said yarn (200), wherein said yarn is preferably suitable for tufting.62.- The method of any of claims 59 to 61, characterized in that said converting comprises twisting the plurality of filaments (2026) to produce the said yam (200), wherein said yarn is preferably suitable for tufting and / or wherein said twisting the plurality of filaments (2026) comprises applying a S twist or a Z twist.63.- The method of claim 62, characterized in that said twisting the plurality of filaments (2026) comprises adjusting an amount of twist to produce yams (200) of different texture.64.- The method of any of claims 59 to 63, characterized in that said directly providing said yarn (200) in a container (101) comprises loading said container (101) with an amount of yarn (200) corresponding to the amount of yarn (200) needed for a textile design to be produced on a portion of a textile machine, with a margin of less than 10%.65.- The method of any of claims 59 to 64, characterized in that said directly providing said yarn (200) in a container (101) comprises loading said container(101) with an amount of yarn (200), cutting the yarn, loading a subsequent container(101) with a different or equal amount of yarn (200).66.- The method of any of claims 59 to 65, characterized in that said method further comprises drawing out yam (200) from said container (101) for feeding a textile machine.67.- The method of any of claims 59 to 66, characterized in that said plurality of filaments (2026) comprises filaments of different colors and / or filaments of different titers.68.- A method of producing a tufted textile, comprising: spinning a plurality of filaments (2026); converting said plurality of filaments (2026) to a plurality of yarns (200);- injecting at least one yarn (200) of the plurality of yams (200) into at least one container (101); said containers preferably being yarn storage containers (101) according to any of the claims 1 to 21 and / or being comprised in a yarn storage systems (1000) showing the features of any of the claims 22 to 29and drawing the at least one yarn (200) from the at least one container (101) to a tufting machine (2001) to produce a tufted textile.69.- The method of claim 68, characterized in that the tufted textile comprises a tufted carpet.70.- The method of claims 68 or 69, characterized in that said converting said plurality of filaments (2026) to a plurality of yams (200) comprises entangling and / or twisting the plurality of filaments (2026) to produce the plurality of yams (200).71.- The method of any of claims 68 to 70, characterized in that injecting at least one yarn (200) of the plurality of yarns comprises injecting multiple yarns (200) into multiple containers (101).72.- The method of any of claims 68 to 71, characterized in that injecting at least one yarn (200) into at least one container (101) comprises blowing a first yarn (200) into a first extremity (113) of a first container (101).73.- The method of any of claims 68 to 72, characterized in that drawing at least one yarn (200) from the at least one container (101) to a tufting machine (2001) comprises drawing the first yarn (200) from the first extremity (113) of the first container (101) into a tufting machine (2001) to produce tufted textile.74.- The method of any of claims 68 to 72, characterized in that drawing at least one yarn (200) from the at least one container (101) to a tufting machine (2001) comprises drawing the first yam (200) from a second extremity (115) of the first container (101) into a tufting machine (2001) to produce tufted textile.75.- The method of any of claims 68 to 74, characterized in that the at least one container (101) is a tubular container.76.- A creeling system, comprising: one or a plurality of yarn storage systems (1000) each comprising a plurality of yam storage containers (101) or being configured to receive one or more yarn storage containers (1000); said containers preferably being yarn storage containers (101) according to any of the claims 1 to 21 and / or being comprised in a yarn storage systems (1000) showing the features of any of the claims 22 to 29; at least one set of a plurality of inj ectors (2028) for inj ecting defined lengths of yarn (200) into the plurality of yarn storage containers (101); anda controller comprising a memory and configured to direct the at least one set of plurality of injectors (2028) to inject the defined length of yarn (200) into the plurality of yarn storage containers (101).77.- The creeling system of claim 76, characterized in that the memory comprises information for at least a plurality of storage containers (101), preferably each storage container, in each of said plurality of yarn storage systems (1000).78.- The creeling system of claim 76 or 77, characterized in that for each yam storage container (101) of the plurality of yarn storage systems, the memory comprises information of its position 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 in the yarn storage container (101).79.- The creeling system of any of claims 76 to 78, wherein the plurality of injectors (2028) inject the defined lengths of yarn (200) into the plurality of yarn storage containers (101) in the plurality of storage systems (1000) simultaneously.80.- The creeling system of any of claims 76 to 79, characterized in that said creeling system preferably comprises at least one set of a plurality of injectors (2028) for each of the yarn storage systems (1000) that it is able to receive.81.- The creeling system of any of claims 76 to 80, characterized in that each injector (2028) of said set injects a single type of yam (200), i.e. yarn from the same color, type, quality and material, into the containers of a particular yam storage system.82.- The creeling system of any of claims 76 to 81, characterized in that one or more, preferably each, injector (2028) of said set is able to inject yarn (200) in a plurality of columns of the stack of containers (101) and / or able to inject yam (200) in a plurality of rows of the stack of containers (101).

83. A yarn storage container for storing a yam, comprising; a tubular container having an axial length; a tubular wall comprising an air permeable mesh present along the axial length of the tubular container, and having a first and second axial extremity; wherein the first axial extremity of the tubular container comprises an opening for receiving an end of a yam; and wherein the second axial extremity of the tubular container comprises an air-permeable endcap.

84. The yarn storage container of claim 83, wherein the air permeable mesh is comprised of strands.

85. The yarn storage container of claim 84, wherein the strands are arranged in a pattern where at least a first plurality of strands are at right angles to a second plurality of strands.

86. The yarn storage container of claim 85, wherein the mesh comprises a single layer.

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

88. The yam storage container of claim 86, wherein the amount of open area of the mesh is between 70% and 95%89. The yam storage container of claim 86, wherein the amount of open area of the mesh is between 90% and 93%.

90. The yam storage container of claim 86, wherein the amount of open area of the mesh is 91%.

91. The yarn storage container according to claim 88, wherein the air permeable mesh is composed of a material chosen from the group consisting of polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, metals, and fiberglass.

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

93. The yarn storage container according to claim 92, wherein the shaft comprises a grommet and a yarn retainer.

94. The yarn storage container according to claim 93, wherein the grommet is electrically conductive.

95. A yam storage system for storing yarn, comprising: a plurality of cylinders comprised of mesh fabric; wherein each cylinder has a first axial extremity and a second axial extremity; wherein the mesh fabric is comprised of a plurality of crossing strands; wherein the first axial extremity of each of the plurality of cylinders is configured to receive an end of yarn; and wherein the yarn storage system comprises wheels configured to move the yam storage system.

96. The yarn storage system of claim 95, wherein the mesh fabric is air permeable and is comprised of strands.

97. The yarn storage container of claim 96, wherein the strands are arranged in a pattern where at least a first plurality of strands are at right angles to a second plurality of strands.

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

99. The yam storage container of claim 86, wherein the amount of open area of the mesh is between 70% and 95%100. The yam storage container of claim 86, wherein the amount of open area of the mesh is between 90% and 93%.

101. The yarn storage container according to claim 99, wherein the mesh fabric is composed of a material chosen from the group consisting of polypropylene, polyethylene terephthalate, polyurethane, vinyl-coated polyester, metals, and fiberglass.

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

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