Apparatus and method for placing multiple filaments into a bundle

Abstract

The apparatus (100) for arranging a plurality of filaments (103) transported by a transport device (101) into at least two distinct subsets of the filaments comprises at least one fluid flow providing device (108) for providing a fluid flow (109) toward at least one portion of the filaments (103) transported by the transport device (101), thereby deflecting the path of the portion of the filaments in a second direction (110) different from the first direction (107) as the filaments are transported by the transport device (101). The filaments are thus separated into at least two filament subsets (103A, 103B) of filaments. The filament subsets can then be arranged into at least two distinct, advantageously separately re-openable bundles (113).

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present invention relates to an apparatus and method for disposing multiple filaments into a bundle. More particularly, the present invention relates to an apparatus and method for disposing multiple filaments into a bundle. [Background technology]

[0002] Systems for providing a filament from a wet suspension are known, in which the suspension is fed through multiple nozzles to provide the filament on a surface of an input area of ​​a transfer device, such as a belt conveyor or a rotating cylinder. Typically, large systems include more than 3,500 nozzles, and therefore essentially the same number of filament lines on the surface of the transfer device. The transfer device is used not only to transfer the filament from the input area to the output area, but also to heat and dry the filament during transfer, since the filament received on the input area of ​​the transfer device is wet due to the wet suspension extruded through the nozzles.

[0003] Once heated, the filaments are dried by the output section, and then the dried filaments are guided to further processes such as a winding device that winds the filaments into a continuous filament bundle, which is the precursor to a yarn or string that can be further used to produce textiles.

[0004] There are several problems associated with further processing of the filament bundle coming from the output of the transport device. Namely, when it is wound, the wound continuous filament bundle can no longer be opened into smaller bundles because the filaments become entangled within the bundle. In addition, the wound continuous filament bundle contains approximately 3,500 filaments, or even more, depending on the number of nozzles, which is too large for any additional processing, such as for making yarn. As an example, the yarns used for the finest textiles have fewer than 100 filaments in the yarn and a yarn count of less than 5 g / 10 km, or even less than 2 g / 10 km, or even less. Therefore, the bundle must be divided into smaller pieces, and numerous intermediate stages are still required to achieve the desired size of the bundle. This naturally not only complicates the overall system but also increases the time and energy consumption required to obtain the desired size of the bundle. Summary of the Invention

[0005] It is an object of the present invention to mitigate or eliminate problems associated with the known prior art, and in particular to provide an apparatus and method for laying out a plurality of filaments such that the bundle achieved from the laid out filaments is of a desired size, e.g., in yarn count, and such that no further manipulation of the bundle is required to achieve the desired yarn count of the bundle.

[0006] The object of the invention can be achieved by means of the features of the independent claims.

[0007] The present invention relates to an apparatus for placing a plurality of filaments according to claim 1. Additionally, the present invention relates to a method for placing a plurality of filaments according to claim 16.

[0008] According to one embodiment of the present invention, an apparatus for disposing a plurality of filaments includes a transfer device for receiving filaments from a plurality of outputs, such as nozzles, onto a surface of the transfer device at an input region. The system typically includes more than 3,000, advantageously more than 3,500, material outputs or nozzles to provide essentially the same number of filaments, and thus essentially the same number of filament lines, on the surface of the transfer device. It should be noted that the number of nozzles is not limited to these numbers alone, and advantageously, a greater number of nozzles and therefore a greater number of filament lines may be included. A filament line is a path along which a filament travels in a first direction, at least initially or just from the input region.

[0009] The transfer device transfers the filament from the input region to the output region in a first direction and further to a further process, such as a folding or winding process of the filament by a winding device. According to one embodiment of the present invention, the apparatus includes at least one fluid flow providing device for providing a fluid flow toward at least one portion of the filament being transferred by the transfer device. The fluid flow then deflects the path of the portion of the filament in a second direction that is different from the first direction or perpendicular (or at least one component perpendicular) to the first direction, thus separating the portion into subsets from the remainder of the transferred filament. In this manner, the apparatus is configured to provide at least two subsets. The two subsets can then be manipulated or arranged into two separate bundles of continuous filament for further processing of the filament.

[0010] A continuous filament here means a filament whose length is at least the length of the transport device between the input and output regions, but can of course be much longer. In theory, the length of a continuous filament can be the length for which there is enough material coming from the material output to the input region of the transport device, the time the transport device is transporting the filament, and what the further processing of the filament is.

[0011] Of course, the apparatus may include multiple fluid flow providing devices for providing multiple fluid flows and thus multiple filament subsets. According to an advantageous embodiment, the fluid flow providing devices are arranged consecutively in a first direction so as not to interfere with each other's fluid flows and thus the separation of the filaments into subsets. The fluid flow providing devices are configured to arrange portions of the filaments into subsets, each subset having at most a certain number of filaments, to achieve a bundle having at most a certain number of filaments. According to an advantageous embodiment of the invention, even if there are more than 3000 material outputs or nozzles providing more than 3000 filaments, it is possible to achieve subsets and bundles having fewer than 300 filaments, more advantageously fewer than 200 filaments, and most advantageously at most 150 or 100 filaments.

[0012] The use of a fluid flow to arrange the filaments into separate subsets is highly advantageous, i.e., there is no need for mechanical deflectors or separators, which typically cause disturbances such as entanglement of thin, light filaments in mechanical structures. A fluid flow does not have this drawback. In addition, the fluid flow, such as the angle of attack or velocity of the fluid flow, can be precisely controlled, thereby controlling the efficiency of separation of the filaments into separate subsets. Additionally, the fluid flow can also control the path of the filaments very precisely and in a desired manner, compared to, for example, a mechanical deflector; i.e., the fluid flow impacts the filaments so that they tend to continue their path in the direction induced by the fluid flow. It should be noted that without the control of the fluid flow according to the present invention, small, very light filaments can easily become entrained in air currents around the apparatus; i.e., some type of air current is almost always present, for example, due to moving transport devices and temperature differences.

[0013] Furthermore, the present invention provides a distinct advantage: bundles can be achieved from continuous filaments, whereby the yarn count of the bundle is at the desired fineness level, e.g., 5 g / 10 km, 2 g / 10 km, etc., so that the bundle can be used directly to make, for example, yarn, without the need for multiple intermediate means, such as stapling the fibers or filaments of the bundle. Additionally, it should be noted that the separate bundles can be of different sizes, and the fluid flow providing devices can be arranged so that the number of filaments in different subsets varies, and thus the yarn counts of different bundles also deviate from each other. According to the present invention, this can be done by controlling the output of the fluid flow providing devices, e.g., by closing a portion of the output of a particular fluid flow providing device. Advantageously, the fluid flow providing device can be equipped with, for example, a suitable valve for opening or closing a particular portion of its output, or the opening and closing can be performed manually.

[0014] It should further be appreciated that the material output may output filaments having different characteristics, such as thickness, acceptor or chemical composition, or post-treatment agents, to the input region of the transfer device, and then the fluid flow providing device 108 may be used to separate the filaments having the different characteristics and separate the filament subsets accordingly. Furthermore, the separate filament subsets having filaments with different characteristics may then be collected and directed to provide them further into separate bundles, such that each bundle may comprise a filament subset having a particular characteristic.

[0015] In addition, the apparatus may also include a collection device for collecting and guiding each of the filament subsets into a separate bundle. The bundles are then guided from the collection device to further processing, such as a winding device. The number of filament subsets, collection devices, and simultaneous bundles depends on the need; for example, if a finer quality, a smaller number of filaments in a single yarn, or a lower yarn count is desired, a greater number of filament subsets, collection devices, and bundles are required. The collection device may further include a pressure manipulation device for reducing the pressure within the collection device, thereby individually causing a suction effect on each of the separate filament subsets from the output region after the fluid flow providing device. The pressure manipulation device is advantageously an ejector. This allows the filament subsets separated by the fluid flow providing device(s) to be effectively collected from the surface of the transfer device to the input of the collection device, and additionally, can accelerate the transfer speed of the filaments or bundles through the collection device.

[0016] The present invention offers distinct advantages, such as a precise, effective, non-contact manner for placing filaments, thereby avoiding or at least minimizing, for example, entanglement of the filaments in structures or mechanical deflectors, or filament floating in an uncontrolled manner. Additionally, the present invention allows for the arrangement of filaments into filament subsets of desired sizes and further into bundles of desired sizes, with the advantages already disclosed elsewhere herein. Advantageously, the bundles are distinct and separately releasable bundles, which can be directly used for further processes, such as winding or folding processes, or even directly used to produce yarns having suitable and desired yarn counts, without additional intermediate means, such as stapling. Additionally, adjustment of the apparatus of the present invention is easy when the fluid flow providing device and its output can be easily adjusted or controlled, as shown herein.

[0017] The exemplary embodiments presented in this text should not be construed as imposing limitations on the applicability of the appended claims. The verb "comprises" is used in this text as an open limitation that does not exclude the presence of unrecited features. Features recited according to the claims are freely combinable with each other unless expressly stated otherwise.

[0018] The novel features which are regarded as characteristic of the invention are set forth with particularity in the appended claims. However, the invention itself, both as to its organization and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of certain illustrative embodiments when read in connection with the accompanying drawings.

[0019] The invention will now be explained in more detail with reference to exemplary embodiments according to the accompanying drawings, in which: [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 illustrates a side view of an exemplary apparatus for disposing a plurality of filaments into subsets and separate reopenable bundles, in accordance with an advantageous embodiment of the present invention. [Figure 2] FIG. 1 illustrates a top view of an exemplary apparatus for disposing a plurality of filaments into subsets and separate reopenable bundles, in accordance with an advantageous embodiment of the present invention. [Figure 3] 1 illustrates an example of a fluid flow providing device in accordance with an advantageous embodiment of the present invention; [Figure 4] FIG. 1 illustrates a top view of an exemplary apparatus having a number of fluid flow providing devices for arranging a number of filaments into a number of subsets and a number of separate reopenable bundles, in accordance with an advantageous embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0021] FIG. 1 shows a side view, and FIG. 2 shows a top view, of an exemplary apparatus 100 for arranging a plurality of filaments 103 into subsets 103A, 103B and further into separate bundles 113, in accordance with an advantageous embodiment of the present invention. The bundles are advantageously reopenable separately (separately from each other), allowing the bundle to reopen essentially to the size to which it was wound. Thus, reopenable and reopened bundles also comprise the same number of continuous filaments as the bundle provided by the guide device, and thus, for example, the wound bundle. The apparatus comprises a transport device 101 for receiving filaments 103 from multiple outputs 105, such as nozzles, onto a surface of the transport device 101 within an input region 104. The transport device 101 shown in the figure is a belt conveyor-type device, although other types of transport devices, such as, for example, a rotating cylinder, can also be used.

[0022] The transport device 101 transports the filament in a first direction 107 from an input region 104 to an output region 106. The apparatus 100 also includes one or more fluid flow providing devices 108 for providing a fluid flow 109 toward at least a portion of the filament 103 on a surface of the transport device 101. The fluid flow providing devices 108 are advantageously disposed between the input region 104 and the output region 106.

[0023] The angle of attack of the fluid flow 109 toward the filament 103 can be adjustable, but is advantageously arranged to deflect the path of the filament in a second direction 110 perpendicular to the first direction 107. In this manner, the portion of the filament 103 is separated into subset 103B, and the remainder of the filament 103 is left in another subset 103A, thereby providing at least two subsets and even two separate bundles 113 of continuous filament for further processing of the filament. While FIG. 2 shows an example with one fluid flow providing device 108, for example, FIG. 4 shows an example with six fluid flow providing devices 108, where the apparatus also provides six subsets 103A-103F. As can be seen in FIG. 4, the fluid flow providing devices 108 are arranged consecutively in the first direction 107.

[0024] The apparatus may also include a collection device 111 for collecting and guiding each of the filament subsets 103A-103F into a separate bundle 113. The bundle 113 is further guided from the collection device 111 to a winding device 102. It should be noted that the winding device 102 is optional, as winding is merely one example of further processing of the bundle, and the winding device 102 may be replaced, for example, by a folder (not shown). The collection device 111 may also include a pressure manipulation device 112 for reducing pressure within the collection device 111, thereby causing a suction effect separately on each of the separate filament subsets 103A-103F from the output region 106 after the fluid flow providing device 108. According to one example, the pressure manipulation devices 112 may be controllable independently of one another, thus providing a different and unequal suction effect separately on each of the separate filament subsets.

[0025] The apparatus may also comprise one winding device 102 common to all collection devices 111 and bundles 113, or separate winding devices 102 for at least one collection device 111 and bundles 113. If separate winding devices 102 are used, the winding devices 102 may be independently controlled, for example, so that the separate bundles 113 are wound at different rotational speeds of the winding device 102, thereby achieving, for example, different tensions for the different bundles 113, as required.

[0026] An example of a fluid flow providing device 108 is shown in FIG. 3. The fluid flow providing device may comprise a pipe having an input 118 for receiving a fluid flow 117, one or more outputs 115, and an internal fluid conduit from the input 118 to the output 114. The output 114 may be implemented, for example, by a capillary tube extending from the pipe and / or by a capillary hole extending from the conduit through the pipe wall to the outer surface of the pipe. By way of example, outputs may be located along the pipe, for example, every 1 to 5 cm, advantageously about every 2 cm. The pipe may have, for example, a relatively thick wall (compared to the diameter of the hole), in which case the hole can be manufactured to have, for example, a precise focusing effect. Additionally, the hole or capillary tube (or their longitudinal axis 119) may be positioned at a specific angle 115, such as 15° to 45°, relative to the longitudinal axis 120 of the pipe. However, it should be noted that the angle of attack is independent of the angle of the capillaries or holes relative to the longitudinal axis of the pipe; the angle of attack is determined by the position of the fluid flow providing device relative to the transport device and the transported filaments.

[0027] The output 114 of the fluid flow providing device 108 may have an inner diameter of 0.5 to 5 mm, preferably 0.8 to 2 mm, and most preferably 0.8 to 1.0 mm. This offers distinct advantages: when the inner diameter is within the aforementioned range, the focus of the high-speed fluid flow is very precise, and the velocity of the high-speed fluid flow can be maintained very high. In addition, when the inner diameter is within the aforementioned range, the diameter of the high-speed fluid flow is also small compared to the operational scale, allowing for very precise and specific control of the path. Furthermore, when the diameter of the high-speed fluid flow is small, the volumetric flow rate of the fluid used for the high-speed fluid flow, and therefore its consumption, can be kept very low, while the sudden high-speed fluid flow does not interfere with the environment of the material whose path is under control. Therefore, the overall system is highly effective yet energy-efficient.

[0028] Furthermore, when the volumetric flow rate is very low, the momentum of the high-velocity fluid stream is also relatively low, so that the velocity of the high-velocity fluid stream decreases rapidly, and furthermore, the velocity of the high-velocity fluid stream is less than the velocity of the filaments at 10 cm, more preferably 20 cm, and most preferably 50 cm from the output of the fluid stream providing device, where the velocity of the filaments is the velocity induced by the moving transport device that also transports the filaments.

[0029] It should be noted that in accordance with the present invention, the volumetric flow rate, and therefore momentum, of the high velocity fluid stream can also be controlled, for example, by controlling the velocity or density of the high velocity fluid stream.

[0030] The output may simply be implemented by a uniform capillary or hole having an essentially constant diameter, or the output may have a varying inner diameter. The output may also be implemented by a nozzle-type structure, such as, for example, a compressed air nozzle. The nozzle may have, for example, a conical internal structure such that the inner diameter of the nozzle narrows in the direction of flow. Thus, the nozzle can be used, for example, to more precisely control the direction and / or velocity of the fluid flow. Additionally, the direction of the output may be, for example, manually controllable, or the output may be provided by a microcontroller to change direction.

[0031] Furthermore, the device may have outputs with different diameters. According to one example, the smaller diameter output is arranged in the downstream direction of the transport device's travel, and the larger diameter output is arranged in the upstream direction of the transport device's travel. This provides greater variation in the filament path, especially upstream, and more precise control downstream, although of course the system can be arranged in the opposite manner if desired. In addition, the smaller diameter in the downstream section can cause an increased velocity gradient in the direction of travel and thus, for example, a drawing effect on the filament, if desired.

[0032] Additionally, according to one embodiment, the high velocity fluid stream can also be used as a carrier fluid for additives such as ions, plasma, additives, dyes and / or functional additives or other additives. This provides an additional advantage, namely, the material can be manipulated in a controlled manner by the additive, while at the same time, the additive can be guided in a controlled manner to the same location as the material, such as the filament, is being transported.

[0033] According to one example, the velocity of the high-speed fluid stream is configured to be higher than the rate of transport of material in the first direction 107 by the transport device. In this example, the velocity gradient of the high-speed fluid stream is configured to induce a force pulling the filament toward the maximum value of the velocity gradient, thereby altering the path of the filament in a desired manner. Thus, very precise control of the path of the filament, and therefore the placement of the filament, can be achieved. Additionally, the velocity gradient of the high-speed fluid stream can also cause material, such as filaments, to compress closer to each other or toward the maximum value of the velocity gradient of the high-speed fluid stream, which may be a desired phenomenon in some particular applications.

[0034] As disclosed elsewhere herein, the apparatus can include multiple fluid stream providing devices, which can also include one or more outputs for providing and focusing multiple high-speed fluid streams toward the filament or a portion of the filament. Additionally, according to one example, the initial velocity of the high-speed fluid stream at the output of the fluid stream providing device, or the impact velocity of the high-speed fluid impinging on the filament, is advantageously at least twice, preferably three to five times, or even most advantageously more than five times the transport velocity of the filament. According to one example, the flow rate of the fluid stream provided by the fluid stream providing device can be controlled, and the velocity of the high-speed fluid stream can be in the range of 50 to 330 m / s, more advantageously 50 to 200 m / s or 100 to 150 m / s, such that the transport velocity of the filament in the first direction 107 by the transport device is typically 10 to 20 m / s. However, these are merely examples and the invention is not limited to these, and in some examples the density of the high velocity fluid flow and the density of the material whose path is being controlled may have an effect on selecting a suitable velocity difference for the velocity of the high velocity fluid (and / or the rate of transport velocity of the material).

[0035] The apparatus may also include an air compression device 116 for supplying compressed air 117 to an input 118 of the fluid flow providing device 108 .

[0036] Additionally, the fluid flow providing device 108 may comprise at least one valve 121 or the like for opening and closing a particular portion of the output 114 of the fluid flow providing device 108. Additionally, according to one embodiment, the apparatus may also comprise a manipulator 122 for rotating the fluid flow providing device 108 about its axis or for moving the fluid flow providing device 108 in a first and / or second direction, thereby adjusting the fluid flow in a desired manner relative to the transfer device and / or the transferred filament.

[0037] Additionally, the flow of material, such as a transported filament, is advantageously continuous, so that as some portions of the material are deflected, the remainder readily follows the previously deflected portions of the material.

[0038] The present invention has been described above with reference to the above-mentioned embodiments, and several advantages of the present invention have been demonstrated. Even though pressurized air is mentioned as an example of a high-velocity fluid flow, it is clear that other types of fluids, such as nitrogen, can also be used. In addition, even if the filaments are transported by a belt conveyor, other types of transport devices, such as a rotating cylinder, can also be used.

[0039] The features recited in the dependent claims may be freely combined with one another unless expressly stated otherwise.

Claims

1. 1. An apparatus (100) for arranging a plurality of filaments (103) transported by a transport device (101) into at least two distinct subsets of the filaments, the transport device (101) being configured to receive the filaments (103) from a plurality of outputs (105) at an input region (104) of the transport device onto a surface of the transport device (101), transport the filaments in a first direction (107) from the input region (104) to an output region (106) of the transport device, and further transport the filaments to a further process; The device (100) comprises: an apparatus (100) comprising at least one fluid flow providing device (108) for providing a fluid flow (109) toward at least one portion of the filament (103) being transported by the transport device (101), thereby deflecting the path of the portion of the filament in a second direction (110) different from the first direction (107), separating the portion into a subset (103B) from the remainder (103A) of the filament (103), and further providing at least two distinct subsets (103A, 103B) of the filament.

2. 2. The apparatus of claim 1, wherein the filament subsets (103A, 103B) are further arranged into at least two separate bundles (113) for the further processing of the filaments, said bundles being advantageously essentially separately re-openable bundles to the size they were wound.

3. The apparatus of claim 2, wherein the apparatus comprises at least one winding device (102) for winding the bundle of filaments.

4. 10. The apparatus according to any one of the preceding claims, comprising at least two fluid flow providing devices (108) for providing a fluid flow (109) towards at least two portions of the filaments (103) transported by the transport device (101), thereby providing at least three distinct subsets (103A, 103B, 103C) of the filaments and further three distinct bundles (113) for the further processing of the bundles, the at least two fluid flow providing devices (108) being arranged in succession in the first direction (107).

5. 10. The apparatus according to claim 1, further comprising at least two, preferably as many as the number of filament subsets, for collecting and guiding the filament subsets after the fluid flow providing device and for separating the filament subsets into bundles for the further process, such as a winding or folding process.

6. 6. The apparatus of claim 5, wherein the collection device (111) comprises a pressure manipulation device (112) for reducing pressure within the collection device (111) and thereby causing a suction effect separately on each of the distinct filament subsets (103A, 103B) after the fluid flow providing device (108).

7. The apparatus of claim 6 , wherein the pressure manipulation device (112) comprises an ejector.

8. 10. The apparatus of claim 1, wherein the apparatus comprises at least 300, preferably more than 500, more preferably more than 1000, and most preferably more than 3000 or 3500 outputs (105), e.g., nozzles, for providing essentially the same number of filaments (103), and the fluid flow providing device (108) is configured to arrange portions of the filaments (103) into a plurality of the filament subsets (103A, 103B, 103C, 103D, 103F) such that at least one filament subset, and thus at least one bundle (113), has less than 300 filaments, more preferably less than 200 filaments, and most preferably at most 150 or 100 filaments.

9. 10. The apparatus of claim 1, wherein the fluid stream providing device (108) comprises an input (113) for receiving a fluid stream and a plurality of outputs (114) for providing and focusing a plurality of high-velocity fluid streams toward the transported filament (103), the velocity of the high-velocity fluid streams being configured to be higher than a material transport rate such that a velocity gradient of the high-velocity fluid streams induces a pulling force that pulls the filament toward a maximum value of the velocity gradient, thereby altering the path of the filament (103).

10. 10. The apparatus of any one of the preceding claims, wherein at least one fluid flow providing device (108) is arranged between the input area (104) and the output area (106).

11. 10. An apparatus according to any one of the preceding claims, wherein the fluid flow providing device (108) is a fluid conduit, such as a pipe, the fluid conduit having a plurality of outputs (114) along the fluid conduit.

12. The apparatus of any one of claims 9 to 11, wherein the output (114) of the fluid flow providing device (108) comprises a nozzle, such as a compressed air nozzle.

13. 13. Apparatus according to any one of claims 9 to 12, wherein the apparatus comprises outputs (114) with different diameters, an output with a smaller diameter being arranged downstream in the direction of advancement (107) of the transfer device (101) and an output with a larger diameter being arranged upstream in the direction of advancement (107) of the transfer device (101).

14. 10. Apparatus according to any one of the preceding claims, comprising an air compression device (116) for supplying (117) compressed air to the input (113) of the fluid flow providing device (108).

15. 1. A method for arranging a plurality of filaments (103) transported by a transport device (101) into at least two distinct subsets of said filaments, comprising: The method (100) comprises: receiving a filament (103) from a plurality of outputs (105) at an input area (104) of the transfer device onto a surface of the transfer device (101), and transporting the filament in a first direction (107) from the input area (104) to an output area (106) of the transfer device and further for further processing; providing a fluid flow (109) towards at least one portion of the filament (103) being transported by the transport device (101), thereby deflecting the path of the portion of the filament in a second direction (110) different from the first direction (107), separating the portion into a filament subset (103B) from the remainder (103A) of the filament (103), and further providing at least two distinct filament subsets (103A, 103B) of the filament.

16. 16. The method of claim 15, wherein the filament subsets (103A, 103B) are further separated into at least two separate bundles (113) for the further processing of the filaments, said bundles being advantageously separately re-openable bundles.

17. 17. The method of claim 15 or 16, wherein the flow rate of the fluid stream provided by the fluid stream providing device is controlled, and the velocity of the fluid stream is between 50 and 330 m / s, preferably between 50 and 200 m / s, most preferably between 50 and 150 m / s.

18. The method according to any one of claims 15 to 17, wherein the filament subsets (103A, 103B) and further the bundle (113) according to claim 16 are made from continuous filaments.

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