Creel equipped with tubes for supplying warp beam winding machines

Abstract

The system includes a warp beam winding machine and a creel having a plurality of positions, each configured to support its respective fiber package. The creel has a first longitudinal end facing the beam winding machine. The system further includes a plurality of tubes, each of which has a first end configured to receive fibers from each of the plurality of positions toward the first longitudinal end of the creel.

Description

【Technical Field】 【0001】 Cross - reference to Related Applications This application claims the benefit and priority of the filing date of U.S. Provisional Patent Application No. 63 / 505,262, filed on May 31, 2023, which is hereby incorporated by reference in its entirety. 【0002】 This disclosure relates to systems and methods for winding warp yarns from creels onto beams. 【Background Art】 【0003】 Fibers can be wound around a beam from a creel to provide warp yarns for manufacturing fabrics. Conventionally, while setting the yarns, an operator has to pull the fibers from each fiber package, along the creel, and to a warp beam winding machine. In addition to being time - consuming, accessing each fiber package located at the top of the creel requires a ladder, which causes ergonomic problems. Further, since the creel does not control the separation of the yarns, it allows the ends to cross, causing yarn breaks and ultimately reducing the quality of the fabric. 【Summary of the Invention】 【0004】 In various aspects, what is described herein is a system that includes a warp beam winding machine and a creel having a plurality of positions configured to support respective fiber packages thereon. The creel has a first longitudinal end facing the beam winding machine. The system further includes a plurality of tubes, each of the plurality of tubes having a respective first end configured to receive fibers from a respective one of the plurality of positions toward the first longitudinal end of the creel. 【0005】 Further advantages of the present invention are partially described below, partially evident from the description, or can be learned through the practice of the invention. The advantages of the present invention will be realized and achieved by the elements and combinations specifically pointed out in the appended claims. It should be understood that both the above general description and the following detailed description are illustrative and descriptive only and do not limit the invention as described in the claims. 【0006】 These and other features of this embodiment will become clearer from the detailed description, and the accompanying drawings will be referenced in the following description. [Brief explanation of the drawing] 【0007】 [Figure 1] This is a schematic diagram of an exemplary system disclosed herein. [Figure 2] This is a perspective view of a portion of the creel of the system disclosed herein. [Figure 3] This is a perspective view of another part of the creel disclosed herein, showing a tube. [Figure 4] This is a perspective view of another part of the creel disclosed herein, showing a tube. [Figure 5] This is an enlarged section of Figure 4, showing details of the yarn package. All labeled elements, including the tube and creel positions, are associated with a single fiber from a single package. [Figure 6] This is a perspective view of the eyelet board of the system disclosed herein. [Modes for carrying out the invention] 【0008】 Herein, the invention will be described more fully with reference to the accompanying drawings, which illustrate some, though not all, embodiments of the invention. In fact, the invention can be embodied in many different forms and should not be construed as being limited to the embodiments described herein, but rather these embodiments are provided to satisfy the legal requirements to which this disclosure is applicable. Throughout, similar numbers refer to similar elements. It should be understood that the invention is not limited to the specific methodologies and protocols described herein and may be modified in that way. It should also be understood that the terminology used herein is merely to describe specific embodiments and is not intended to limit the scope of the invention. 【0009】 Many modifications and other embodiments of the invention described herein will be conceived by those skilled in the art who have an interest in the teachings presented in the foregoing description and the accompanying drawings. It should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Specific terms are used herein, but they are used in a general and descriptive sense only and not for limiting purposes. 【0010】 As used herein, the singular forms "a," "an," and "the" may optionally refer to multiple objects unless otherwise clearly indicated by the context. For example, unless otherwise indicated by the context, the use of the term "tube" may refer to both a disclosure of an embodiment in which only a single such tube is provided and a disclosure of an embodiment in which multiple such tubes are provided. 【0011】 Unless otherwise clearly indicated, all technical and scientific terms used herein have the same meanings as those generally understood by those skilled in the art to which this invention pertains. 【0012】 As used herein, the terms “optional” or “optionally” mean that the events or circumstances described below may or may not occur, and this description includes both the cases in which such events or circumstances occur and the cases in which they do not occur. 【0013】 As used herein, the term “at least one of” is intended to be synonymous with “one or more of.” For example, “at least one of A, B, and C” explicitly includes A only, B only, C only, and any combination thereof. 【0014】 In this specification, a range may be expressed as “approximately” from one particular value and / or “approximately” to another particular value. Where such a range is expressed, another embodiment includes one particular value and / or other particular values. Similarly, where a value is expressed as an approximation by the use of the preceding word “approximately,” it will be understood that the particular value forms another embodiment. It will be further understood that each endpoint of a range is significant, whether related to other endpoints or independent of other endpoints. At will, in some embodiments, where a value or feature is approximated by the use of the preceding words “approximately,” “substantially,” or “generally,” it is intended that values ​​within a range of up to 15%, up to 10%, up to 5%, or up to 1% (above or below) a particular stated value may be included within the range of these embodiments. Similarly, the use of “substantially” (e.g., “substantially parallel”) or “generally” (e.g., “generally perpendicular”) to refer to surface orientation should be understood to include embodiments where the angle is within approximately 10 degrees, or within 5 degrees, or within 1 degree. 【0015】 As used herein, the term "or" means any one member of a given list, and in alternative embodiments, it may represent the disclosure of any combination of members of that list unless otherwise indicated by the context. 【0016】 Where used herein, unless otherwise indicated, embodiments described or claimed using “comprise,” “comprises,” or “comprising” may instead be described or claimed using “essentially consisting of,” “consisting of,” or equivalent terms. 【0017】 It should be understood that, unless otherwise clearly stated, no method described herein is ever intended to be construed as requiring its steps to be performed in a specific order. Therefore, unless a claim for a method does not actually enumerate the order in which its steps are followed, or unless otherwise specifically stated in the claims or description that the steps should be limited to a specific order, no order is ever intended to be inferred. This is reserved for any possible implicit grounds for interpretation, including the arrangement of steps or operational flows, the obvious meanings arising from grammatical structure or punctuation, and logical matters relating to the number or types of embodiments described in the specification. 【0018】 The following description provides specific details to offer a complete understanding. Nevertheless, those skilled in the art will understand that the apparatus, system, and associated methods of using the apparatus can be implemented and used without these specific details. In fact, the apparatus, system, and associated methods can be put into practice by modifying the illustrated apparatus, system, and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry. 【0019】 In various embodiments, with reference to Figures 1 to 5, disclosed herein is a system 10 comprising a warp beam winding machine 20 and a creel 30. The creel 30 comprises a plurality of positions 32, each configured to support its respective fiber package 40. The creel 30 has a first longitudinal end 34 facing the beam winding machine 20. The system 10 further comprises a plurality of tubes 50, each tube 50 having a first end 52 configured to receive fibers 42 from the yarn package 40 at each of the plurality of positions 32. Each tube 50 extends from its first end 52 toward the first longitudinal end 34 of the creel 30. 【0020】 Multiple positions 32 of the creel 30 may comprise an upper row 36 of positions 32. In some embodiments, at least a portion of the multiple tubes 50 may extend from the upper row 36 of positions 32. In some optional embodiments, the tubes 50 may extend only from the upper row 36 of positions 32. These tubes 50 extending from the upper row 36 can reduce the ergonomic strain on the operator reaching the upper row. In some embodiments, the creel 30 may comprise one or more rows of positions below the upper row. In some embodiments, the multiple tubes 50 may extend to some or all of positions 32 in one or more rows of positions below the upper row 36. In various embodiments, the multiple tubes 50 may be configured to receive thread from at least half of the multiple positions of the creel. In further embodiments, the multiple tubes 50 may be configured to receive thread from at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95%, or at least 99% of the positions of the creel. In some embodiments, the multiple tubes can be configured to receive thread from any position on the creel. Optionally, in these embodiments, each tube 50 of the multiple tubes can extend to all positions 32 of the multiple positions. 【0021】 In some embodiments, the multiple positions 32 of the creel have at least 300 positions. In some embodiments, the multiple positions of the creel have at least 600 positions. In some embodiments, the multiple positions of the creel have at least 1,200 positions. In some embodiments, the multiple positions of the creel have at least 2,500 positions. In some embodiments, at least one of the multiple tubes has a length of at least 20 feet. In some embodiments, at least one of the multiple tubes has a length of at least 40 feet. In some embodiments, at least one of the multiple tubes 50 has a length of at least 60 feet. In some embodiments, at least one of the multiple tubes 50 has a length of at least 80 feet. In some embodiments, at least one of the multiple tubes 50 has a length of at least 100 feet. In some embodiments, at least one of the multiple tubes 50 has a length of at least 120 feet. In some embodiments, at least one of the multiple tubes 50 has a length of at least 140 feet. In some embodiments, at least one of the multiple tubes 50 has a length of at least 150 feet. As should be understood, maintaining consistent tension across all fibers of the warp is important for the quality of the fabric. Passing fibers through a tube is known to increase tension, and the longer the tube, the greater the amount of tension on the fibers. Thus, in contrast to the disclosed system and method, conventional wisdom has taught that using tubes with large creels reduces the quality of the warp. 【0022】 System 10 can further include a plurality of fiber packages 40. Each fiber package 40 of the plurality of fiber packages can be positioned at each of a plurality of positions 32. In some optional embodiments, the fiber package 40 can be an extrusion tape package. In some embodiments, the extrusion tape can extend to the warp beam winding machine 20 without twist or substantially without twist. In other embodiments, the fiber package 40 can comprise any suitable yarn, including, for example, but not limited to, monofilament or multifilament yarn, staple yarn, or bulk continuous fiber yarn. 【0023】 In some embodiments, each position 32 of the plurality of positions can be configured to allow the respective fiber package 40 thereon to rotate as fibers are drawn therefrom. The position 32 can comprise an elongated body 38. For example, the elongated body 38 of each position 32 can comprise a protrusion having a cylindrical outer surface. The fiber package 40 can have a tube with an inner diameter sufficiently larger than the diameter of the outer surface of the protrusion of the position 32 to allow rotation of the fiber package 40 on the position 32. In some embodiments, the position 32 itself can rotate, thereby allowing rotation of the fiber package 40. 【0024】 In some embodiments, each of the plurality of positions 32 can include an elongated body 38 that extends along a respective axis 39. The axis 39 can be, for example, a horizontal axis or a substantially horizontal axis. Optionally, at least some (optionally, all) of the axes 39 of the elongated bodies 38 of the plurality of positions 32 can be parallel or substantially parallel to each other. Each tube 50 of the plurality of tubes extends along an axis 56 (e.g., optionally, an axis having a curvature rather than a straight axis). At the first end 52 of each tube 50 of the plurality of tubes, a tangent 58 to the axis 56 is generally perpendicular to the axis 39 along which the elongated body 38 of each respective position 32, where the first end 52 of the tube 50 is configured to receive the fiber 42, extends. This perpendicularity should be understood to include out-of-plane perpendicularity, and thus this perpendicularity includes orientations of the axis 39 and the tangent 58 such that translating (not rotating) the axis 39 of the position 32 relative to the tangent 58 can result in an intersection at approximately 90 degrees. 【0025】 In some embodiments, the first end 52 of each tube 50 of the plurality of tubes is proximate to each respective position 32 of the plurality of positions where the tube receives the fiber 42. For example, as illustrated in FIG. 4, the fiber 42 can be passed through a tension assembly 70 including at least one tension pulley 72 to the first end 52 of the tube 50. The first end 52 of the tube 50 can be spaced from the first end 34 of the creel 30 toward the tension pulley and at approximately the height at which the fiber leaves the tension pulley. In additional or alternative embodiments, the at least one tension pulley 72 can include a guide 74 that directs the fiber from the tension pulley 72 toward the tube. In these embodiments, the guide 74 can be at the height of the first end 52 of the tube 50. In this way, the fiber 42 need not change direction when entering the tube 50. The first end 52 of the tube 50 can be supported by a bracket. A guide (e.g., a ceramic guide) for reducing friction can be provided at the entrance of the tube 50. 【0026】 Referring to Figure 6, the system 10 may further comprise an eyelet board 60 defining a plurality of openings 62. Each guide 64 (e.g., a ceramic guide) that minimizes friction with the fibers 42 as they pass through the guides can be positioned in each of the multiple openings 62 of the eyelet board 60. Each of the plurality of tubes 50 may have a second end 54 opposite to the first end 52 that communicates with each of the openings 62 of the eyelet board 60. 【0027】 In some embodiments, each tube 50 of a plurality of tubes can be coupled to an eyelet board 60. In some embodiments, the second end 54 of each tube is positioned on the eyelet board 60 (e.g., within 6 inches, 5 inches, 4 inches, 3 inches, 2 inches, 1 inch), or is in contact with or substantially in contact with the eyelet board 60. For example, a guide 64 can be coupled to the second end 54 of the tube 50, and the guide 64 is intended to be positioned within the eyelet board 60. 【0028】 In some embodiments, the eyelet board 60 may comprise multiple segments 66. That is, the eyelet board 60 does not have to be single. For example, as shown in Figure 6, the eyelet board 60 may comprise multiple segments 66 spaced laterally apart from the creel. 【0029】 In some embodiments, the eyelet board 60 may comprise a metal, polymer, or any other suitable material. 【0030】 The linearity of each tube is intended to determine the amount of tension applied to the fibers. In some embodiments, the linearity of each tube can vary by 15% or less, 10% or less, or 5% or less. That is, the length of the tube cannot be longer than the distance the tube extends along the longitudinal axis of the creel plus a percentage variation. For example, a tube extending 50 feet along the longitudinal axis of the creel with a linearity that varies by 10% or less cannot be longer than 55 feet. 【0031】 Compressed air can be used to blow the fibers through each tube 50 from the first end 52 to the second end 54. This substantially increases the speed at which the yarn is set compared to conventional operations. 【0032】 Exemplary aspects With regard to the products, systems, and methods described herein, as well as variations thereof, this specification describes certain specific embodiments of the invention that are more specifically described. However, these particularly enumerated embodiments should not be construed as limiting any different claims containing different or more general teachings described herein, or limiting any "specific" embodiment in any way other than the inherent meaning of the language used therein. 【0033】 Embodiment 1: A system, Warp beam winding machine, A creel comprising multiple positions, each of which has an elongated body configured to support its respective fiber package, the creel having a first longitudinal end facing a beam winding machine, A system comprising: a plurality of tubes, each of the plurality of tubes having a first end configured to receive fibers from each of the plurality of positions, and each tube extending from the respective first end of the tube toward the first longitudinal end of the creel. 【0034】 Embodiment 2: The system according to Embodiment 1, wherein the plurality of positions of the creel are provided with an upper position row, and at least a portion of the plurality of tubes extends from the upper position row. 【0035】 Embodiment 3: The system according to Embodiment 1 or Embodiment 2, wherein the plurality of tubes are configured to receive thread from at least 70% of the plurality of positions of the creel. 【0036】 Embodiment 4: The system according to Embodiment 3, wherein the plurality of tubes are configured to receive thread from any position on the creel. 【0037】 Embodiment 5: The system according to Embodiment 4, wherein each of the plurality of tubes extends to all locations of the creel. 【0038】 Embodiment 6: The system according to any one embodiment of the preceding embodiments, wherein the plurality of positions of the creel comprises at least 2500 positions. 【0039】 Embodiment 7: The system according to any one embodiment of the preceding embodiments, further comprising a plurality of fiber packages, wherein each of the plurality of fiber packages is located at each of the plurality of positions. 【0040】 Embodiment 8: The system according to Embodiment 7, wherein the fiber package is an extruded tape package. 【0041】 Embodiment 9: The system according to Embodiment 7 or Embodiment 8, wherein each of the plurality of positions is configured to allow each of the fiber packages above it to rotate as a fiber is drawn from there. 【0042】 Embodiment 10: The system according to any one embodiment of the preceding embodiments, wherein at least one of the plurality of tubes has a length of at least 100 feet. 【0043】 Embodiment 11: The system according to any one embodiment of the preceding embodiments, wherein the elongated body at each of the plurality of positions extends along its respective axis, and each of the plurality of tubes extends along its axis, and at the first end of each of the plurality of tubes, the tangent of the tube to the axis is generally perpendicular to the axis at each of the positions in which the first end of the tube is configured to receive the fiber. 【0044】 Embodiment 12: The system according to any one embodiment of the preceding embodiments, wherein the first end of each of the plurality of tubes is close to each of the plurality of positions where the tube receives a fiber. 【0045】 Appearance 13: An eyelet board that defines multiple openings, The system according to any one embodiment of the prior art, further comprising: a plurality of ceramic guides, each of the plurality of ceramic guides positioned in each of the plurality of openings of the eyelet board, and each of the plurality of tubes having a second end facing the first end and communicating with each of the openings of the eyelet board. 【0046】 Embodiment 14: The system according to Embodiment 13, wherein each of the plurality of tubes is connected to the eyelet board. 【0047】 Embodiment 15: The system according to Embodiment 13 or Embodiment 14, wherein the eyelet board comprises a plurality of segments. 【0048】 Embodiment 16: The system according to any one embodiment of Embodiments 13 to 15, wherein the second end of each tube is positioned on the eyelet board. 【0049】 Embodiment 17: The system according to any one embodiment of Embodiments 13 to 16, wherein the eyelet board is made of metal. 【0050】 Embodiment 18: The system according to any one embodiment of the preceding embodiments, wherein the creel comprises a plurality of tension assemblies, each tension assembly associated with each of the plurality of positions, each tension assembly comprising a guide, the guide and each of the first ends of the tube being positioned at their respective heights. 【0051】 Embodiment 19: The system according to any one embodiment of the preceding embodiments, wherein each of the fibers extending from at least one of the plurality of tension assemblies does not change direction when the fibers enter the tube. 【0052】 Embodiment 20: A method of using the system described in any one embodiment of the prior embodiments, A method comprising using compressed air to blow fibers of a yarn package through one of the plurality of tubes to a second end of the tube opposite the first end of the tube. 【0053】 The invention described above is described in some detail by illustration and examples for the purpose of clarifying understanding, but certain changes and modifications can be made within the scope of the attached claims.

Claims

[Claim 1] It is a system, Warp beam winding machine, A creel comprising multiple positions, each of which has an elongated body configured to support its respective fiber package, and the creel having a first longitudinal end facing the beam winding machine, A system comprising: a plurality of tubes, each of the plurality of tubes having a first end configured to receive fibers from each of the plurality of positions, and each tube extending from the respective first end of the tube toward the first longitudinal end of the creel. [Claim 2] The system according to claim 1, wherein the plurality of positions of the creel are provided with an upper position row, and at least a portion of the plurality of tubes extends from the upper position row. [Claim 3] The system according to claim 1, wherein the plurality of tubes are configured to receive threads from at least 70% of the plurality of positions on the creel. [Claim 4] The system according to claim 3, wherein the plurality of tubes are configured to receive thread from any position on the creel. [Claim 5] The system according to claim 4, wherein each of the plurality of tubes extends to any position on the creel. [Claim 6] The system according to claim 1, wherein the plurality of positions of the creel comprises at least 2500 positions. [Claim 7] The system according to claim 1, further comprising a plurality of fiber packages, wherein each of the plurality of fiber packages is positioned at each of the plurality of positions. [Claim 8] The system according to claim 7, wherein the fiber package is an extruded tape package. [Claim 9] The system according to claim 7, wherein each of the plurality of positions is configured to allow each of the fiber packages above it to rotate as a fiber is drawn from there. [Claim 10] The system according to claim 1, wherein at least one of the plurality of tubes has a length of at least 100 feet. [Claim 11] The system according to claim 1, wherein the elongated body at each of the plurality of positions extends along its respective axis, and each of the plurality of tubes extends along its axis, and at the first end of each of the plurality of tubes, the tangent of the tube to the axis is generally perpendicular to the axis at each of the positions in which the first end of the tube is configured to receive the fiber. [Claim 12] The system according to claim 1, wherein the first end of each of the plurality of tubes is close to each of the plurality of positions where the tube receives a fiber. [Claim 13] An eyelet board that defines multiple openings, The system according to claim 1, further comprising a plurality of ceramic guides, each of which is positioned in each of the plurality of openings of the eyelet board, and each of which is a plurality of tubes, having a second end facing the first end and communicating with each of the openings of the eyelet board. [Claim 14] The system according to claim 13, wherein each of the plurality of tubes is connected to the eyelet board. [Claim 15] The system according to claim 13, wherein the eyelet board comprises a plurality of segments. [Claim 16] The system according to claim 13, wherein the second end of each tube is positioned on the eyelet board. [Claim 17] The system according to claim 13, wherein the eyelet board is made of metal. [Claim 18] The system according to claim 13, wherein the creel comprises a plurality of tension assemblies, each tension assembly associated with each of the plurality of positions, each tension assembly comprising a guide, the guide and each first end of the tube being positioned at their respective heights. [Claim 19] The system according to claim 1, wherein each of the fibers extending from at least one of the plurality of tension assemblies does not change direction when the fibers enter the tube. [Claim 20] A method of using the system described in any one of the prior claims, A method comprising using compressed air to blow fibers of a yarn package through one of the plurality of tubes to a second end of the tube opposite the first end of the tube.

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