Systems and methods for guiding fibers

Abstract

A fiber guide for guiding fibers in a fiber processing system has a surface including a plurality of openings through which the fibers can pass in a direction from the upstream side of the surface to the downstream side of the surface. The plurality of openings includes at least one pair of openings adjacent to each other and spaced apart from each other. The entrance of a first opening is offset from the entrance of a second opening. This offset is in the direction in which the fibers pass from the upstream side of the surface to the downstream side of the surface. A distance d1 between the entrance of the first opening and the entrance of the second opening is greater than a distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers can pass.

Description

[Technical Field]

[0001] The present invention relates to fiber processing equipment, particularly for fibers intended to be used as reinforcement in fiber reinforced composite materials. (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Patent Application No. 62 / 883,832, filed August 7, 2019, entitled "SYSTEM AND METHOD FOR GUIDING FIBERS," the contents of which are incorporated herein by reference in their entirety for all purposes. [Background technology]

[0002] Textile processing in industrial environments requires guiding moving fibers, usually in the form of fiber bundles, from one location to another. During such movement, the moving fibers often need to be guided by contact with at least one, and usually two or more, stationary guides, such as eyelets or other such guiding surfaces. Summary of the Invention [Problem to be solved by the invention]

[0003] Thus, the moving fibers come into contact with multiple such stationary points or surfaces, and at these contact points, friction exists that can easily break the delicate fibers in the bundle, resulting in the fiber bundle (sometimes called a tow) breaking. [Means for solving the problem]

[0004] According to one aspect of the present invention, a fiber guide configured to guide fibers in a fiber processing system is provided. The fiber guide includes a surface defining a plurality of openings through which fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening having an inlet positioned to receive fibers from the upstream side of the surface. The plurality of openings includes at least one pair of first and second openings adjacent to each other and spaced apart from each other. The inlet of a first opening of the at least one pair of first and second openings is offset from the inlet of a second opening of the at least one pair of first and second openings, the offset being in a direction through which the fibers can pass from the upstream side of the surface to the downstream side of the surface. A distance d1 between the inlet of the first opening and the inlet of the second opening is greater than a distance d2 between the first opening and the second opening measured transversely to the direction through which the fibers can pass. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 shows an example of an eyelet that can be used in an embodiment of the present invention. [Figure 2] Figure 2 shows the broken fiber. [Figure 3] Figure 3 shows the threads running parallel through the eyelets. [Figure 4] Figure 4 shows the threads running parallel through the eyelets. [Figure 5] Figure 5 shows the threads running parallel through the eyelets. [Figure 6] Figure 6 shows an eyelet board. [Figure 7] Figure 7 shows threads running parallel through the eyelets. [Figure 8] FIG. 8 shows an embodiment of an eyelet board according to an aspect of the present invention. [Figure 9] FIG. 9 shows another embodiment of an eyelet board according to an aspect of the invention. [Figure 10] Figure 10 shows the results of yarn collection over time. DETAILED DESCRIPTION OF THE INVENTION

[0006] The present invention provides a fiber guide that reduces breakage and the associated buildup and accumulation of fuzz or fluff and single fibers or threads or tows during processing of fibers, such as fibers used to reinforce composite materials. The fiber guide includes a series of openings, which may be lined with or have eyelets attached thereto. The openings are positioned in a specific relationship to one another. The eyelets themselves have geometric shapes and material properties.

[0007] More specifically, in the manufacture of fiber-reinforced composites, the fibers may be glass fibers, carbon fibers, aramid fibers, basalt fibers, or other fibrous materials. These fibers are typically in the form of a single thread or tow, each consisting of a single strand of fiber. As mentioned above, during processing, these single fibers tend to break, causing the fiber bundle to shred, whether in the form of a tow or thread.

[0008] Chopped fibers in the form of "fluff" or "fluff" tend to accumulate and then sometimes break. As such, the deposits can travel downstream with the fiber bundle and collect on process equipment. Furthermore, fiber breakage represents lost raw material, which is an economic problem. Therefore, the present invention provides a method for minimizing this fiber breakage without disrupting the operation of existing fiber processing equipment.

[0009] Composite materials require multiple tows or threads, each consisting of individual fiber bundles, to be processed together. For good performance, the threads should be individually guided. One common solution for collecting fibers of a specific shape is to use a surface, such as a board, with multiple openings formed therein. Thus, fibers, or fibers in the form of threads, are fed through multiple openings in the board, which guide them through the fiber processing operation. Each of these openings thus defines a guide surface for each tow or thread. These openings are typically defined by or may be lined with "eyelets" that act as individual guide surfaces for each tow or thread. In the following description, the terms "aperture" and "eyelet" should be understood to refer to the type of structure that defines the openings or guide openings in the eyelet board through which the fibers pass during processing.

[0010] 1 shows photographs of a number of different exemplary such eyelets. All of these exemplary eyelets are generally circular in cross section, although other cross-sectional shapes are possible, such as angular, rectangular, semicircular, etc. Additionally, while these eyelets are generally circular, they may be open on one side, for example, "U" or "C" shaped in cross section, with either a curved or straight side.

[0011] It has been discovered that the placement of the multiple openings that may be lined with these eyelets relative to one another on the eyelet board plays a role in the amount of fiber that breaks. These factors are discussed in more detail in the following description.

[0012] With respect to the relative position of the openings / eyelets to adjacent (nearby) eyelets, the eyelets are mounted "upstream", i.e., at the entrance of the openings in the board, so that multiple tows or yarns can be guided in the same direction during fiber processing. These boards are also called "eyelet boards."

[0013] As briefly mentioned above, so-called "fluff" or "fluff" deposits of fibers tend to accumulate on these eyelet boards. This buildup can result in breakdowns in fiber processing lines. This buildup of fibers on the eyelet boards, which guide the fibers from the spools to the creel, is a challenge in fiber processing and manufacturing of fiber-reinforced composites because, if the fluff deposit is substantial, it can travel downstream with the fibers to the next step in the composite manufacturing line. When a tow / yarn of fibers with a fluff deposit reaches a location for downstream processing, the fiber in the tow / yarn bundle attached to the fluff deposit can break, which can then cause adjacent fibers to break as well.

[0014] Figure 2 is a photograph of the initiation stage of such fuzz or fluff deposition on a bundle of fibers, such as a tow or yarn fiber. As can be seen in the photograph, the fuzz comprises many individual broken fibers as a result of chopping of the tow at the contact points (usually the eyelets).

[0015] A typical fluff deposition process on an eyelet board is as follows. Step 1 is shown diagrammatically in Figure 3. Two bundles of fibers 10, 12, also called yarns or tows, run parallel in the direction of the arrows and enter separate openings that may be lined with eyelets 14, 16, shown diagrammatically in cross section. These eyelets are mounted on the same surface, in this case a board, also called an eyelet board 18. A single severed fiber 20 is severed from the yarn 10. Note that a first end 22 of the fiber 20 is now free, while the remainder of the fiber 20 is still entrained within the bundle of fibers in the tow 10.

[0016] Step 2 is shown diagrammatically in Figure 4. As shown in Figure 4, as a first end 22 of the broken fiber 20 approaches the upstream side of an adjacent eyelet 16 or opening in the eyelet board 18, the end 22 of the broken fiber becomes pinched between adjacent yarns or tows 12 moving through the eyelet 16. As shown in Figure 4, the arrows indicate the direction in which the tows 10 and 12 are moving. Thus, the free end 22 becomes enmeshed within the adjacent tow 12, and the remainder of the single fiber 20 enmeshed within the tow 10 is pulled along with the remainder of the tow 10.

[0017] Step 3 is shown diagrammatically in FIG. 5. Because the free end 22 is sandwiched between the eyelet 16 and the tow 12, the other end of the fiber 20 is pulled through the eyelet 14 by the remainder of the tow 10. Thus, as shown in FIG. 5, the fiber 20 is deposited between the two eyelets 14 and 16. By repeating these steps 1-3 multiple times, the fiber 20 is deposited between two adjacent eyelets 14 and 16, thereby forming a U-shape or bridge between the two eyelets, i.e., between adjacent openings in the eyelet board surface, and generating a large amount of fuzz. It can be seen that as more fiber is deposited, friction on the eyelet or opening increases, thereby accelerating the cycle of breakage as more fibers break as they are pulled across the broken fibers trapped within the eyelet or opening.

[0018] Figure 6 shows a photograph of an example of such a U-shaped fuzz pile formed between two adjacent openings aligned with eyelets on the surface of an eyelet board. In addition to the direct problem of causing fiber loss over time, if the fuzz pile becomes too large, it can migrate with the tow or yarn, negatively impacting the next step in the fiber processing operation. For example, fuzz can accumulate in small holes and bridge the gap between two holes. As the fuzz pile grows, it eventually migrates with the tow. When it reaches the downstream slot plate, it cannot pass through, causing fiber tearing and subsequent fiber tearing, resulting in tow loss.

[0019] Surprisingly, the inventors have found that this phenomenon tends to significantly disappear when the distance between two adjacent openings / eyelets is greater than the length of a single broken fiber. Typically, this minimum distance is 25.4 mm or 2.5 cm for a typical carbon fiber, such as P35 carbon fiber available from Zoltek Corporation. However, in most cases, the purpose of the eyelet board is to guide or gather the yarns more closely together as they are formed into shapes or weaving or other processes required to form a composite in downstream processing. Therefore, the distance between yarns / tows in the eyelets in the openings should be significantly less than 2.5 cm, for example less than 20 mm, or less than 19 mm, or less than 18 mm, or less than 17 mm, or less than 16 mm, or less than 15 mm, or less than 14 mm, or less than 13 mm, or less than 12 mm, or less than 11 mm, or less than 10 mm, or less than 9 mm, or less than 8 mm, or less than 7 mm, or less than 6 mm, or less than 5 mm, or less than 4 mm, or less than 3 mm, or less than 2 mm, or even less than 1 mm.

[0020] Thus, the present invention is directed, in certain embodiments, to a fiber guide that minimizes yarn fuzz or fluff and the single fibers of the yarn that cause the buildup and accumulation of such fuzz / fluff. The inventors have determined that alternating offset inlet openings in an eyelet board allow for closer gathering of fiber tows while simultaneously minimizing the buildup of fuzz / fluff from broken fibers.

[0021] An example of a related geometric board configuration is shown schematically in Figure 7, which is a side cross-sectional view of multiple tows / yarns 26 passing through a plurality of eyelets 28 / apertures in an eyelet board 32. Figure 8 shows a side cross-sectional view of an exemplary offset pair of eyelets / apertures mounted within an eyelet board 34. As seen in Figure 8, an embodiment according to one aspect of the present invention, the tows / yarns 26 are guided through eyelets 36 and eyelets 38 that are offset from adjacent eyelets 36.

[0022] As shown in FIG. 8 , the offset between the plurality of eyelets / apertures 36 and the plurality of eyelets / apertures 38 can be defined by distances d1 and d2. To minimize the buildup of fuzz / fluff due to fiber breakage, the distance d1 between the entrance of the plurality of first apertures 36 and the plurality of second apertures 38 is greater than the distance d2, measured transversely to the direction indicated by the arrow through which the fiber tows / yarns 26 pass. For the avoidance of doubt, these distances d1 and d2 can be considered to be measured from the upstream end of the adjacent plurality of apertures that guide the incoming fibers. In the embodiment shown in FIG. 8 , this is the location where the passage opening of the aperture is smallest. Therefore, the diameter of the plurality of apertures is not a factor in measuring these distances.

[0023] Without being bound by theory, it is possible that when one set of eyelets is offset from another adjacent set of eyelets, the U-shape or bridge is unbalanced so that no fuzz can be deposited, and therefore even the tip of the first broken fiber cannot be deposited, and therefore the acceleration cycle of the broken fiber may never begin.

[0024] Figure 9 shows a photograph of an exemplary such eyelet board utilizing multiple offset eyelets within multiple openings in the eyelet board surface to guide the fiber tows. Example 1 (below) shows results regarding the amount of fuzz deposition (grams / hour) from the eyelet board shown in Figure 6 compared to the amount of fuzz collected from the eyelet board shown in Figure 9.

[0025] Exemplary aspects of the present invention are as follows. Aspect 1: 1. A fiber guide configured to guide fibers in a fiber processing system, the fiber guide comprising: a surface defining a plurality of openings through which fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening having an inlet positioned to receive a fiber from the upstream side of the surface; The plurality of openings include at least one pair of first and second openings adjacent to each other and spaced apart from each other; An entrance of a first opening of the at least pair of first and second openings is offset from an entrance of a second opening of the at least pair of first and second openings, the offset being in a direction in which fibers can pass from the upstream side of the surface to the downstream side of the surface, and a distance d1 between the entrance of the first opening and the entrance of the second opening is greater than a distance d2 between the first opening and the second opening measured transversely to the direction in which fibers can pass.

[0026] Aspect 2: The fiber guide of embodiment 1 further comprises a board defining a surface and a plurality of eyelets coupled to the board at positions corresponding to the selected plurality of openings and defining entrances to the selected plurality of openings.

[0027] Aspect 3: In the fiber guide according to either of the first and second aspects, the entrance of the first opening is offset from the surface of the board.

[0028] Aspect 4: In the fiber guide according to any one of aspects 1 to 3, the distance d1 between the entrance of the first opening and the entrance of the second opening is 25.4 mm or more, and the distance d2 between the first opening and the second opening measured across the direction in which the fiber can pass is less than 25.4 mm.

[0029] Aspect 5: The fiber processing system a source of fiber; a fiber guide disposed downstream from the fiber source, the fiber guide configured to guide the fibers as they are received from the fiber source; a surface defining a plurality of openings through which fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening having an inlet positioned to receive a portion of the fibers from the upstream side of the surface; The plurality of openings include at least one pair of first and second openings adjacent to each other and spaced apart from each other; The entrance of a first opening of the at least pair of first and second openings is offset from the entrance of a second opening of the at least pair of first and second openings, the offset being in a direction in which fibers can pass from the upstream side of the surface to the downstream side of the surface, thereby increasing the distance d1 between the entrance of the first opening and the entrance of the second opening compared to the distance d2 between the first opening and the second opening measured transversely to the direction in which fibers can pass.

[0030] Aspect 6: In the fiber processing system of embodiment 5, the fiber guide further includes a board defining a surface and a plurality of eyelets coupled to the board at positions corresponding to the selected plurality of openings, the plurality of eyelets defining entrances to the selected plurality of openings.

[0031] Aspect 7: 1. A system for guiding fibers traveling along substantially parallel paths between an upstream location and a downstream location, comprising: a fiber guide defining at least a pair of fiber guide passages, the fiber guide being positioned between the upstream position and the downstream position; Each fiber guide passage has a guide opening configured to receive a portion of the fiber as the fiber moves between the upstream position and the downstream position, each of the guide openings being defined by a guide surface; The fiber guide passages of the pair of fiber guide passages are spaced apart from each other and are disposed close to each other; The guide surface of one of the pair of fiber guide passages is close to the guide surface of the guide opening of the other of the pair of fiber guide passages, and the position of the guide surface of the guide opening of one of the pair of fiber guide passages is located upstream in the direction along the path relative to the guide surface of the guide opening of the other of the pair of fiber guide passages.

[0032] Aspect 8: 1. A method for guiding fibers in a fiber processing system, the method comprising: passing the fibers through a plurality of openings defined in the surface in a direction from an upstream side of the surface to a downstream side of the surface, each opening having an inlet positioned to receive a portion of the fibers from the upstream side of the surface; A step of maintaining at least one pair of first and second openings adjacent to each other and spaced apart from each other, wherein an inlet of a first opening of the at least one pair of first and second openings is offset from an inlet of a second opening of the at least one pair of first and second openings, the offset being in a direction of fiber passage from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the direction of fiber passage.

[0033] Aspect 9: The method of embodiment 8 further includes passing the fibers through a plurality of openings defined in the board and a plurality of eyelets coupled to the board at locations corresponding to the selected plurality of openings, the plurality of eyelets defining entrances to the selected plurality of openings.

[0034] Aspect 10: 1. A method of configuring a fiber guide to reduce fiber deposition within the fiber guide, the fiber guide having a surface defining a plurality of openings through which fibers can pass in a direction from an upstream side to a downstream side of the surface, the method comprising: maintaining at least one pair of first and second openings adjacent to each other and spaced apart from each other; and offsetting an inlet of a first opening of the at least one pair of first and second openings from an inlet of a second opening of the at least one pair of first and second openings, the offset being in a direction in which the fibers pass from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers pass.

[0035] Aspect 11: The method of embodiment 10 further includes coupling a plurality of eyelets to the board at locations corresponding to the selected plurality of openings, the plurality of eyelets defining entrances to the selected plurality of openings.

[0036] (example) Example 1: The amount of fluff deposition (grams / hour) from the eyelet board shown in FIG. 6 was compared to the amount of fluff deposition collected from the eyelet board shown in FIG. The fibers were threaded for 1 hour through the eyelet board shown in Figure 6 (without offset adjacent eyelets). The fibers were then threaded for 1 hour through the eyelet board shown in Figure 9 (with offset adjacent eyelets). When each line was stopped, the fuzz deposited on each type of board was weighed and compared. The process conditions and results are shown in Tables 1 and 2, respectively.

[0037] [Table 1]

[0038] [Table 2]

[0039] As can be seen from Table 2, the use of offset eyelets reduces the amount of fuzz buildup on the eyelet board by approximately three times.

[0040] Example 2: Long-term experiment on the effect of offset eyelets Next, a similar experiment to Example 1 was conducted, but two eyelet boards (with and without adjacent eyelets) were used on two separate fiber-lines for 18 days. Fluff was collected every two hours, and the average grams per hour for each day was calculated. These data are shown in Figure 10 for each date. Note that on January 5th, the line using the eyelet board with offset eyelets went down for reasons unrelated to fluff deposition on the eyelet board. However, when the line was operational, the global trend for the offset eyelets was significantly lower fluff deposition than for the non-offset eyelets. Over the course of the experiment (for days when both lines were running), approximately 73% less fluff was deposited on the line utilizing the offset eyelets. Also note that the amount of fluff generated appears to decrease over time for the offset eyelets, which may be due to a starting effect.

[0041] For Examples 1 and 2, it is clear that the use of offset eyelets significantly reduces the amount of fuzz buildup on the eyelet board (-73%).

[0042] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications can be made in the details within the scope and range of equivalents of the claims without departing from the invention.

[0043] While preferred embodiments of the present invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous modifications, changes, and substitutions will occur to those skilled in the art without departing from the spirit of the invention. It is therefore intended that the appended claims cover all such modifications as come within the spirit and scope of the invention. According to aspect (1), there is provided a fiber guide configured to guide fibers in a fiber processing system, comprising: The fiber guide is a surface defining a plurality of openings through which the fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening including an inlet positioned to receive the fibers from the upstream side of the surface; the plurality of openings include at least one pair of a first opening and a second opening adjacent to each other and spaced apart from each other; the inlet of the first opening of the at least pair of first and second openings is offset from the inlet of the second opening of the at least pair of first and second openings, the offset being in a direction that allows the fiber to pass from the upstream side of the surface to the downstream side of the surface, and a distance d1 between the inlet of the first opening and the inlet of the second opening is greater than a distance d2 between the first opening and the second opening measured transversely to the direction that allows the fiber to pass. According to aspect (2), the device further comprises a board defining the surface and a plurality of eyelets coupled to the board at positions corresponding to a plurality of selected openings, the plurality of eyelets defining the entrances to the plurality of selected openings. According to aspect (3), the entrance of the first opening is offset from the surface of the board. According to aspect (4), the distance d1 between the entrance of the first opening and the entrance of the second opening is 25.4 mm or more, and the distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers can pass is less than 25.4 mm. According to aspect (5), there is provided a fiber processing system, a source of fiber; a fiber guide disposed downstream from the fiber source, the fiber guide configured to guide the fibers as they are received from the fiber source; The fiber guide is a surface defining a plurality of openings through which the fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening including an inlet positioned to receive a portion of the fibers from the upstream side of the surface; the plurality of openings include at least one pair of a first opening and a second opening adjacent to each other and spaced apart from each other; The fiber processing system, wherein the inlet of the first opening of the at least pair of first and second openings is offset from the inlet of the second opening of the at least pair of first and second openings, the offset being in a direction in which the fibers can pass from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers can pass. According to aspect (6), the fiber guide further includes a board defining the surface and a plurality of eyelets coupled to the board at positions corresponding to a plurality of selected openings, the plurality of eyelets defining the entrances to the plurality of selected openings. According to aspect (7), there is provided a system for guiding fibers moving along substantially parallel paths between an upstream location and a downstream location, the system comprising: The system comprises: a fiber guide defining at least a pair of fiber guide passages, the fiber guide being positioned between the upstream location and the downstream location; each fiber guide passage having a guide opening configured to receive a portion of the fiber as the fiber moves between the upstream position and the downstream position, each guide opening being defined by a guide surface; The pair of fiber guide passages are spaced apart from each other but are positioned close to each other; the guide surface of the guide opening of one of the pair of fiber guide passages is adjacent to the guide surface of the guide opening of the other of the pair of fiber guide passages, A system in which the position of the guide surface of the guide opening of one of the pair of fiber guide passages is located upstream in a direction along the path relative to the guide surface of the guide opening of the other of the pair of fiber guide passages. According to aspect (8), there is provided a method for guiding fibers in a fiber processing system, comprising: The method comprises: passing the fibers through a plurality of openings defined in the surface in a direction from an upstream side of the surface to a downstream side of the surface, each opening having an inlet positioned to receive a portion of the fibers from the upstream side of the surface; maintaining at least one pair of first and second openings adjacent to and spaced apart from one another, wherein the inlet of the first opening of the at least one pair of first and second openings is offset from the inlet of the second opening of the at least one pair of first and second openings, the offset being in a direction of fiber passage from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the direction of fiber passage. According to aspect (9), the method further includes passing the fibers through a plurality of openings defined in a board at positions corresponding to a plurality of selected openings and a plurality of eyelets coupled to the board, the plurality of eyelets defining the entrances to the selected plurality of openings. According to aspect (10), there is provided a method for configuring a fiber guide that reduces fiber accumulation in the fiber guide, the method comprising: the fiber guide having a surface defining a plurality of openings through which fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface; The method comprises: maintaining at least one pair of first and second openings adjacent to each other and spaced apart from each other; offsetting an inlet of the first opening of the at least pair of first and second openings from an inlet of the second opening of the at least pair of first and second openings, the offset being in a direction of fiber passage from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the direction of fiber passage. According to aspect (11), the method further includes a step of coupling a plurality of eyelets to the board at positions corresponding to a plurality of selected openings, the plurality of eyelets defining the entrances to the plurality of selected openings.

Claims

1. 1. A fiber guide configured to guide fibers in a fiber processing system, comprising: The fiber guide is the surface defining a plurality of openings through which the fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening including an inlet positioned to receive the fibers from the upstream side of the surface; a board defining said surface; a plurality of eyelets coupled to the board at locations corresponding to selected ones of the plurality of openings; and the plurality of openings include at least one pair of a first opening and a second opening adjacent to each other and spaced apart from each other; a plurality of said eyelets defining said entrances to selected said plurality of openings; the inlet of the first opening of at least one pair of the first opening and the second opening is offset from the inlet of the second opening of at least one pair of the first opening and the second opening, the offset being in a direction in which the fibers can pass from the upstream side of the surface to the downstream side of the surface, and a distance d1 between the inlet of the first opening and the inlet of the second opening is greater than a distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers can pass; one of the plurality of eyelets and the adjacent other eyelet are attached to the board in an alternately offset manner, and one of the eyelets has a cylindrically formed main body portion extending toward the upstream side and a first annular edge portion formed at an end of the main body portion on the side offset toward the upstream side from the surface of the board, and the other eyelet is connected to the board and has a second annular edge portion located downstream of the first edge portion, The entrances of selected ones of the plurality of openings are formed in the first edges of a plurality of the eyelets and in the second edges of a plurality of the eyelets.

2. 2. The fiber guide of claim 1, wherein a distance d1 between the entrance of the first opening and the entrance of the second opening is 25.4 mm or more, and a distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers can pass is less than 25.4 mm.

3. 1. A fiber processing system comprising: a source of fiber; a fiber guide disposed downstream from the fiber source, the fiber guide configured to guide the fibers as they are received from the fiber source; The fiber guide is the surface defining a plurality of openings through which the fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface, each opening including an inlet positioned to receive a portion of the fibers from the upstream side of the surface; a board defining said surface; a plurality of eyelets coupled to the board at locations corresponding to selected ones of the plurality of openings; and the plurality of openings include at least one pair of a first opening and a second opening adjacent to each other and spaced apart from each other; a plurality of said eyelets defining said entrances to selected said plurality of openings; the inlet of the first opening of at least one pair of the first opening and the second opening is offset from the inlet of the second opening of at least one pair of the first opening and the second opening, the offset being in a direction in which the fibers can pass from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the direction in which the fibers can pass; one of the plurality of eyelets and the adjacent other eyelet are attached to the board in an alternately offset manner, and one of the eyelets has a cylindrically formed main body portion extending toward the upstream side and a first annular edge portion formed at an end of the main body portion on the side offset toward the upstream side from the surface of the board, and the other eyelet is connected to the board and has a second annular edge portion located downstream of the first edge portion, The fiber processing system, wherein the inlets of selected ones of the plurality of openings are formed in the first edges of a plurality of the eyelets and in the second edges of a plurality of the eyelets.

4. 1. A method for guiding fibers in a fiber processing system, comprising: The method comprises: passing the fibers through a plurality of openings defined in the surface in a direction from an upstream side of the surface to a downstream side of the surface, each opening having an inlet positioned to receive a portion of the fibers from the upstream side of the surface; maintaining at least one pair of first and second openings adjacent to and spaced apart from one another, wherein the inlet of the first opening of the at least one pair of first and second openings is offset from the inlet of the second opening of the at least one pair of first and second openings, the offset being in a direction of fiber passage from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the fiber passage direction; and passing the fibers through openings defined in a board defining the surface and through a plurality of eyelets coupled to the board at locations corresponding to the selected openings; a plurality of said eyelets defining said entrances to selected said plurality of openings; one of the plurality of eyelets and the adjacent other eyelet are attached to the board in an alternately offset manner, and one of the eyelets has a cylindrically formed main body portion extending toward the upstream side and a first annular edge portion formed at an end of the main body portion on the side offset toward the upstream side from the surface of the board, and the other eyelet is connected to the board and has a second annular edge portion located downstream of the first edge portion, The method, wherein the entrances of the plurality of apertures are formed in the first edges of a plurality of the eyelets and in the second edges of a plurality of the eyelets.

5. 1. A method of configuring a fiber guide that reduces fiber buildup on the fiber guide, comprising: the fiber guide having a surface defining a plurality of openings through which fibers can pass in a direction from an upstream side of the surface to a downstream side of the surface; The method comprises: maintaining at least one pair of first and second openings adjacent to each other and spaced apart from each other; offsetting an inlet of the first opening of at least one pair of the first opening and the second opening from an inlet of the second opening of at least one pair of the first opening and the second opening, the offset being in a direction of fiber passage from the upstream side of the surface to the downstream side of the surface, thereby increasing a distance d1 between the inlet of the first opening and the inlet of the second opening compared to a distance d2 between the first opening and the second opening measured transversely to the fiber passage direction; and coupling a plurality of eyelets to a board defining the surface at locations corresponding to the plurality of selected openings; the plurality of eyelets define the entrances to selected of the plurality of openings; one of the eyelets and the adjacent other eyelet are attached to the board in an alternately offset manner, one of the eyelets having a cylindrically formed main body extending toward the upstream side and a first annular edge formed at an end of the main body on the side offset toward the upstream side from the surface of the board, and the other eyelet having a second annular edge connected to the board and located downstream of the first edge, The method, wherein the entrances of the plurality of apertures are formed in the first edges of a plurality of the eyelets and in the second edges of a plurality of the eyelets.

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