Fiber opening apparatus

Abstract

A fiber opener including at least one set of adjacent rotating members having a shaft with the adjacent rotating members positioned relative to each other to provide at least one pinch point between the adjacent rotating members. The fiber opener includes a plurality of fiber opener teeth that are removably connected to the shaft.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Nos. 63 / 711,738 filed Oct. 24, 2024, and 63 / 883,737 filed Sep. 18, 2025, the disclosures of which are hereby incorporated in their entirety by reference herein.TECHNICAL FIELD

[0002] The disclosure is directed to a fiber opening apparatus having rotating members with removable fiber opening teeth.BACKGROUND

[0003] Traditional fiber opening systems have been developed for the textile industry. Typically, the systems separate one material from another such as cotton fibers from undesirable materials. These systems typically function by loosening, separating, and opening compressed bales of fibers, such as cotton, wool, or synthetic materials and remove undesirable materials from further processing. Traditional fiber opening systems utilize rotating members that are provided with a series of teeth that are welded to the members to create a single unit.SUMMARY

[0004] According to at least one embodiment, a fiber opener is disclosed. The fiber opener may include at least one set of adjacent rotating members, each rotating member having a shaft with a proximal end and a distal end. The adjacent rotating members may be positioned relative to each other to provide at least one pinch point between the adjacent rotating members. The fiber opener may also include a plurality of fiber opener teeth that are removably connected to the shaft. The plurality of fiber opener teeth may be structured to separate fibers from one another as input fiber passes through the at least one pinch point. The shaft of the rotating member may have a slot extending along a length of the shaft from the proximal end to the distal end of the shaft. The shaft of the rotating member may have a slot disposed between the proximal end and the distal end of the shaft. The fiber opener may be provided with a bearing connected to the proximal end of the shaft, wherein the bearing is adapted to cooperate with a driving mechanism to drive the at least one set of adjacent rotating members. The plurality of fiber opener teeth may be provided with an aperture that has at least one groove, or raised opening, extending from the aperture. The plurality of fiber opener teeth may not be permanently connected to one another. The slot may protrude from the shaft to create a raised portion on the shaft. The at least one raised opening or groove of the plurality of fiber opener teeth is sized to receive the corresponding protrusion of the shaft to enable the plurality of fiber opener teeth to be removably connected to the shaft. Alternatively, the at least one raised opening (groove) of the plurality of fiber opener teeth corresponds with a recessed slot in the shaft, and wherein the raised opening of the plurality of fiber opener teeth and the recessed slot in the shaft are sized to receive a key stock to enable the plurality of fiber opener teeth to be removably connected to the shaft. The plurality of fiber opener teeth may be provided with a first segment extending from the aperture and a second segment extending from the aperture, spaced apart from the first segment. The first segment and the second segment may form a curved shape between them. The first segment of the plurality of fiber opener teeth may be provided with a base which gradually narrows at a top portion of the first segment. The second segment of the plurality of fiber opener teeth may be provided with a base which gradually narrows at a top portion of the second segment. The fiber opener may be further provided with a hard stop / lock connected to the distal end of the shaft to keep the plurality of fiber opener teeth stationary on the shaft. The fiber opener may also include a spacer removably connected to the shaft. The spacer may be provided with at least one groove. A distance between each of the plurality of fiber opener teeth may be adjustable on the shaft.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 shows a non-limiting example of a fiber opener according to one or more embodiments disclosed herein;

[0006] FIGS. 2 and 3 show a non-limiting example of a single roller bank of the fiber opener shown in FIG. 1;

[0007] FIGS. 4 to 7 are various views of a non-limiting example shaft of the rotating member according to one or more embodiments disclosed herein;

[0008] FIGS. 8 and 9 are perspective views of a non-limiting example rotating member of the roller bank according to one or more embodiments disclosed herein;

[0009] FIGS. 10 and 11 are enlarged end views of a non-limiting example rotating member of the roller bank according to one or more embodiments disclosed herein;

[0010] FIGS. 12 to 14 are various views of a non-limiting example tooth component of the rotating member according to one or more embodiments disclosed herein;

[0011] FIGS. 15 and 16 show exploded views of a non-limiting example rotating member according to one or more embodiments disclosed herein;

[0012] FIGS. 17 to 19 are various views of non-limiting example spacer and tooth component of the rotating member according to one or more embodiments disclosed herein; and

[0013] FIGS. 20 to 22 are various views of a non-limiting example washer component of the rotating member according to one or more embodiments disclosed herein;

[0014] FIG. 23 shows an exploded view of a non-limiting example housing of the roller bank according to one or more embodiments disclosed herein;

[0015] FIGS. 24 and 25 are various views of a non-limiting example housing of the roller bank according to one or more embodiments disclosed herein; and

[0016] FIG. 26 shows a front view of non-limiting example slider plate component for the housing according to one or more embodiments disclosed herein.DETAILED DESCRIPTION

[0017] Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

[0018] Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and / or use are to be understood as modified by the word “about” in describing the broadest scope of the disclosure. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the disclosure implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed. Unless stated otherwise, the wt. % is based on the total weight of the substrate and the vol. % is based on the total volume of the substrate.

[0019] The first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.

[0020] It must also be noted that, as used in the specification and the appended claims, the singular form “a,”“an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

[0021] As used herein, the term “substantially,”“generally,” or “about” means that the amount or value in question may be the specific value designated or some other value in its neighborhood. Generally, the term “about” denoting a certain value is intended to denote a range within + / −5% of the value. As one example, the phrase “about 100” denotes a range of 100+ / −5, i.e. the range from 95 to 105. Generally, when the term “about” is used, it can be expected that similar results or effects according to the disclosure can be obtained within a range of + / −5% of the indicated value. The term “substantially” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” may signify that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.

[0022] It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4, . . . , 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits. Similarly, whenever listing integers are provided herein, it should also be appreciated that the listing of integers explicitly includes ranges of any two integers within the listing.

[0023] As used herein, the term “and / or” means that either all or only one of the elements of said group may be present. For example, “A and / or B” means “only A, or only B, or both A and B”. In the case of “only A,” the term also covers the possibility that B is absent, i.e. “only A, but not B”.

[0024] It is also to be understood that this disclosure is not limited to the specific embodiments and methods described below, as specific components and / or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present disclosure and is not intended to be limiting in any way.

[0025] The term “comprising” is synonymous with “including,”“having,”“containing,” or “characterized by.” These terms are inclusive and open-ended and do not exclude additional, unrecited elements or method steps. The term “including” or “includes” may encompass the phrases “comprise,”“consist of,” or “essentially consist of.”

[0026] The phrase “consisting of” excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0027] The phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.

[0028] With respect to the terms “comprising,”“consisting of,” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed subject matter can include the use of either of the other two terms.

[0029] The term “one or more” means “at least one” and the term “at least one” means “one or more.” The terms “one or more” and “at least one” include “plurality” as a subset.

[0030] The description of a group or class of materials as suitable for a given purpose in connection with one or more embodiments implies that mixtures of any two or more of the members of the group or class are suitable. Also, the description of a group or class of materials as suitable for a given purpose in connection with one or more embodiments implies that the group or class of materials can “comprise,”“consist of,” and / or “consist essentially of” any member or the entirety of that group or class of materials. First definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.

[0031] Various equipment has been developed for operations with natural and synthetic fiber. With the need for textile production, various machinery has been developed to collect and separate textile fibers such as carding machines for cotton. Majority of the textile fiber openers focus on removing unwanted material from fiber collected on the fields. Typically, the plant fiber is harvested and compressed into bales. Yet, the bales contain many unwanted materials unsuitable for textile production. Various opening apparati have thus been designed to separate the unwanted material from the desirable fiber. Typically, such apparati thus separate one material from another.

[0032] It has been found that such machinery is typically not suitable for fiber separation in the horticultural industry. Just like in the textile industry, fiber, such as wood and / or bark fiber, used for horticultural purposes is compressed into bales for transportation purposes. Yet unlike in the textile industry, the horticultural fiber is used in its entirety. The fibers are of uniform material with no portion to be discarded. The fibers need to be merely separated from one another to a certain degree while generally preserving their integrity, particle distribution, and other properties.

[0033] One of the reasons the textile machinery is not suitable for the horticultural fiber opening is the structure and arrangement of rotating elements and teeth included on the rotating elements. For example, in situations with higher volumes of input fiber, the rotating members get clogged up and the teeth on the textile rotating members typically wear down quickly or become damaged. The damage may lead to inconsistent fiber opening results. However, with traditional fiber opening systems, no singular section or tooth on the rotating members can be replaced. Rather, the entire rotating member must be removed from the system and replaced. This often requires a significant amount of time as well as cost.

[0034] Therefore, it would be desirable to develop a fiber opening system which can deliver more consistent fiber opening results and provide more economical and efficient replacement.

[0035] In one or more embodiments, a fiber opener is disclosed. The fiber opener may include at least one or more of the following sections: a transportation section, a fiber bale breaker, a feeder, a fiber opener, an input section, a mixing section, or a combination thereof. Some or all of these sections may be attached to one another, either temporarily or permanently. The plurality of sections may be arranged in more than one order to achieve an equivalent result. The fiber opener may be connected to other production systems, temporarily or permanently. The number and dimensions of each section will depend on requirements of a specific application.

[0036] FIG. 1 illustrates a non-limiting example of a fiber opener 20. As shown in FIG. 1, the fiber opener 20 includes a transportation section 22 and a fiber opener section 24. The transportation section 22 may deliver a bale of fiber to other sections of the fiber opener 20, to another production system, or outside of the fiber opener 20. The transportation section 22 may include any kind of transportation device capable of fulfilling this function. The transportation section 22 may include a conveyor, such as a conveyor belt, a screw conveyor, an angled conveyor, a platform, an auger, a bucket elevator, an apron, or the like. The surface of the transportation section 22 may be roughened to prevent slipping of the bales or fibers. Alternatively, the transportation section 22 may have a smooth surface according to another embodiment. The transportation section 22 may further include one or more removable inserts for adjusting dimensions of an opening to accommodate different sizes of bales or fibers.

[0037] The fiber opener 20 is also provided with the fiber opener section 24. In traditional fiber opener systems, this section includes at least two stacks of rotating members or roller banks. The first roller bank would be utilized to cut the fibers, and the second roller bank would be utilized to expand the fibers and make them relatively fluffy or decrease the fiber density. Due to the requirement of two sets of rotating members, traditional fiber opener systems are generally large, heavy, and costly. In contrast, the herein-disclosed fiber opener section 24 includes a single roller bank 58, as shown in FIGS. 2-3. The roller bank 58 is a singular unit. The benefits of having a single roller bank 58 within the fiber opener 20 is that the roller bank 58 can effectively perform the same task as the two roller banks that traditional fiber opener systems use while having a reduction in manufacturing costs and assembly time, an increase in transportation efficiency of the equipment, etc., compared to traditional fiber opener systems.

[0038] The single roller bank 58 may include a housing 66 and at least one set of rotating members 26 that are located within the housing 66. The rotating members 26 are positioned relative to each other to provide at least one pinch point 80 between the rotating members 26. The rotating members 26 are adjacent to each other, run parallel to each other, or both. Each rotating member 26 includes a shaft 28. The shaft 28 has a proximal end 30, a distal end 32, and may include a plurality of fiber opener teeth 34. The shaft 28 may be cylindrical, rectangular, triangular, or have any other appropriate shape to accommodate the plurality of fiber opener teeth 34. Additionally, the plurality of fiber opener teeth 34 are structured to separate individual fibers from one another, lower density of the input fiber, or both, as input fiber passes through the at least one pinch point 80.

[0039] FIGS. 4-7 show a non-limiting example of the shaft 28 in greater detail. The shaft 28 may include a slot 36, a non-limiting example of which is shown in FIGS. 4 and 7. The slot 36 may extend along the length of the shaft 28 from the proximal end 30 to the distal end 32. Alternatively, the slot 36 may be disposed between the proximal end 30 and the distal end 32. The shaft 28 may be provided with a single slot 36 that extends on one side of the shaft 28, as shown in FIGS. 4 and 5. FIG. 4 illustrates the slot 36 of the shaft 28. FIG. 5 illustrates the shaft 28, illustrating the side of the shaft 28 that is opposing the slot 36. The shaft 28 may be provided with multiple slots as opposed to a singular slot. For example, the shaft 28 may have 1, 2, 3, 4, 5, 6, 7, 8, 9, or more slots.

[0040] With continued reference to FIGS. 4-7, as well as FIGS. 8-11, the shaft 28 may include a lock 68, provided on the distal end 32 of the shaft 28 to prevent the plurality of fiber opener teeth 34 from sliding off the shaft 28. The lock 68 may be connected with the shaft 28, creating one component. Alternatively, the lock 68 may be a separate, removable component from the shaft 28. The shaft 28 also includes a threaded engagement area 40 located towards the proximal end 30 of the shaft 28. A compression nut 54 may be provided on the threaded engagement area 40 of the shaft 28, as shown in FIGS. 10-11. The compression nut 54 may be placed on the shaft 28 after the plurality of fiber opener teeth 34 are on the shaft 28 to prevent the teeth 34 from sliding off the shaft 28. The compression nut 54 may be located on an interior portion of the housing 66 when the rotating members 26 are placed in the roller bank 58. The shaft 28 may be driven by a belt or chain once the plurality of fiber opener teeth 34 are located on the shaft 28.

[0041] The shaft 28 further includes a spacer 70 and a lock washer 72, each of which is described in more detail below with regards to FIGS. 17-22. As shown in FIGS. 8-9, in at least one embodiment, the arrangement of the components on the rotating members 26 is: lock 68, tooth 34, spacer 70, tooth 34, spacer 70, . . . , spacer 70, lock washer 72, and compression nut 54. The shaft 28 may also include at least one bearing 74 located at the proximal end 30, the distal end 32, or both. When the bearing 74 is located at the proximal end 30 of the shaft 28, the bearing 74 is placed on a portion of the shaft 28 outside of the housing 66.

[0042] As previously stated, the shaft 28 is sized to receive the plurality of fiber opener teeth 34. The fiber opener teeth 34 may be removably or engagingly connected to the shaft 28. The teeth 34 may be repeatedly movable to and from the shaft 28. In at least one embodiment, the teeth 34 may be removably connected to the shaft 28 between the lock 68, and the compression nut 54. When the lock 68 and the compression nut 54 are in place, the teeth 34 remain connected to the shaft 28, but when the compression nut 54 is removed, the teeth 34 may be removed, or slidingly disengaged, from the shaft 28. Additionally, any singular component of the plurality of fiber opener teeth 34 may be removably disengageable from the shaft 28. Further, the plurality of fiber opener teeth 34 and the shaft 28 have an opening from disengageably receiving the other of the plurality of fiber opener teeth 34 and the shaft 28. This feature is advantageous in contrast to traditional fiber opening systems in which the teeth are welded to the shaft, or otherwise permanently affixed to the shaft. In situations where a singular tooth on the shaft becomes damaged, there is no way of fixing it without removing and replacing the entire part with a new shaft and a new set of teeth. In the present disclosure, the ability to keep the plurality of fiber opener teeth 34 connected to the shaft 28 without permanently affixing the components together is beneficial because should a tooth component become damaged, this enables only the damaged tooth component to be replaced, rather than the entire tooth assembly. The shaft 28 and the teeth 34 are thus free of a weld or another permanent connection between each other. In other words, the teeth 34 and the shaft 28 are not permanently connected to each other. The ability to replace a singular component requires much less time and is less expensive than replacing the entire shaft with all the teeth.

[0043] FIGS. 12-14 illustrate a non-limiting example of a singular tooth component of the plurality of fiber opener teeth 34. The tooth 34 may include an aperture 42. The aperture 42 may be located centrally or be provided in a central location of the tooth 34. Alternatively, the aperture 42 may be located in a non-central location of the tooth 34 or be offset with respect to the central axis of the tooth 34. The aperture 42 may include at least one groove or raised opening 44 extending from the aperture 42. As shown in FIG. 12-14, the aperture 42 includes two raised openings 44 (or grooves), however, any number of raised openings is contemplated.

[0044] In one embodiment, the raised opening 44 of the aperture 42 of the plurality of fiber opener teeth 34 is sized to match the size of the slot 36 of the shaft 28. The raised opening 44 and the slot 36 may be further defined as recessed portions. The raised opening 44 and the slot 36 may be sized to receive a key stock 82, as shown in FIGS. 15-16. In one example, the key stock 82 is first received by the slot 36 in the shaft 28; and then the fiber opener teeth 34 are slid over the shaft 28 and key stock 82. In another example, the fiber opener teeth 34 are first slid onto the shaft 28; and then the key stock 82 is extended through the raised opening 44 of the aperture 42 of the plurality of fiber opener teeth 34 and the slot 36 of the shaft 28 to connect the plurality of fiber opener teeth 34 to the shaft 28. Once the key stock 82 is removed from the slot 36 and the raised opening 44, the plurality of fiber opener teeth 34 may be freely removed from the shaft 28.

[0045] In another embodiment, the raised opening 44 of the aperture 42 may be sized to correspond to the size of the slot 36 of the shaft 28. The slot 36 may protrude from the shaft 28, creating a raised portion on the shaft 28. The groove 44 may include one or more recessed portions. The raised portion 44 of the plurality of fiber opener teeth 34 may be sized to slide over the protrusion of the slot 36 on the shaft 28. This can effectively connect the teeth 34 to the shaft 28 and prevent the teeth 34 from rotating freely on the shaft 28. Alternatively, the slot 36 may include one or more recessed portions and the raised portion 44 of the plurality of fiber opener teeth may be protrusions from the aperture 42.

[0046] The plurality of fiber opener teeth 34 may include one or more segments. As is shown in FIGS. 12-14, a tooth 34 may include a first segment 46 and a second segment 48. The second segment 48 is spaced apart from the first segment 46. The first segment 46 and the second segment 48 both extend from the aperture 42. The first segment 46 is provided with a base 62 which gradually narrows at a top portion 50 of the first segment 46. The second segment 48 is provided with a base 64 which gradually narrows at a top portion 52 of the second segment 48. The first segment 46 and the second segment 48 form a curved shape between them to aid in decreasing the fiber density. The tooth 34 may include two first and two second segments. In the illustrated embodiment, there are four total segments shown in the plurality of fiber opener teeth 34. In the shown embodiments, each segment, as discussed with the first segment 46 and the second segment 48, all have a curved shape between them and the segments gradually narrow at their respective top portions. The four segments shown are also equal in size. Yet any number, size, and shape of the segments and teeth is contemplated.

[0047] For example, a tooth 34 may include two or more identical or non-identical segments. The segments may be all sized and shaped differently or identically. Alternatively, a first portion of the teeth may have the same size and shape while a second portion of the teeth may differ from the first portion in size, shape, or both. For example, a first portion of the teeth may have a different thickness or width than a second portion of the teeth. The first and second portions may alternate or be provided in blocks of x number of teeth in a row. The blocks may be alternating.

[0048] The individual teeth 34 may be all aligned on the shaft in the same way, forming a continuous curved shape between aligned segments, as is shown in FIGS. 8 and 9. Alternatively, at least some of the teeth may be offset such that the segments do not align precisely. The offset may be gradual such that the curve forms a spiral along the length of the shaft. The segments may be offset by a certain degree such as 20 to 90, 25 to 75, or 30 to 65 degrees.

[0049] Referring to FIGS. 17-19, a non-limiting example of the spacer 70 is illustrated in more detail. One or more spacers 70 may be included between the individual teeth 34. The spacer 70 may vary in size or thickness so as to adjust the distance between the individual teeth 34. In one embodiment, the end spacer 70 that is placed on the shaft 28 is of a smaller size than the other spacers 70 distributed on the shaft 28. The spacer 70 may be cylindrical, rectangular, or have any other appropriate shape to fit between the teeth 34 and on the shaft 28. The spacer 70 may be removably connected to the shaft 28. The spacer 70 may include an aperture 60 and at least one raised opening or groove 56 extending from the aperture 60. The raised opening 56 may be further defined as a recessed portion and may be sized to receive the key stock 82. In one embodiment, the raised opening (i.e., groove) 56 of the spacer 70 is designed to align with the raised opening 44 of the plurality of fiber opener teeth 34 and the slot 36 of the shaft 28. In one example, the key stock 82 is first received by the slot 36 in the shaft 28; and then the plurality fiber opener teeth 34 and the spacer 70 are slid onto the shaft 28. In another example, the plurality of fiber opener teeth 34 and the spacer 70 are first placed on the shaft 28; and then the key stock 82 is slid through the raised opening 56 of the spacer 70, the raised opening 44 of the plurality of fiber opener teeth 34 and the slot 36 of the shaft 28 to connect the plurality of fiber opener teeth 34 and the spacer 70 to the shaft 28. The spacer 70 being connected to the shaft 28 by the key stock 82 also prevents the plurality of fiber opener teeth 34 and spacer 70 from sliding off the shaft 28.

[0050] In another embodiment, the raised opening 56 of the spacer 70 may be designed to align with the slot 36 of the shaft 28. As the teeth 34 are placed on the shaft 28, the spacer 70 may be installed onto the shaft 28. The slot 36 may protrude from the shaft 28, creating a raised portion on the shaft 28. The groove 56 of aperture 60 of the spacer 70 may include recessed portions. The raised opening 56 of the spacer 70 may be sized to slide over the raised portions of the slot 36 on the shaft 28. This can effectively connect the spacer 70 to the shaft 28 and prevent the spacer 70 from rotating or moving on the shaft 28. Alternatively, the slot 36 may include recessed portions, and the raised portion 56 may be a protrusion instead of a recessed portion. In this embodiment, there is no key stock needed to secure the spacer 70 to the shaft 28.

[0051] FIGS. 20-22 illustrate a non-limiting example of the lock washer 72 in more detail. The lock washer 72 may be cylindrical, rectangular, or have any other appropriate shape to fit on the shaft 28. The lock washer 72 may be removably connected to the shaft 28. The lock washer 72 may include an aperture 76 and at least one groove or raised opening 78. The raised opening (groove) 78 may be further defined as a recessed portion and may be sized to receive the key stock 82. In one embodiment, the raised opening 78 of the lock washer 72 is designed to align with the raised opening 44 of the plurality of fiber opener teeth 34, the raised opening 56 of the spacer 70, and the slot 36 of the shaft 28. In one example, the key stock 82 is first received by the slot 36 in the shaft 28; and then the lock washer 72 is slid onto the shaft 28. In another example, the lock washer 72 is first placed on the shaft 28; and then the key stock 82 is slid through the raised opening 78 of the lock washer 72 to connect the lock washer 72 to the shaft 28. The lock washer 72 being connected to the shaft 28 by the key stock 82 also prevents the plurality of fiber opener teeth 34, the spacer 70, and the lock washer 72 from sliding off the shaft 28.

[0052] In another embodiment, the raised opening 78 of the lock washer 72 may be designed to align with the slot 36 of the shaft 28. The slot 36 may protrude from the shaft 28, creating a raised portion on the shaft 28. The groove 78 of aperture 76 of the lock washer 72 may include recessed portions. The raised opening of the groove 78 may be sized to slide over the protrusion of the slot 36 on the shaft 28. This can effectively connect the lock washer 72 to the shaft 28 and prevent the lock washer 72 from rotating or moving on the shaft 28. Alternatively, the slot 36 may include recessed portions, and the raised opening 78 may be a protrusion from the aperture 76. In this embodiment, there is no key stock needed to secure the lock washer 72 to the shaft 28.

[0053] FIGS. 23-24 illustrate the housing 66 of the roller bank 58. The housing 66 is provided with a door 84 that allows a user to easily and quickly access the rotating members 26 within the roller bank 58. The housing 66 is further provided with a slider plate 86, as shown more clearly in FIGS. 25-26. The slider plate 86 may be combined with the housing 66 to form one component, or the slider plate 86 may be a separate, removable component from the housing 66. The slider plate 86 is illustrated with a first aperture 88 and a second aperture 90, each sized to receive the shaft 28 of the rotating members 26. The first aperture 88 is shown as a circular opening, and the second aperture 90 is shown as an elongated opening. The elongated opening of the second aperture 90 allows a user to move one of the rotating members 26 closer to or farther away from another rotating member 26. This enables a user to customize the spacing (pinch point 80) between the rolling members 26. Typical fiber opener systems do not have the capability to adjust the distance between the rolling members; and being able to adjust the distance is advantageous because it allows customization to accommodate fibers of different lengths, diameters, and densities. In another embodiment, the first aperture 88 is provided with an elongated opening, and the second aperture 90 is provided with a circular opening. Alternatively, the first aperture 88 and the second aperture 90 may be the same shape. The first aperture 88 and the second aperture 90 may be of any suitable shape to receive the shaft 28 of the rotating members 26.

[0054] A method of using the herein-disclosed apparatus is disclosed herein. The method may include providing a bale of compressed fiber to the fiber opener section via a transportation section. The bale may be automatically or mechanically contacted with the opening apparatus within the single bank of rollers. The method may include separating individual fibers from one another in the pinch point between the individual rollers of the single roller bank. The separating may be performed with minimal damage to the fiber, change of particle distribution of the fiber, cutting of the fiber, or the like. The method may further include passing the fiber bale via the opener section until a desirable fiber density is achieved.

[0055] The method may further include stopping the apparatus to inspect the state of teeth, ensure the teeth are not damaged, and replacing the teeth. The inspecting may include identifying a damaged tooth element. The method may include removing the locking mechanism, compression nut, teeth, spacers, or a combination thereof. The method may include removing a number of teeth preceding the damaged tooth component, removing the damaged tooth component, and replacing it with a new tooth. The method may further include adding the original teeth, except the damaged tooth, back onto the shaft following placement of the new tooth. The method may include securing the teeth on the shaft, for example by activating the locking mechanism, installing the compression nut, or both.

[0056] While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.

Claims

1. A fiber opener comprising:at least one set of adjacent rotating members, each rotating member having a shaft with a proximal end and a distal end, the adjacent rotating members being positioned relative to each other to provide at least one pinch point between the adjacent rotating members; anda plurality of fiber opener teeth removably connected to the shaft, the plurality of fiber opener teeth structured to lower fiber density as input fiber passes through the at least one pinch point.

2. The fiber opener of claim 1, wherein the shaft has a recessed slot extending along a length of the shaft from the proximal end to the distal end of the shaft.

3. The fiber opener of claim 1, wherein the shaft has a recessed slot disposed between the proximal end and the distal end of the shaft.

4. The fiber opener of claim 1, wherein at least one of the plurality of fiber opener teeth are removably disengageable from the shaft.

5. The fiber opener of claim 1, wherein the plurality of fiber opener teeth are removably disengageable from the shaft.

6. The fiber opener of claim 1, wherein the shaft has a recessed slot sized to receive a corresponding protrusion of at least one of the plurality of fiber opener teeth to enable the at least one of the plurality of fiber opener teeth to be removably connected to the shaft.

7. The fiber opener of claim 1, wherein each of the plurality of fiber opener teeth has an aperture and at least one raised opening extending from the aperture.

8. The fiber opener of claim 7, wherein the at least one raised opening of the plurality of fiber opener teeth is sized to receive a corresponding protrusion of the shaft to enable the plurality of fiber opener teeth to be removably connected to the shaft.

9. The fiber opener of claim 7, wherein the at least one raised opening of the plurality of fiber opener teeth corresponds with a recessed slot in the shaft, and wherein the raised opening of the plurality of fiber opener teeth and the recessed slot in the shaft are sized to receive a key stock to enable the plurality of fiber opener teeth to be removably connected to the shaft.

10. The fiber opener of claim 7, wherein each of the plurality of fiber opener teeth further comprises a first segment extending from the aperture and a second segment extending from the aperture, spaced apart from the first segment, and wherein the first segment and the second segment form a curved shape.

11. The fiber opener of claim 10, wherein the first segment of the plurality of fiber opener teeth is provided with a base which gradually narrows at a top portion of the first segment.

12. The fiber opener of claim 10, wherein the second segment of the plurality of fiber opener teeth is provided with a base which gradually narrows at a top portion of the second segment.

13. The fiber opener of claim 10, wherein the plurality of fiber opener teeth are arranged such that the first segments are aligned.

14. The fiber opener of claim 1, wherein the shaft further comprises a bearing connected to the proximal end of the shaft, wherein the bearing is adapted to cooperate with a driving mechanism to drive the at least one set of adjacent rotating members.

15. The fiber opener of claim 1, wherein a distance between each of the plurality of fiber opener teeth is adjustable on the shaft.

16. A fiber opener comprising:at least one set of adjacent rotating members, each rotating member having a shaft with a proximal end and a distal end, the adjacent rotating members being positioned relative to each other to provide at least one pinch point between the adjacent rotating members; anda plurality of fiber opener teeth removably supported by the shaft, the plurality of fiber opener teeth structured to lower fiber density as input fiber passes through the at least one pinch point.

17. A fiber opener comprising:at least one set of adjacent rotating members oriented within a housing, each rotating member having a shaft with a proximal end and a distal end, the adjacent rotating members being positioned relative to each other to provide at least one pinch point between the adjacent rotating members; anda plurality of fiber opener teeth removably connected to the shaft, the plurality of fiber opener teeth structured to lower fiber density as input fiber passes through the at least one pinch point.

18. The fiber opener of claim 17, wherein the plurality of fiber opener teeth are removably disengageable from the shaft.

19. The fiber opener of claim 17, wherein the housing further comprises a slider plate, wherein the slider plate has a first and a second aperture sized to receive the proximal end of the shaft of the rotating members.

20. The fiber opener of claim 19, wherein the first aperture of the slider plate has a size and the second aperture of the slider plate has a size larger than the size of the first aperture to enable the at least one pinch point between the adjacent rotating members to be adjusted by moving one of the rotating members along a length of the second aperture of the slider plate.

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