Method and configuration for connecting roving assemblies

Abstract

A pair of connected roving assemblies having a first roving assembly (302) with a first main strand (306) of continuous first glass fibers, the first main A strand (306) extending from a first leading end portion (310) to a first trailing end portion (312) opposite the first leading end portion (310), a second roving assembly (304) having a second main strand (308) of continuous second glass fibers, the second main strand (308) extending from a second leading end portion (314) to a second trailing end portion (316) opposite the first leading end portion (314), and a first connection (326) connecting the first trailing end portion (312) to the second leading end portion (314). The first connection (326) includes a first minor strand (A) of the first main strand (306) forming a first spiral wrap around the second leading end portion (314) of the second roving assembly (304) and a second minor strand (B1) of the first main strand (306) forming a second spiral wrap around the second leading end portion (314) of the second roving assembly (304).

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 477,855 , filed Dec. 30, 2022, the entire content of which is incorporated by reference herein.FIELD

[0002] The present invention relates to roving assemblies, and more particularly to a method of, and fastening configuration for, operatively connecting the fiber stands of a first roving assembly to the fiber strands of the second roving assembly.BACKGROUND

[0003] It is generally known in the art to wind elongate filaments or strands onto a rotating support to form cakes (sometimes also referred to in the art as bobbins or packages or spools or rolls) of the wound material. In the field of glass fiber materials, it is generally known to draw a plurality of glass fibers from a molten glass source flowing through a bushing assembly having a plurality of bushings to obtain a relatively large number (e.g., a thousand) of glass fibers / A predetermined number of the glass fibers are grouped to obtain a respective glass fiber strand (sometimes referred to in the art as a split). One or more glass fiber strands are then wound on a rotatable spindle having an axis of rotation to form a cake or bobbin.

[0004] FIG. 1 is a schematic illustration of a conventional glass fiber strand winding system 100 in accordance with the foregoing. A bushing 102, which may be part of a bushing assembly, is a metallic box-shaped structure through which molten glass (from a conventional source of molten glass, not shown) flows to form a plurality (as many as several thousands) of individual glass filaments 104 that can be drawn (i.e., pulled) through the rest of the process. A conventional sizing composition may be optionally deposited on the glass filaments 104 by a conventional sizing device 106. In an example of a conventional sizing device, the filaments 104 may be passed through or adjacent to the sizing device 106 to deposit a predetermined sizing composition, for example, by passing the filaments 104 against a surface (such as a roller) wetted with the sizing composition. The sizing composition may be useful, for example, for protecting the glass filaments from breakage or to enhance bonding with a reinforcing matrix, in a composite material.

[0005] Next, the filaments 104 are separated by a separating device 108 into several groups of filaments to obtain discrete glass fiber strands 110, each glass fiber strand 110 having a plurality of filaments, up to about two hundred (200) filaments each. The conventional separating device 108 has, for example, a plurality of spaced apart teeth like a comb. Accordingly, each group of filaments is separated from other groups by the teeth of the separating device 108 to define the corresponding plurality of generally planar glass fiber strands 110. The one or more glass fiber strands 110 are thereafter wound on a spindle or other elongate rotating support 112 to obtain a wound cake 114 of glass fiber strands. It is known in the art to use a mechanical traversing apparatus 116 to laterally displace the one or more glass fiber strands along an axial length of the spindle 112 to distribute the glass fiber strands during winding, to obtain a cake 114 that is wound consistently and, particularly, that can unwound reliably when desired. The mechanical traversing apparatus in FIG. 1 is indicated schematically at 116, and generally functions by rotating along an axis of rotation X to displace the glass fiber strands 110 in a reciprocating fashion back and forth along an axial portion of the spindle 112, while the glass fiber strands 110 are being wound onto spindle 112, to create a uniform cake 114. A rotatably mounted spindle 112 is driven to rotate about an axis of rotation X′ by conventional mechanical driving means, such as a motor (not shown here).

[0006] As seen in FIG. 2, once several cakes 114 are wound, the plurality of respective glass fiber strands 110 wound about each cake 114 as illustrated in FIG. 1 is thereafter pulled from a plurality of cakes 114, as represented in FIG. 2. The several pluralities of glass fiber strands 110 taken from the plurality of cakes 114 are thereafter wound together to form a “roving assembly”120 (sometimes referred to as a “multi-end” (in reference to the amassed grouping of discrete glass fiber strands) package or “doff”).

[0007] For example, in FIG. 2, each of the three (3) cakes 114 may each comprise twelve (12) wound glass fiber strands 110. To manufacture the roving assembly 120, each group of twelve (12) glass fiber strands from each cake 114 are taken together to form the roving assembly 120. Thus, the roving assembly 120 should provide thirty-six (36) glass fiber strands when it is unwound in subsequent use. A roving assembly 120 is typically used as a source of continuous glass fiber, for example, for subsequent production of chopped glass fiber for use as a composite material reinforcement (i.e., the glass fibers are chopped and incorporated into the composite material to reinforce the composite material). In such use, the roving assembly 120 is unwound at relatively high speed to provide the glass fiber for subsequent manufacturing processes.

[0008] As seen in FIG. 3, in a continuous manufacturing process multiple roving assemblies are often operatively connected in series. FIG. 3 illustrates a first roving assembly 202 operatively connected to a second roving assembly 204 so that when a first strand 206 comprising the roving assembly) from the first roving assembly 202 has been completely unwound, the process continues using a second strand 208 from the second roving assembly 204, and so forth. In particular, the first strand 206 from the first roving assembly 202 has a first leading end 210 and a first trailing end 212 and the second strand 208 from the second roving assembly 204 has a second leading end 214 and a second trailing end 216. To operatively connect the first roving assembly 202 to the second roving assembly 204, the first trailing end 212 of the first strand 206 and the second leading end 214 of the second strand 208 are tied together into a transfer knot 220. This process can be repeated for each discrete fiber strand on the roving assemblies 202, 204.

[0009] A conventional transfer knot 220, however, can result in a defect in the final product. For example, a conventional transfer knot 220 includes a solid lump or ball of glass fibers strands that form the knot. For example, one conventional transfer knot 220 commonly used has a lump or ball with a thickness or diameter of approximately 3.35 mm. Such a lump or ball of glass fibers can fail to sufficiently disperse when chopped in the manufacturing process. Because the chopped glass fibers of the transfer knot 220 are not being reliably dispersed (i.e., some fibers remain clumped), the final product (e.g., a fiberglass vehicle body panel), which typically requires a smooth, consistent finish, may have a lump (or other non-smooth finish) and / or a discoloration caused by the transfer knotSUMMARY

[0010] Various aspects of the present inventive concepts are directed to roving assemblies, and more particularly to a method of, and fastening configuration for, operatively connecting the fiber stands of a first roving assembly to the fiber strands of the second roving assembly.

[0011] In some examples, a pair of roving assemblies are connected by a first connection. The first roving assembly has one or more strands of continuous first glass fibers with a first main strand having a first leading end portion and a first trailing end portion opposite the first leading end portion. The second roving assembly has one or more strands of continuous second glass fibers with a second main strand having a second leading end portion and a second trailing end portion opposite the first leading end portion. The first connection connects the first trailing end portion to the second leading end portion. The first connection includes a first minor strand of the first main strand forming a first spiral wrap around the second leading end portion of the second roving assembly and a second minor strand of the first main strand forming a second spiral wrap around the second leading end portion of the second roving assembly.

[0012] In some examples, a method of connecting a first roving assembly to a second roving assembly, includes separating a first trailing end of a first main strand of the first roving assembly into a first minor strand, a second minor strand, and a third minor strand. The first minor strand is spirally wrapped around a second leading end portion of a second main strand of the second roving assembly to form a first spiral wrap. The second minor strand is spirally wrapped around the second leading end portion to form a second spiral wrap. The first spiral wrap and the second spiral wrap are positioned at a first end of the first roving assembly to form a first connection.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Features and advantages of the present invention will become apparent to those of ordinary skill in the art to which the invention pertains from a reading of the following description together with the accompanying drawings.

[0014] FIG. 1 is a schematic representation of a conventional system for winding a plurality of strands, particularly glass fiber strands, into a cake or the like.

[0015] FIG. 2 is a schematic representation of a conventional process of winding a roving assembly using multiple fiber strands taken from multiple cakes of the type represented in FIG. 1.

[0016] FIG. 3 is a schematic representation of a conventional method of connecting two roving assemblies in series.

[0017] FIG. 4 is a schematic representation of a first and second roving assembly.

[0018] FIGS. 5-11 are schematic representations of an exemplary method of, and a fastening configuration for, connecting the roving assembles of FIG. 4 in series according to the present invention.DETAILED DESCRIPTION

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these exemplary embodiments belong. The terminology used in the description herein is for describing exemplary embodiments only and is not intended to be limiting of the exemplary embodiments. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein. Although other methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein.

[0020] As used in the specification and the appended claims, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0021] Unless otherwise indicated, all numbers expressing quantities of ingredients, chemical and molecular properties, reaction conditions, and so forth, as well as physical and measured attributes, used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present exemplary embodiments. At the very least each numerical parameter should be construed considering the number of significant digits and ordinary rounding approaches.

[0022] Unless otherwise indicated, any element, property, feature, or combination of elements, properties, and features, may be used in any embodiment disclosed herein, regardless of whether the element, property, feature, or combination of elements, properties, and features was explicitly disclosed in the embodiment. It will be readily understood that features described in relation to any aspect described herein may be applicable to other aspects described herein provided the features are compatible with that aspect. In particular: features described herein in relation to the method may be applicable to the product and vice versa.

[0023] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the exemplary embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Every numerical range given throughout this specification and claims will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

[0024] The present disclosure relates to connecting the fiber strands of a first roving assembly to the fiber strands of the second roving assembly in a manner that allows for a continuous manufacturing process while avoiding or inhibiting defects resulting from the connection from forming in a final product that utilizes chopped fibers from the fiber strands.

[0025] FIGS. 4-11 illustrates an exemplary method and fastening configuration for operatively connecting a first roving assembly 302 to a second roving assembly 304. The first roving assembly 302 comprises a wound first main strand 306 and the second roving assembly 304 comprises a wound second main strand 308. The first main strand 306 is connected to the second main strand 308 such that once the first main strand 306 has been completely unwound, the second main strand 308 begins to unwind. It will be appreciated that this exemplary method / configuration could be carried out for any number of discrete strands on the roving assemblies 302, 304. Further, it will be appreciated that this exemplary method / configuration can be used to connect more than just two roving assemblies in series. The exemplary method / configuration, for example, can be used to connects all of the roving assemblies of a pallet, a package, or a group together in series. Further exemplary method / configuration can also be used to multiple pallets, packages, or groups of roving assemblies in series by connecting the trailing roving assembly a first pallet, a package, or a group of roving assemblies to trailing roving assembly of a second pallet, a package, or a group, and so on. Thus, the exemplary method / configuration can be utilized to create a continuous supply of glass fiber strands for processing.

[0026] The first main strand 306 has a first leading end portion 310 and a first trailing end portion 312 opposite the first leading end portion 310. The entire length of the first main strand 306 extends from the first leading end portion 310 to the first trailing end portion 312. The second main strand 308 has a second leading end portion 314 and a second trailing end portion 316 opposite the second leading end portion 314. The entire length of the second main strand 308 extends from the second leading end portion 314 to the second trailing end portion 316. The first and second leading end portions 310, 314 are arranged to be the first portions of the main strands 306, 308 unwound from the first and second roving assemblies 302, 304, respectively. In the illustrated example of FIG. 4, the first leading end portion 310 and the second leading end portion 314 are illustrated as extending from a first inner diameter 318 of the first roving assembly 302 and a second inner diameter 320 of the second roving assembly 304, respectively. Further, the first trailing end portion 312 and the second trailing end portion 316 are illustrated as extending from a first upper end 322 of the first roving assembly 302 and a second upper end 324 of the second roving assembly 304, respectively. In other examples, however, the roving assemblies 302, 304 can be wound and arranged such that the first and second leading end portions 310, 314 and the first and second trailing end portion 312, 316 extends from other locations on the respective roving assemblies 302, 304.

[0027] To operatively connect the first roving assembly 302 to the second roving assembly 304, the first trailing end portion 312 of the first main strand 306 and the second leading end portion 314 of the second main strand 308 are connected via a first connection 326 (FIG. 11).

[0028] Referring to FIG. 5, to operatively connect the first trailing end portion 312 to the second leading end portion 314 (FIG. 4), the first trailing end portion 312 is split or divided into two separate strands (i.e., groups of fibers): a minor strand A and a minor strand B. In some examples, the number of fibers in the minor strand A in the range of 80% to 120%, or 90% to 110%, the number of fibers in the minor stand B (i.e., generally evenly split). In other examples, however, the minor strand A can have less than 80% or greater than 120% of the number of fibers of the minor strand B.

[0029] Referring to FIG. 6, after the first trailing end portion 312 is split into the minor strand A and the minor strand B, at least a portion of the minor strand B is split or divided into two separate strands (i.e., groups of fibers): a minor strand B1 and a minor strand B2. In some examples, the number of fibers in the minor strand B1 is in the range of 80% to 120%, or 90% to 110%, the number of fibers in the minor stand B2 (i.e., generally evenly split). In other examples, however, the minor strand B1 can have less than 80% or greater than 120% the number of fibers of the minor strand B2.

[0030] Thus, in some examples, the minor strand A includes more strands from the first trailing end portion 312 than each of the minor strand B1 and the minor strand B2. In some examples, for example, the minor strand A includes 40% to 60% of the total strands of the first trailing end portion 312, and each of the minor strand B1 and the minor strand B2 include 10% to 30% of the total number of strands of the first trailing end portion 312. Thus, minor strand A, in some examples, has roughly twice as many strands as each of the minor strand B1 and the minor strand B2.

[0031] Referring to FIG. 7, with the minor strand A and the minor strand B1 extending generally in the same direction (e.g., parallel to each other, generally in a V-shape, forming an angle with each other of less than 60 degrees, etc.), the second leading end portion 314 of the second roving assembly 304 is positioned traverse and in front of the minor strand A and traverse and behind the minor strand B1 (or vice versa). Thus, the minor strand A and the minor strand B1 are positioned on opposite sides (i.e., the front and the back) of the second leading end portion 314. In the example of FIG. 7, the second leading portion 314, the minor strand A, and the minor strand B1 form an H-shape.

[0032] Referring to FIG. 8, with second leading end portion 314 extending traverse to the minor strand A and the minor strand B1, the minor strand A is wrapped once around the front and over the back of the second leading end portion 314 to form a first spiral wrap 330 of the minor strand A around the second leading end portion 314. The minor strand A is wrapped around the second leading end portion 314 inward (i.e., in the direction toward the minor strand B1). Similarly, the minor strand B1 is wrapped once around the back and over the front of the second leading end portion 314 to form a second spiral wrap 332 of the minor stand B1 around the second leading end portion 314. The minor strand B1 is wrapped around the second leading end portion 314 inward (i.e., in the direction toward the minor strand A). In the example of FIG. 8, the minor strand A is spiral wrapped in the opposite direction (around the front and over the back) as the minor strand B1 (around the back and over the front). In other examples, however, the minor strand A and the minor strand B1 can be wrapped in the same direction. In the example of FIG. 8, both the minor strand A and the minor strand B1 are wrapped around the second leading end portion 314 a single time (i.e., a single spiral wrap).

[0033] Referring to FIG. 9, once the minor strand A and / or the minor strand B1 have been spirally wrapped around the second leading end portion 314, the primary connection 326 is formed by moving the position of the first spiral wrap 330 and the second spiral wrap 332 on the minor strand A and the minor strand B1, respectively, to near, or at, the upper end 322 of the first roving assembly 302 and pulling the spiral wraps tightly around the second leading end portion 314. For example, the first spiral wrap 330 and the second spiral wrap 332 can be moved to where the first trailing end portion 312 (FIG. 5) separates from the wound roving assembly 302 and where the minor strand B1 separates from the minor strand B2. Since the minor strand A and the minor strand B1 are wrapped around the second leading end portion 314, moving the first spiral wrap 330 and the second spiral wrap 332 to the upper end 322 of the first roving assembly 302 also moves that portion of the second leading end portion 314 which the first spiral wrap 330 and the second spiral wrap 332 wrap around, to the upper end 322. The primary connection 326, when formed, has a width or diameter in the range of 1.8 mm to 2.6 mm, or 2.0 mm to 2.4 mm, or 2.1 mm to 2.2 mm. In comparison, the width or diameter of each of the first trailing end portion 312 and the second leading end portion 314 is in the range of about 1.1 mm to about 1.4 mm, or about 1.25 mm and the width of conventional knot As shown in FIG. 9, once the first spiral wrap 330 and the second spiral wrap 332 are positioned at the upper end 322 of the first roving assembly 302, a loose terminal end portion 340 of each of the second leading end portion 314, the minor strand A, the minor strand B1, and the minor strand B2 extends from the upper end 322 of the first roving assembly 302 (i.e., from the primary connection 326) and a transition portion 342 of the second leading end portion 314 extends from the second roving assembly 304 to the primary connection 326.

[0034] Referring to FIG. 10, to secure the loose terminal end portions 340 (FIG. 9), the loose terminal end portions 340 are combined into a single combined strand 344. The single combined strand 344 is then wrapped around the transition portion 342 of the second leading end portion 314 to secure an end portion 346 of the single combined strand 344 to the transition portion 342. In the illustrated example, the single combined strand 344 is spiral wrapped once around the transition portion 342 to form a loop 348 and then pulled tight to form a secondary connection 350. In other examples, however, the single combined strand 344 can be wrapped around the transition portion 342 of the second leading end portion 314 to secure an end portion 346 of the single combined strand 344 to the transition portion 342 in any suitable manner.

[0035] Referring to FIG. 11, when the first roving assembly 302 and the second roving assembly 304 are connected as described above regarding FIGS. 4-10, the second leading end portion 314 of the second main strand 308 is connected to trailing first end portion 312 of the first main strand 306 by the primary connection 326. The primary connection 326 is configured, when chopped, to substantially disperse into separated chopped fibers (i.e., not remain in a clump of fibers). In this way, the primary connection essentially disappears or goes away during downstream processing (i.e., chopping / cutting of the fiber strands). As a result, the primary connection 326 does not cause a defect in the surface finish of a finished product produced from chopped strand of the primary connection 326 or any significant visual discoloration or blemish on the finished product (e.g., a fiberglass-reinforced vehicle panel). In the illustrated example, the primary connection 326 is formed by the first spiral wrap 330 and the second spiral wrap 332.

[0036] In addition, the loose terminal end portions 340 of the second leading end portion 314 and the trailing first end portion 312 are connected to the transition portion 342 of the second leading end portion 314 via the secondary connection 350. As with the primary connection 326, the secondary connection 350 is configured, when chopped, to substantially disperse into separated chopped fibers (i.e., not remain in a clump of fibers). As a result, the secondary connection 350 does not cause a defect in the surface finish of a finished product produced from chopped strand of the secondary connection 350 or any significant visual discoloration or blemish on the finished product (e.g., a fiberglass-reinforced vehicle panel).

[0037] The disclosed exemplary method and fastening configuration results in a loop 352 being formed between the primary connection 326 and the secondary connection 350 by the transition portion 342 and the combined strand 344. In some examples, the distance X between the primary connection 326 and the secondary connection 350 is in the range of 2.0 to 4.0 inches, or 2.2 to 3.8 inches, or 2.5 to 3.3 inches. In other examples, however, the distance X can be greater than 4.0 inches and less than 2.0 inches. In some examples, the distance Y between the secondary connection and a bottom end 354 of the first roving assembly 302 is in the range of 1.0 to 4.0 inches, 1.5 to 3.5 inches, or 2.0 to 3.0 inches. In other examples, however, the distance Y can be less than 1.0 inches and greater than 4.0 inches. In some examples, the total height of the first roving assembly 302 is in the range 9.5 inches to 11.5 inches, or 10 inches to 11 inches, or 10.2r inches to 10.75 inches. All numerical ranges are understood to include all possible incremental sub-ranges within the outer boundaries of the range. Thus, for example, a distance of 2.0 inches to 4.0 inches discloses, for example, 2.0 inches to 3 inches, 2.5 inches to 4.0 inches, 2.3 inches to 3.5 inches, etc.

[0038] The method of, and fastening configuration for, operatively connecting two roving assemblies of the present invention may have any combination or sub-combination of the properties disclosed and the ranges for those properties disclosed herein. While the present invention has been illustrated by the description of embodiments thereof, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. For example, while the first connection is described as including a single spiral wrap of the minor strand A and a single spiral wrap of the minor strand B1, in some embodiment, minor strand A and / or minor strand B can be spirally wrapped around the second leading end portion multiple times as long as, when chopped, the first connection is substantially dispersed into separated chopped fibers. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of the general inventive concepts.

Examples

Embodiment Construction

[0019]Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these exemplary embodiments belong. The terminology used in the description herein is for describing exemplary embodiments only and is not intended to be limiting of the exemplary embodiments. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein. Although other methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein.

[0020]As used in the specification and the appended claims, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0021]Unless otherwise indicated, all numbers expressing quantities of ingredients, chemical and molecular pr...

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 477,855 , filed Dec. 30, 2022, the entire content of which is incorporated by reference herein.FIELD

[0002] The present invention relates to roving assemblies, and more particularly to a method of, and fastening configuration for, operatively connecting the fiber stands of a first roving assembly to the fiber strands of the second roving assembly.BACKGROUND

[0003] It is generally known in the art to wind elongate filaments or strands onto a rotating support to form cakes (sometimes also referred to in the art as bobbins or packages or spools or rolls) of the wound material. In the field of glass fiber materials, it is generally known to draw a plurality of glass fibers from a molten glass source flowing through a bushing assembly having a plurality of bushings to obtain a relatively large number (e.g., a thousand) of glass fibers / A predetermined number of the glass fibers are grouped to obtain a respective glass fiber strand (sometimes referred to in the art as a split). One or more glass fiber strands are then wound on a rotatable spindle having an axis of rotation to form a cake or bobbin.

[0004] FIG. 1 is a schematic illustration of a conventional glass fiber strand winding system 100 in accordance with the foregoing. A bushing 102, which may be part of a bushing assembly, is a metallic box-shaped structure through which molten glass (from a conventional source of molten glass, not shown) flows to form a plurality (as many as several thousands) of individual glass filaments 104 that can be drawn (i.e., pulled) through the rest of the process. A conventional sizing composition may be optionally deposited on the glass filaments 104 by a conventional sizing device 106. In an example of a conventional sizing device, the filaments 104 may be passed through or adjacent to the sizing device 106 to deposit a predetermined sizing composition, for example, by passing the filaments 104 against a surface (such as a roller) wetted with the sizing composition. The sizing composition may be useful, for example, for protecting the glass filaments from breakage or to enhance bonding with a reinforcing matrix, in a composite material.

[0005] Next, the filaments 104 are separated by a separating device 108 into several groups of filaments to obtain discrete glass fiber strands 110, each glass fiber strand 110 having a plurality of filaments, up to about two hundred (200) filaments each. The conventional separating device 108 has, for example, a plurality of spaced apart teeth like a comb. Accordingly, each group of filaments is separated from other groups by the teeth of the separating device 108 to define the corresponding plurality of generally planar glass fiber strands 110. The one or more glass fiber strands 110 are thereafter wound on a spindle or other elongate rotating support 112 to obtain a wound cake 114 of glass fiber strands. It is known in the art to use a mechanical traversing apparatus 116 to laterally displace the one or more glass fiber strands along an axial length of the spindle 112 to distribute the glass fiber strands during winding, to obtain a cake 114 that is wound consistently and, particularly, that can unwound reliably when desired. The mechanical traversing apparatus in FIG. 1 is indicated schematically at 116, and generally functions by rotating along an axis of rotation X to displace the glass fiber strands 110 in a reciprocating fashion back and forth along an axial portion of the spindle 112, while the glass fiber strands 110 are being wound onto spindle 112, to create a uniform cake 114. A rotatably mounted spindle 112 is driven to rotate about an axis of rotation X′ by conventional mechanical driving means, such as a motor (not shown here).

[0006] As seen in FIG. 2, once several cakes 114 are wound, the plurality of respective glass fiber strands 110 wound about each cake 114 as illustrated in FIG. 1 is thereafter pulled from a plurality of cakes 114, as represented in FIG. 2. The several pluralities of glass fiber strands 110 taken from the plurality of cakes 114 are thereafter wound together to form a “roving assembly”120 (sometimes referred to as a “multi-end” (in reference to the amassed grouping of discrete glass fiber strands) package or “doff”).

[0007] For example, in FIG. 2, each of the three (3) cakes 114 may each comprise twelve (12) wound glass fiber strands 110. To manufacture the roving assembly 120, each group of twelve (12) glass fiber strands from each cake 114 are taken together to form the roving assembly 120. Thus, the roving assembly 120 should provide thirty-six (36) glass fiber strands when it is unwound in subsequent use. A roving assembly 120 is typically used as a source of continuous glass fiber, for example, for subsequent production of chopped glass fiber for use as a composite material reinforcement (i.e., the glass fibers are chopped and incorporated into the composite material to reinforce the composite material). In such use, the roving assembly 120 is unwound at relatively high speed to provide the glass fiber for subsequent manufacturing processes.

[0008] As seen in FIG. 3, in a continuous manufacturing process multiple roving assemblies are often operatively connected in series. FIG. 3 illustrates a first roving assembly 202 operatively connected to a second roving assembly 204 so that when a first strand 206 comprising the roving assembly) from the first roving assembly 202 has been completely unwound, the process continues using a second strand 208 from the second roving assembly 204, and so forth. In particular, the first strand 206 from the first roving assembly 202 has a first leading end 210 and a first trailing end 212 and the second strand 208 from the second roving assembly 204 has a second leading end 214 and a second trailing end 216. To operatively connect the first roving assembly 202 to the second roving assembly 204, the first trailing end 212 of the first strand 206 and the second leading end 214 of the second strand 208 are tied together into a transfer knot 220. This process can be repeated for each discrete fiber strand on the roving assemblies 202, 204.

[0009] A conventional transfer knot 220, however, can result in a defect in the final product. For example, a conventional transfer knot 220 includes a solid lump or ball of glass fibers strands that form the knot. For example, one conventional transfer knot 220 commonly used has a lump or ball with a thickness or diameter of approximately 3.35 mm. Such a lump or ball of glass fibers can fail to sufficiently disperse when chopped in the manufacturing process. Because the chopped glass fibers of the transfer knot 220 are not being reliably dispersed (i.e., some fibers remain clumped), the final product (e.g., a fiberglass vehicle body panel), which typically requires a smooth, consistent finish, may have a lump (or other non-smooth finish) and / or a discoloration caused by the transfer knotSUMMARY

[0010] Various aspects of the present inventive concepts are directed to roving assemblies, and more particularly to a method of, and fastening configuration for, operatively connecting the fiber stands of a first roving assembly to the fiber strands of the second roving assembly.

[0011] In some examples, a pair of roving assemblies are connected by a first connection. The first roving assembly has one or more strands of continuous first glass fibers with a first main strand having a first leading end portion and a first trailing end portion opposite the first leading end portion. The second roving assembly has one or more strands of continuous second glass fibers with a second main strand having a second leading end portion and a second trailing end portion opposite the first leading end portion. The first connection connects the first trailing end portion to the second leading end portion. The first connection includes a first minor strand of the first main strand forming a first spiral wrap around the second leading end portion of the second roving assembly and a second minor strand of the first main strand forming a second spiral wrap around the second leading end portion of the second roving assembly.

[0012] In some examples, a method of connecting a first roving assembly to a second roving assembly, includes separating a first trailing end of a first main strand of the first roving assembly into a first minor strand, a second minor strand, and a third minor strand. The first minor strand is spirally wrapped around a second leading end portion of a second main strand of the second roving assembly to form a first spiral wrap. The second minor strand is spirally wrapped around the second leading end portion to form a second spiral wrap. The first spiral wrap and the second spiral wrap are positioned at a first end of the first roving assembly to form a first connection.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Features and advantages of the present invention will become apparent to those of ordinary skill in the art to which the invention pertains from a reading of the following description together with the accompanying drawings.

[0014] FIG. 1 is a schematic representation of a conventional system for winding a plurality of strands, particularly glass fiber strands, into a cake or the like.

[0015] FIG. 2 is a schematic representation of a conventional process of winding a roving assembly using multiple fiber strands taken from multiple cakes of the type represented in FIG. 1.

[0016] FIG. 3 is a schematic representation of a conventional method of connecting two roving assemblies in series.

[0017] FIG. 4 is a schematic representation of a first and second roving assembly.

[0018] FIGS. 5-11 are schematic representations of an exemplary method of, and a fastening configuration for, connecting the roving assembles of FIG. 4 in series according to the present invention.DETAILED DESCRIPTION

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these exemplary embodiments belong. The terminology used in the description herein is for describing exemplary embodiments only and is not intended to be limiting of the exemplary embodiments. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein. Although other methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein.

[0020] As used in the specification and the appended claims, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0021] Unless otherwise indicated, all numbers expressing quantities of ingredients, chemical and molecular properties, reaction conditions, and so forth, as well as physical and measured attributes, used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present exemplary embodiments. At the very least each numerical parameter should be construed considering the number of significant digits and ordinary rounding approaches.

[0022] Unless otherwise indicated, any element, property, feature, or combination of elements, properties, and features, may be used in any embodiment disclosed herein, regardless of whether the element, property, feature, or combination of elements, properties, and features was explicitly disclosed in the embodiment. It will be readily understood that features described in relation to any aspect described herein may be applicable to other aspects described herein provided the features are compatible with that aspect. In particular: features described herein in relation to the method may be applicable to the product and vice versa.

[0023] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the exemplary embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Every numerical range given throughout this specification and claims will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

[0024] The present disclosure relates to connecting the fiber strands of a first roving assembly to the fiber strands of the second roving assembly in a manner that allows for a continuous manufacturing process while avoiding or inhibiting defects resulting from the connection from forming in a final product that utilizes chopped fibers from the fiber strands.

[0025] FIGS. 4-11 illustrates an exemplary method and fastening configuration for operatively connecting a first roving assembly 302 to a second roving assembly 304. The first roving assembly 302 comprises a wound first main strand 306 and the second roving assembly 304 comprises a wound second main strand 308. The first main strand 306 is connected to the second main strand 308 such that once the first main strand 306 has been completely unwound, the second main strand 308 begins to unwind. It will be appreciated that this exemplary method / configuration could be carried out for any number of discrete strands on the roving assemblies 302, 304. Further, it will be appreciated that this exemplary method / configuration can be used to connect more than just two roving assemblies in series. The exemplary method / configuration, for example, can be used to connects all of the roving assemblies of a pallet, a package, or a group together in series. Further exemplary method / configuration can also be used to multiple pallets, packages, or groups of roving assemblies in series by connecting the trailing roving assembly a first pallet, a package, or a group of roving assemblies to trailing roving assembly of a second pallet, a package, or a group, and so on. Thus, the exemplary method / configuration can be utilized to create a continuous supply of glass fiber strands for processing.

[0026] The first main strand 306 has a first leading end portion 310 and a first trailing end portion 312 opposite the first leading end portion 310. The entire length of the first main strand 306 extends from the first leading end portion 310 to the first trailing end portion 312. The second main strand 308 has a second leading end portion 314 and a second trailing end portion 316 opposite the second leading end portion 314. The entire length of the second main strand 308 extends from the second leading end portion 314 to the second trailing end portion 316. The first and second leading end portions 310, 314 are arranged to be the first portions of the main strands 306, 308 unwound from the first and second roving assemblies 302, 304, respectively. In the illustrated example of FIG. 4, the first leading end portion 310 and the second leading end portion 314 are illustrated as extending from a first inner diameter 318 of the first roving assembly 302 and a second inner diameter 320 of the second roving assembly 304, respectively. Further, the first trailing end portion 312 and the second trailing end portion 316 are illustrated as extending from a first upper end 322 of the first roving assembly 302 and a second upper end 324 of the second roving assembly 304, respectively. In other examples, however, the roving assemblies 302, 304 can be wound and arranged such that the first and second leading end portions 310, 314 and the first and second trailing end portion 312, 316 extends from other locations on the respective roving assemblies 302, 304.

[0027] To operatively connect the first roving assembly 302 to the second roving assembly 304, the first trailing end portion 312 of the first main strand 306 and the second leading end portion 314 of the second main strand 308 are connected via a first connection 326 (FIG. 11).

[0028] Referring to FIG. 5, to operatively connect the first trailing end portion 312 to the second leading end portion 314 (FIG. 4), the first trailing end portion 312 is split or divided into two separate strands (i.e., groups of fibers): a minor strand A and a minor strand B. In some examples, the number of fibers in the minor strand A in the range of 80% to 120%, or 90% to 110%, the number of fibers in the minor stand B (i.e., generally evenly split). In other examples, however, the minor strand A can have less than 80% or greater than 120% of the number of fibers of the minor strand B.

[0029] Referring to FIG. 6, after the first trailing end portion 312 is split into the minor strand A and the minor strand B, at least a portion of the minor strand B is split or divided into two separate strands (i.e., groups of fibers): a minor strand B1 and a minor strand B2. In some examples, the number of fibers in the minor strand B1 is in the range of 80% to 120%, or 90% to 110%, the number of fibers in the minor stand B2 (i.e., generally evenly split). In other examples, however, the minor strand B1 can have less than 80% or greater than 120% the number of fibers of the minor strand B2.

[0030] Thus, in some examples, the minor strand A includes more strands from the first trailing end portion 312 than each of the minor strand B1 and the minor strand B2. In some examples, for example, the minor strand A includes 40% to 60% of the total strands of the first trailing end portion 312, and each of the minor strand B1 and the minor strand B2 include 10% to 30% of the total number of strands of the first trailing end portion 312. Thus, minor strand A, in some examples, has roughly twice as many strands as each of the minor strand B1 and the minor strand B2.

[0031] Referring to FIG. 7, with the minor strand A and the minor strand B1 extending generally in the same direction (e.g., parallel to each other, generally in a V-shape, forming an angle with each other of less than 60 degrees, etc.), the second leading end portion 314 of the second roving assembly 304 is positioned traverse and in front of the minor strand A and traverse and behind the minor strand B1 (or vice versa). Thus, the minor strand A and the minor strand B1 are positioned on opposite sides (i.e., the front and the back) of the second leading end portion 314. In the example of FIG. 7, the second leading portion 314, the minor strand A, and the minor strand B1 form an H-shape.

[0032] Referring to FIG. 8, with second leading end portion 314 extending traverse to the minor strand A and the minor strand B1, the minor strand A is wrapped once around the front and over the back of the second leading end portion 314 to form a first spiral wrap 330 of the minor strand A around the second leading end portion 314. The minor strand A is wrapped around the second leading end portion 314 inward (i.e., in the direction toward the minor strand B1). Similarly, the minor strand B1 is wrapped once around the back and over the front of the second leading end portion 314 to form a second spiral wrap 332 of the minor stand B1 around the second leading end portion 314. The minor strand B1 is wrapped around the second leading end portion 314 inward (i.e., in the direction toward the minor strand A). In the example of FIG. 8, the minor strand A is spiral wrapped in the opposite direction (around the front and over the back) as the minor strand B1 (around the back and over the front). In other examples, however, the minor strand A and the minor strand B1 can be wrapped in the same direction. In the example of FIG. 8, both the minor strand A and the minor strand B1 are wrapped around the second leading end portion 314 a single time (i.e., a single spiral wrap).

[0033] Referring to FIG. 9, once the minor strand A and / or the minor strand B1 have been spirally wrapped around the second leading end portion 314, the primary connection 326 is formed by moving the position of the first spiral wrap 330 and the second spiral wrap 332 on the minor strand A and the minor strand B1, respectively, to near, or at, the upper end 322 of the first roving assembly 302 and pulling the spiral wraps tightly around the second leading end portion 314. For example, the first spiral wrap 330 and the second spiral wrap 332 can be moved to where the first trailing end portion 312 (FIG. 5) separates from the wound roving assembly 302 and where the minor strand B1 separates from the minor strand B2. Since the minor strand A and the minor strand B1 are wrapped around the second leading end portion 314, moving the first spiral wrap 330 and the second spiral wrap 332 to the upper end 322 of the first roving assembly 302 also moves that portion of the second leading end portion 314 which the first spiral wrap 330 and the second spiral wrap 332 wrap around, to the upper end 322. The primary connection 326, when formed, has a width or diameter in the range of 1.8 mm to 2.6 mm, or 2.0 mm to 2.4 mm, or 2.1 mm to 2.2 mm. In comparison, the width or diameter of each of the first trailing end portion 312 and the second leading end portion 314 is in the range of about 1.1 mm to about 1.4 mm, or about 1.25 mm and the width of conventional knot As shown in FIG. 9, once the first spiral wrap 330 and the second spiral wrap 332 are positioned at the upper end 322 of the first roving assembly 302, a loose terminal end portion 340 of each of the second leading end portion 314, the minor strand A, the minor strand B1, and the minor strand B2 extends from the upper end 322 of the first roving assembly 302 (i.e., from the primary connection 326) and a transition portion 342 of the second leading end portion 314 extends from the second roving assembly 304 to the primary connection 326.

[0034] Referring to FIG. 10, to secure the loose terminal end portions 340 (FIG. 9), the loose terminal end portions 340 are combined into a single combined strand 344. The single combined strand 344 is then wrapped around the transition portion 342 of the second leading end portion 314 to secure an end portion 346 of the single combined strand 344 to the transition portion 342. In the illustrated example, the single combined strand 344 is spiral wrapped once around the transition portion 342 to form a loop 348 and then pulled tight to form a secondary connection 350. In other examples, however, the single combined strand 344 can be wrapped around the transition portion 342 of the second leading end portion 314 to secure an end portion 346 of the single combined strand 344 to the transition portion 342 in any suitable manner.

[0035] Referring to FIG. 11, when the first roving assembly 302 and the second roving assembly 304 are connected as described above regarding FIGS. 4-10, the second leading end portion 314 of the second main strand 308 is connected to trailing first end portion 312 of the first main strand 306 by the primary connection 326. The primary connection 326 is configured, when chopped, to substantially disperse into separated chopped fibers (i.e., not remain in a clump of fibers). In this way, the primary connection essentially disappears or goes away during downstream processing (i.e., chopping / cutting of the fiber strands). As a result, the primary connection 326 does not cause a defect in the surface finish of a finished product produced from chopped strand of the primary connection 326 or any significant visual discoloration or blemish on the finished product (e.g., a fiberglass-reinforced vehicle panel). In the illustrated example, the primary connection 326 is formed by the first spiral wrap 330 and the second spiral wrap 332.

[0036] In addition, the loose terminal end portions 340 of the second leading end portion 314 and the trailing first end portion 312 are connected to the transition portion 342 of the second leading end portion 314 via the secondary connection 350. As with the primary connection 326, the secondary connection 350 is configured, when chopped, to substantially disperse into separated chopped fibers (i.e., not remain in a clump of fibers). As a result, the secondary connection 350 does not cause a defect in the surface finish of a finished product produced from chopped strand of the secondary connection 350 or any significant visual discoloration or blemish on the finished product (e.g., a fiberglass-reinforced vehicle panel).

[0037] The disclosed exemplary method and fastening configuration results in a loop 352 being formed between the primary connection 326 and the secondary connection 350 by the transition portion 342 and the combined strand 344. In some examples, the distance X between the primary connection 326 and the secondary connection 350 is in the range of 2.0 to 4.0 inches, or 2.2 to 3.8 inches, or 2.5 to 3.3 inches. In other examples, however, the distance X can be greater than 4.0 inches and less than 2.0 inches. In some examples, the distance Y between the secondary connection and a bottom end 354 of the first roving assembly 302 is in the range of 1.0 to 4.0 inches, 1.5 to 3.5 inches, or 2.0 to 3.0 inches. In other examples, however, the distance Y can be less than 1.0 inches and greater than 4.0 inches. In some examples, the total height of the first roving assembly 302 is in the range 9.5 inches to 11.5 inches, or 10 inches to 11 inches, or 10.2r inches to 10.75 inches. All numerical ranges are understood to include all possible incremental sub-ranges within the outer boundaries of the range. Thus, for example, a distance of 2.0 inches to 4.0 inches discloses, for example, 2.0 inches to 3 inches, 2.5 inches to 4.0 inches, 2.3 inches to 3.5 inches, etc.

[0038] The method of, and fastening configuration for, operatively connecting two roving assemblies of the present invention may have any combination or sub-combination of the properties disclosed and the ranges for those properties disclosed herein. While the present invention has been illustrated by the description of embodiments thereof, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. For example, while the first connection is described as including a single spiral wrap of the minor strand A and a single spiral wrap of the minor strand B1, in some embodiment, minor strand A and / or minor strand B can be spirally wrapped around the second leading end portion multiple times as long as, when chopped, the first connection is substantially dispersed into separated chopped fibers. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of the general inventive concepts.

Examples

Embodiment Construction

[0019]Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these exemplary embodiments belong. The terminology used in the description herein is for describing exemplary embodiments only and is not intended to be limiting of the exemplary embodiments. Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein. Although other methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein.

[0020]As used in the specification and the appended claims, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0021]Unless otherwise indicated, all numbers expressing quantities of ingredients, chemical and molecular pr...

Claims

1. A pair of connected roving assemblies, comprising:a first roving assembly comprising a first main strand of continuous first glass fibers, the first main strand having a first leading end portion and a first trailing end portion opposite the first leading end portion;a second roving assembly comprising a second main strand of continuous second glass fibers, the second main strand having a second leading end portion and a second trailing end portion opposite the first leading end portion; andwherein the connected rovings assemblies are characterized by:a first connection connecting the first trailing end portion to the second leading end portion, the first connection comprising:a first minor strand of the first main strand forming a first spiral wrap around the second leading end portion of the second roving assembly; anda second minor strand of the first main strand forming a second spiral wrap around the second leading end portion of the second roving assembly; anda second connection, wherein the second connection includes a combined strand comprising a loose end portion of the first minor strand, the second minor strand, the second leading end of the second main strand, and a third minor strand of the first main strand, and wherein the combined strand forms a third spiral wrap around the second leading end portion at a location on the second leading end portion between the first connection and the second roving assembly.

2. The pair of connected roving assemblies of claim 1, wherein the first spiral wrap is wrapped opposite the second spiral wrap.

3. The pair of connected roving assemblies of claim 1, wherein the first spiral wrap is positioned adjacent the second spiral wrap at a first end of the first roving assembly.

4. The pair of connected roving assemblies of claim 3, further comprising a third minor strand of the first main strand not wrapped around the second leading end portion at the first end of the first roving assembly.

5. The pair of connected roving assemblies of claim 1, wherein the first connection is position at a first end of the first roving assembly and second connection is positioned along the side of the first roving assembly at about 40% to 60% of the total height of the first roving assembly.

6. (canceled)7. The pair of connected roving assemblies of-claim claim 1, wherein the first minor strand includes a greater number of strands of glass fiber than the third minor strand.

8. The pair of connected roving assemblies of claim 1, wherein first minor strand includes a greater number of strands of glass fiber than the second minor strand.

9. The pair of connected roving assemblies of claim 1, wherein the total number of glass fiber strands in the first main strand is a first number of strands and the first minor strand includes 40% to 60% of the first number of strands.

10. The pair of connected roving assemblies of claim 9, wherein the second minor strand includes 10% to 30% of the first number of strands.

11. A method of connecting a first roving assembly to a second roving assembly, wherein the first roving assembly comprising a first main strand of continuous first glass fibers, the first main strand having a first leading end portion and a first trailing end portion opposite the first leading end portion and the second roving assembly comprising a second main strand of continuous second glass fibers, the second main strand having a second leading end portion and a second trailing end portion opposite the first leading end portion, the-wherein the method is characterized by:separating the first trailing end into a first minor strand, a second minor strand, and a third minor strand;spiral wrapping the first minor strand around the second leading end portion to form a first spiral wrap;spiral wrapping the second minor strand around the second leading end portion to form a second spiral wrap;positioning the first spiral wrap and the second spiral wrap at a first end of the first roving assembly to form a first connection;combining the first minor strand, the second minor strand, the second leading end portion, and the third minor strand into a combined strand; andspiral wrapping the combined strand around the second leading end portion at a location between the first location and the second roving assembly to form a second connection.

12. The method of claim 11, wherein spiral wrapping the first minor strand around the second leading end portion is in a first direction and spiral wrapping the second minor strand around the second leading end portion is in a second direction opposite the first direction.

13. (canceled)14. The method of claim 11, wherein the first minor strand includes a greater number of strands of glass fiber than the second minor strand.

15. The method of claim 11, wherein first minor strand includes a greater number of strands of glass fiber than the third minor strand.

16. The method of claim 11, wherein the total number of glass fiber strands in the first main strand is a first number of strands and the first minor strand includes 40% to 60% of the first number of strands.

17. The method of claim 16, wherein the second minor strand includes 10% to 30% of the first number of strands.

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