Compact Creel Yarn Feeding Design
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Solution Overview
Problem
Existing creel designs for tufting machines, such as the bullhorn style, are not compact enough for certain applications and can lead to yarn entanglement when multiple yarn rolls are fed simultaneously, requiring additional space and joining steps.
Innovation Solution
A compact creel design featuring a linear stacked yarn roll arrangement where two or more yarn cones are mounted on a single arm, with the yarns feeding in opposite directions to prevent entanglement and allowing for a more compact configuration, accommodating both bullhorn and new creel styles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bullhorn style creel construction is used with multiple yarn rolls, then yarn feeding continuity is maintained, but the creel occupies excessive space and yarn entanglement occurs
Solution Approach 1:
The patent transitions from a horizontal bullhorn arrangement to a vertical stacked arrangement, utilizing the vertical dimension to stack yarn rolls one above another. This dimensional change allows multiple yarn rolls to be fed through a single eyelet without requiring excessive horizontal space, thereby resolving the contradiction between maintaining yarn feeding continuity and reducing creel space occupation.
Solution Approach 2:
The patent implements a nested configuration where multiple yarn rolls are stacked vertically within a compact footprint. The yarn rolls are arranged in a nested-like structure where each roll occupies a vertical level, allowing them to share the same horizontal space and feed through a common eyelet, thus reducing overall creel space while maintaining feeding reliability.
2Reliability
If multiple yarn rolls are fed simultaneously through the same eyelet, then yarn continuity is maintained, but yarn entanglement occurs
Solution Approach 1:
The patent segments the yarn feed paths by providing individual guide eyes for each yarn roll, positioned at different vertical levels. This segmentation allows each yarn to travel through its own designated path before combining, preventing interference and entanglement between adjacent yarns while maintaining continuity. The segmented approach resolves the contradiction by organizing multiple yarn feeds into distinct, non-interfering channels.
3Area of stationary object
If linear stacked yarn roll arrangement is used, then creel compactness is improved, but complex feeding coordination is required
Solution Approach 1:
The patent employs universal guide eyes that can accommodate multiple yarn rolls of different sizes and types. The guide eye structure is designed to universally handle various yarn configurations, simplifying the feeding coordination despite the compact stacked arrangement. This multi-functional design reduces the complexity by providing a standardized interface that works across different yarn roll configurations.
Data Source
AI summary
A compact creel utilization method provides arms cantileverdly extending from supports which support at least two yarn rolls thereon. Some embodiments have a front roll connected to the rear roll. Other embodiments simultaneously feed to a common eyelet or other feed opening.