WO2024249852A1 - Creel comprising tubes for supplying warp beaming machine - Google Patents

Abstract

A system includes a warp beaming machine and a creel having a plurality of positions each configured to support a respective fiber package thereon. The creel has a first longitudinal end facing the beaming machine. The system further includes a plurality of tubes, each tube of the plurality of tubes having a respective first end that is configured to receive fiber from a respective position of the plurality of positions toward the first longitudinal end of the creel.

Description

CREEL COMPRISING TUBES FOR SUPPLYING WARP BEAMING MACHINE

CROSS-REFERENCE TO RELATED APPLICATION

|0001] This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/505,262, filed May 31, 2023, the entirety of which is incorporated by reference herein.

FIELD

10002] This disclosure relates to systems and methods for beaming a warp from a creel.

BACKGROUND

|0003] Fibers can be wound around a beam from a creel to provide a warp for manufacturing textiles. Conventionally, during thread up, operators have to pull fiber from respective fiber packages, along the creel, and to the warp beaming machine. In addition to the thread up being time consuming, reaching each of the fiber packages at the top of the creel requires a ladder and creates an ergonomics issue. Further, the creel does not control the yam separation, thereby allowing for crossed ends, causing a breakout, and ultimately reducing quality of the textile.

SUMMARY

10004] Described herein, in various aspects, is a system comprising a warp beaming machine and a creel comprising a plurality of positions each configured to support a respective fiber package thereon. The creel has a first longitudinal end facing the beaming machine. The system further comprises a plurality of tubes, each tube of the plurality of tubes having a respective first end that is configured to receive fiber from a respective position of the plurality of positions toward the first longitudinal end of the creel.

10005] Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. DESCRIPTION OF THE DRAWINGS

[0006] These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

[0007] FIG. 1 is a schematic view of an exemplary system as disclosed herein.

|0008] FIG. 2 is a perspective view of a portion of a creel of the system as disclosed herein.

10009] FIG. 3 is a perspective view of another portion of the creel as disclosed herein, showing tubes.

10010] FIG. 4 is a perspective view of another portion of the creel as disclosed herein, showing tubes.

10011] FIG. 5 is a close-up portion of FIG. 4, showing detail of a yam package. The labeled elements, including the tube and creel position, are all associated with a single fiber from a single package.

[0012] FIG. 6 is a perspective view of an eyelet board of the system as disclosed herein.

DETAILED DESCRIPTION

[0013] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.

[0014] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0015] As used herein the singular forms “a,” “an,” and “the” can optionally include plural referents unless the context clearly dictates otherwise. For example, unless the context dictates otherwise, use of the term “a tube” can represent disclosure of embodiments in which only a single such tube is provided, as well as disclosure of embodiments in which a plurality of such tubes are provided.

[0016] All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

[0017] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

|0018] As used herein, the term “at least one of’ is intended to be synonymous with “one or more of.” For example, “at least one of A, B and C” explicitly includes only A, only B, only C, and combinations of each.

|0019] Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values or characteristics are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects. Similarly, use of “substantially” (e.g., “substantially parallel”) or “generally” (e.g., “generally perpendicular”) to refer to the orientation of a surface should be understood to include embodiments in which angles are within about ten degrees, or within five degrees, or within one degree. [0020] The word “or” as used herein means any one member of a particular list and, unless context dictates otherwise, in alternative embodiments, can represent disclosure of any combination of members of that list.

[0021] As used herein, except where otherwise indicated, it is understood that embodiments described or claimed using “comprise,” “comprises,” or “comprising” can be alternatively be described or claimed using “consisting essentially of’ or “consisting of’ or equivalent terms.

10022] It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

10023] The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus, system, and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the apparatus, system, and associated methods can be placed into practice by modifying the illustrated apparatus, system, and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry.

[0024] Disclosed herein, in various aspects and with reference to FIGS. 1-5, is a system 10 comprising a warp beaming machine 20 and a creel 30. The creel 30 comprises a plurality of positions 32 each configured to support a respective fiber package thereon 40. The creel 30 has a first longitudinal end 34 facing the beaming machine 20. The system 10 further comprises a plurality of tubes 50, each tube 50 of the plurality of tubes having a respective first end 52 that is configured to receive fiber 42 from a yam package 40 at a respective position 32 of the plurality of positions. Each tube 50 extends from its first end 52 toward the first longitudinal end 34 of the creel 30. [0025] The plurality of positions 32 of the creel 30 can comprise an upper row 36 of positions 32. In some aspects, at least a portion of the plurality of tubes 50 can extend from the upper row 36 of positions 32. In some optional aspects, the tubes 50 can extend from only the upper row 36 of positions 32. These tubes 50 extending from the upper row 36 can reduce the ergonomic strain of operators reaching the upper row. In some aspects, the creel 30 can comprise one or more rows of positions below the upper row. In some aspects, the plurality of tubes 50 can extend to some or all of the positions 32 in the one or more rows of positions below the upper row 36. In various aspects, the plurality of tubes 50 can be configured to receive yams from at least half of the plurality of positions of the creel. In further aspects, the plurality of tubes 50 can be configured to receive yams from at least 60%, or at least 70%, or at least 80%, or at least 90%, at last 95%, or at least 99% of the positions of the creel. In some aspects, the plurality of tubes can be configured to receive yams from every position of the creel. Optionally, in these aspects, a respective tube 50 of the plurality of tubes can extend to every position 32 of the plurality of positions.

10026] In some aspects, the plurality of positions 32 of the creel comprises at least 300 positions. In some aspects, the plurality of positions of the creel comprises at least 600 positions. In some aspects, the plurality of positions of the creel comprises at least 1,200 positions. In some aspects, the plurality of positions of the creel comprises at least 2,500 positions. In some aspects, at least one tube of the plurality of tubes has a length of at least 20 feet. In some aspects, at least one tube of the plurality of tubes has a length of at least 40 feet. In some aspects, at least one tube 50 of the plurality of tubes has a length of at least 60 feet. In some aspects, at least one tube 50 of the plurality of tubes has a length of at least 80 feet. In some aspects, at least one tube 50 of the plurality of tubes has a length of at least 100 feet. In some aspects, at least one tube 50 of the plurality of tubes has a length of at least 120 feet. In some aspects, at least one tube 50 of the plurality of tubes has a length of at least 140 feet. In some aspects, at least one tube 50 of the plurality of tubes has a length of at least 150 feet. As should be understood, maintaining consistent tension across all fibers of the warp is critical to quality of the textile. Running fiber through tubes is known to increase tension, and the longer the tube, the greater the amount of tension applied to the fiber. Accordingly, in contrast to the disclosed systems and methods, conventional wisdom taught that using tubes with large creels would have decreased warp quality.

[0027] The system 10 can further comprise a plurality of fiber packages 40. Each fiber package 40 of the plurality of fiber packages can be positioned on a respective position 32 of the plurality of positions. In some optional aspects, the fiber packages 40 can be extruded tape packages. In some aspects, the extruded tape can extend to the warp beaming machine 20 with no or substantially no twists. In other aspects, the fiber packages 40 can comprise any suitable yam, including, for example and without limitation, monofilament yam or multifilament yam, staple yam, or bulk continuous fiber yam.

[0028] In some aspects, each respective position 32 of the plurality of positions can be configured to permit the respective fiber package 40 thereon to rotate as fiber is pulled therefrom. The positions 32 can comprise an elongate body 38. For example, the elongate body 38 of each position 32 can comprise a projection having a cylindrical outer surface. The fiber package 40 can have a tube with an inner diameter that is sufficiently greater than the diameter of the outer surface of the projection of the position 32 to permit rotation of the fiber package 40 on the position 32. In some aspects, the position 32 itself can rotate, thereby permitting rotation of the fiber package 40.

|0029] In some aspects, each position of the plurality of positions 32 can comprise an elongate body 38 that extends along a respective axis 39. The axes 39 can be, for example, horizontal or substantially horizontal axes. Optionally, the axes 39 of at least some (optionally, all) of the elongate bodies 38 of the plurality of positions 32 can be parallel or substantially parallel to one another. Each tube 50 of the plurality of tubes extends along an axis 56 (e.g., optionally, an axis having a curvature rather than a linear axis). At the first end 52 of each tube 50 of the plurality of tubes, a tangent line 58 to the axis 56 is generally perpendicular to the axis 39 along which the elongate body 38 of the respective position 32 from which the first end 52 of the tube 50 is configured to receive the fiber 42. This perpendicularity should be understood to include out-of-plane perpendicularity, so that, included in this perpendicularity, is an orientation of the axis 39 and tangent line 58 wherein translation (not rotation) of the axis 39 of the position 32 relative to the tangent line 58 can result in an intersection at about 90 degrees.

|0030] In some aspects, the first end 52 of each tube 50 of the plurality of tubes is proximate to the respective position 32 of the plurality of positions from which the tube receives fiber 42. For example, as illustrated in FIG. 4, the fiber 42 can be run through a tensioning assembly 70 comprising at least one tensioning pulley 72 and into the first end 52 of the tube 50. The first end 52 of the tube 50 can be spaced toward the first end 34 of the creel 30 relative to the tensioning pulley and approximately at the height at which the fiber leaves the tensioning pulley. In additional or alternative aspects, the at least one tensioning pulley 72 can comprise a guide 74 that directs the fiber from the tensioning pulley 72 to the tube. In these aspects, the guide 74 can be at the height of the first end 52 of the tube 50. In this way, the fiber 42 need not change direction as the fiber enters the tube 50. The first end 52 of the tube 50 can be supported by a bracket. A guide (e.g., a ceramic guide) for reducing friction can be provided at the inlet of the tube 50.

[0031] Referring to FIG. 6, the system 10 can further comprise an eyelet board 60 defining a plurality of openings 62. A respective guide 64 (e.g., a ceramic guide) that minimizes friction with the fiber 42 as it passes across the guide can be positioned in a respective opening 62 of the plurality of openings of the eyelet board 60. Each tube 50 of the plurality of tubes can have a second end 54 that is opposite the first end 52 and in communication with a respective opening 62 of the eyelet board 60.

[0032] In some aspects, each tube 50 of the plurality of tubes can be coupled to the eyelet board 60. In some aspects, the second end 54 of each tube is positioned at the eyelet board (e.g., within 6 inches, within 5 inches, within 4 inches, within 3 inches, within 2 inches, within 1 inch, or abutting or substantially abutting the eyelet board 60. For example, it is contemplated that the guide 64 can be coupled to the second end 54 of the tube 50, and the guide 64 can be positioned within the eyelet board 60.

[0033] In some aspects, the eyelet board 60 can comprise a plurality of segments 66. That is, the eyelet board 60 need not be unitary. For example, as shown in FIG. 6, the eyelet board 60 can comprise a plurality of segments 66 that are spaced transversely to the creel.

[0034] In some aspects, the eyelet board 60 can comprise metal, polymer, or any suitable material.

[0035] It is contemplated that the straightness of each tube can determine the amount of tension added to the fiber. In some aspects, the straightness of each tube can vary by no more than 15%, or no more than 10%, or no more than 5%. That is, the length of the tube can be no longer than the distance that the tube extends along a longitudinal axis of the creel, plus the percent variation. Accordingly, as one example, a tube that extends 50 feet along the longitudinal axis of the creel and has a straightness varying by no more than 10% can be no longer than 55 feet.

[0036] Using compressed air, fiber can be blown through each tube 50 from the first end 52 to the second end 54. This can substantially increase the speed of thread-up over conventional operations. EXEMPLARY ASPECTS

|0037] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

|0038] Aspect 1 : A system comprising: a warp beaming machine; a creel comprising a plurality of positions each position of the plurality of positions comprising an elongate body configured to support a respective fiber package thereon, the creel having a first longitudinal end facing the beaming machine; and a plurality of tubes, each tube of the plurality of tubes having a respective first end that is configured to receive fiber from a respective position of the plurality of positions, wherein each tube extends from the respective first end of the tube toward the first longitudinal end of the creel.

[0039] Aspect 2: The system of aspect 1, wherein the plurality of positions of the creel comprise an upper row of positions, wherein at least a portion of the plurality of tubes extend from the upper row of positions.

|0040] Aspect 3: The system of aspect 1 or aspect 2, wherein the plurality of tubes are configured to receive yams from at least 70% of the plurality of positions of the creel.

[0041 ] Aspect 4: The system of aspect 3, wherein the plurality of tubes are configured to receive yams from every position of the creel.

|0042] Aspect 5: The system of aspect 4, wherein a respective tube of the plurality of tubes extends to every position of the creel.

|0043] Aspect 6: The system of any one of the preceding aspects, wherein the plurality of positions of the creel comprises at least 2500 positions. [0044] Aspect 7 : The system of any one of the preceding aspects, further comprising a plurality of fiber packages, wherein each fiber package of the plurality of fiber packages is positioned on a respective position of the plurality of positions.

[0045] Aspect 8: The system of aspect 7, wherein the fiber packages are extruded tape packages.

[0046] Aspect 9: The system of aspect 7 or aspect 8, wherein each respective position of the plurality of positions is configured to permit the respective fiber package thereon to rotate as fiber is pulled therefrom.

[0047] Aspect 10: The system of any one of the preceding aspects, wherein at least one tube of the plurality of tubes has a length of at least 100 feet.

[0048] Aspect 1 1 : The system of any one of the preceding aspects, wherein the elongate body of each position of the plurality of positions extends along a respective axis, wherein each tube of the plurality of tubes extends along an axis, wherein at the first end of each tube of the plurality of tubes, a tangent line to the axis of the tube is generally perpendicular to the axis of the respective position from which the first end of the tube is configured to receive the fiber.

[0049] Aspect 12: The system of any one of the preceding aspects, wherein the first end of each tube of the plurality of tubes is proximate to the respective position the plurality of positions from which the tube receives fiber.

[0050] Aspect 13: The system of any one of the preceding aspects, further comprising: an eyelet board defining a plurality of openings; and a plurality of ceramic guides, each ceramic guide of the plurality of ceramic guides positioned in a respective opening of the plurality of openings of the eyelet board, wherein each tube of the plurality of tubes has a second end that is opposed to the first end and in communication with a respective opening of the eyelet board.

[0051 ] Aspect 14: The system of aspect 13, wherein each tube of the plurality of tubes is coupled to the eyelet board.

[0052] Aspect 15: The system of aspect 13 or aspect 14, wherein the eyelet board comprises a plurality of segments. [0053] Aspect 16: The system of any one of aspects 13-15, wherein the second end of each tube is positioned at the eyelet board.

[0054] Aspect 17: The system of any one of aspects 13-16, wherein the eyelet board comprises metal.

[0055] Aspect 18: The system of any one of the preceding aspects, wherein the creel comprises a plurality of tensioning assemblies, each tensioning assembly associated with a respective position of the plurality of positions, wherein each tensioning assembly comprises a guide, wherein the guide and the respective first end of the tube are is positioned at a respective height.

[0056] Aspect 19: The system of any one of the preceding aspects, wherein the respective fiber extending from at least one tensioning assembly of the plurality of tensioning assemblies does not change direction as the fiber enters the tube.

[0057] Aspect 20: A method of using the system of any one of the preceding aspects, the method comprising: blowing, using compressed air, a fiber of a yam package through a tube of the plurality of tubes to a second end of the tube, opposite the first end of the tube.

|0058] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.

Claims

CLAIMS What is claimed is:

1. A system comprising: a warp beaming machine; a creel comprising a plurality of positions each position of the plurality of positions comprising an elongate body configured to support a respective fiber package thereon, the creel having a first longitudinal end facing the beaming machine; and a plurality of tubes, each tube of the plurality of tubes having a respective first end that is configured to receive fiber from a respective position of the plurality of positions, wherein each tube extends from the respective first end of the tube toward the first longitudinal end of the creel.

2. The system of claim 1, wherein the plurality of positions of the creel comprise an upper row of positions, wherein at least a portion of the plurality of tubes extend from the upper row of positions.

3. The system of claim 1, wherein the plurality of tubes are configured to receive yams from at least 70% of the plurality of positions of the creel.

4. The system of claim 3, wherein the plurality of tubes are configured to receive yams from every position of the creel.

5. The system of claim 4, wherein a respective tube of the plurality of tubes extends to every position of the creel.

6. The system of claim 1, wherein the plurality of positions of the creel comprises at least 2500 positions.

7. The system of claim 1, further comprising a plurality of fiber packages, wherein each fiber package of the plurality of fiber packages is positioned on a respective position of the plurality of positions.

8. The system of claim 7, wherein the fiber packages are extruded tape packages.

9. The system of claim 7, wherein each respective position of the plurality of positions is configured to permit the respective fiber package thereon to rotate as fiber is pulled therefrom.

10. The system of claim 1, wherein at least one tube of the plurality of tubes has a length of at least 100 feet.

11. Tire system of claim 1, wherein the elongate body of each position of the plurality of positions extends along a respective axis, wherein each tube of the plurality of tubes extends along an axis, wherein at the first end of each tube of the plurality of tubes, a tangent line to the axis of the tube is generally perpendicular to the axis of the respective position from which the first end of the tube is configured to receive the fiber.

12. The system of claim 1, wherein the first end of each tube of the plurality of tubes is proximate to the respective position the plurality of positions from which the tube receives fiber.

13. The system of claim 1, further comprising: an eyelet board defining a plurality of openings; and a plurality of ceramic guides, each ceramic guide of the plurality of ceramic guides positioned in a respective opening of the plurality of openings of the eyelet board, wherein each tube of the plurality of tubes has a second end that is opposed to the first end and in communication with a respective opening of the eyelet board.

14. The system of claim 13, wherein each tube of the plurality of tubes is coupled to the eyelet board.

15. The system of claim 13, wherein the eyelet board comprises a plurality of segments.

16. The system of claim 13. wherein the second end of each tube is positioned at the eyelet board.

17. The system of claim 13. wherein the eyelet board comprises metal.

18. The system of claim 13, wherein the creel comprises a plurality of tensioning assemblies, each tensioning assembly associated with a respective position of the plurality of positions, wherein each tensioning assembly comprises a guide, wherein the guide and the respective first end of the tube are is positioned at a respective height.

19. The system of claim 1, wherein the respective fiber extending from at least one tensioning assembly of the plurality of tensioning assemblies does not change direction as the fiber enters the tube.

20. A method of using the system of any one of the preceding claims, the method comprising: blowing, using compressed air, a fiber of a yam package through a tube of the plurality of tubes to a second end of the tube, opposite the first end of the tube.