Abstract: A Powered Lower Bobbin Feed (“PLBF”) system is disclosed for improving the operation of deflector type rotary braiding machines, such as the Wardwell Rapid Braider. The PLBF eliminates or reduces the impulsive tension spikes set up by the deflection and feed process in current rotary braiding machines by uniquely controlling the lower bobbin filament feed. These tension spikes result from: the rapid rotational acceleration and deceleration required of the lower bobbin as a result of the feed process; the lever arm tension control and bobbin ratchet mechanism; and the shape of the filament deflector surface. Such failure limits the operating speed of rotary braiding machines, the minimum size of filament that can be braided effectively, or the ability to maintain the quality of the braid produced. By eliminating or reducing these spikes, the PLBF therefore can increase the working speed of circular braiding machines and improve the uniformity of braided filaments generated by such machines at a given speed.

Abstract: Photoelectric sensing apparatus is operative for sensing the absence of filament at a particular point on a supply bobbin wherein several strands of filament will still be present on the bobbin. The sensing apparatus includes a light source which directs an angled photoelectric beam at a sensing point near the center of the bobbin and a light sensor which detects reverse reflections of the beam. If there is filament present at the sensing point, the beam will reversely defect off the round surface of the filament back to the light sensor. If there is no filament present at the sensing point, the beam deflects off the exposed core of the bobbin away from the light sensor in a different direction. Electronics means are provided which cooperate with the sensing apparatus to automatically shut-down the machine pursuant to absence of filament at said sensing point.

Abstract: A method of applying an orthopedic cast to an injured body portion consisting of braiding a tubular cast, in situ, around the injured body portion. A somewhat modified conventional braiding machine is operative for applying the tubular braid of fibrous casting yarns around the injured body portion, to form a braided cast which conforms to the shape of the injured body portion. The braided cast is then coated with a matrix material, which provides the necessary rigidity to the cast, yet allows the cast to breathe.