MOBILE CREEL

Abstract

A mobile creel for organizing yarn packages and directing yarn is disclosed. In one aspect, the mobile creel has a plurality of support frames and an upright creel docking post. The front portion of the base of each support frame can be configured for engagement with the lower portion of the upright creel docking post. The creel docking post can simultaneously engage one, two, three, or four support frames.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/265,607, filed on Dec. 1, 2009, the entire disclosure of which is incorporated by reference herein for all purposes.

FIELD OF THE INVENTION

This invention relates to a creel for holding yarn packages in a carpet manufacturing process. More specifically, this invention relates to a highly mobile creel configured for layered storage of yarn packages around a creel docking post in a carpet manufacturing process.

BACKGROUND OF THE INVENTION

A standard creel has a frame provided with a plurality of vertical rows of holders each adapted to hold a respective bobbin comprised of a tubular core and a mass of filament—yarn or thread—wound on the core. A filament is pulled from each bobbin and guided through a respective eye, whence it passes to a warp or weft system of a loom or the like. A standard creel can hold hundreds and even thousands of bobbins, thus space requirement is a problem. Additionally, conventional creel design requires that the tufting machine be placed out of operation during the times an operator is required to change the bobbins on the creel in order to change yarns. Further, a significant amount of labor is required to successfully relocate a standard creel or to load or unload yarn packages on the creel.

Thus, there is a need in the pertinent art for an easily movable creel having a compact design for securely holding yarn packages. Additionally, there is a need in the pertinent art for a creel that is configured to allow for efficient loading and unloading of yarn packages.

SUMMARY

The invention relates to a mobile creel for organizing yarn packages and directing yarn to a carpet manufacturing process. A mobile creel provides flexibility for carpet manufactures in that operators can pre-load mobile creels with yarn packages and roll the mobile creels to a desired location, where the mobile creel can be tied into an existing yarn feed. Due to the mobility of the mobile creel, heavier and larger creel packages can be used so as to extend the runtime between creelings throughout the carpet manufacturing process. Because of these extended runtimes and the decreased need for loading and unloading of creel packages, material-handling labor within a textile plant is significantly reduced.

In one aspect, the mobile creel has at least one support frame and an upright creel docking post. Each support frame of the mobile creel has a base with a front portion and a rear portion. The base of each support frame can have a substantially triangular shape. In another aspect, each support frame has a plurality of substantially upright support members extending upwardly from the rear portion of the base. In a further aspect, each support frame can have a plurality of spaced creel mounts positioned on at least one of the support members. Each creel mount can be configured to selectively hold a yarn package.

In another aspect, the upright creel docking post has a lower portion and an upper portion. The front portion of the base of each support frame can be configured for engagement with the lower portion of the upright creel docking post. In a further aspect, each creel mount can be configured so as to be operably positioned to substantially face a portion of the upright creel docking post after engagement of the base by the upright creel docking post. In one non-limiting example, the creel docking post can simultaneously engage one, two, three, or four support frames.

In an additional aspect, the support frame can have a plurality of casters to enable the mobile creel to be readily moved over flooring surfaces within a carpet manufacturing plant. In a further aspect, the creel mounts can be evenly spaced along the outer support members to create a plurality of levels for securing yarn packages. In another aspect, the support frame can have a plurality of substantially horizontal creel package separators mounted on the support members.

In a further aspect, the lower portion of the upright creel docking post can have a guide plate configured to receive the base of each support frame. In another aspect, the lower portion of the docking post has at least one magnet for maintaining the engagement of the front portion of each base with the lower portion of the docking post. In still another aspect, the upper portion of the upright creel docking post can have means for directing at least one path of yarn from the support frames to a selected process, including, for example and without limitation, a carpet tufting machine or a heat setting. For example and without limitation, the means for directing at least one path of yarn can be, alone or in combination, a series of spaced pre-guide rings, a series of spaced ball tension controllers, a plurality of yarn guides, or the like.

DETAILED DESCRIPTION OF THE FIGURES

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:

FIG. 1 is a perspective view of the support frame of the mobile creel according to one aspect of the present invention.

FIG. 2 is a perspective view of the upright creel docking post of the mobile creel according to one aspect of the present invention.

FIG. 3 is a perspective view of the mobile creel according to one aspect of the present invention, illustrating the docking of two support frames to the upright creel docking post.

FIG. 4 is a perspective view of the mobile creel according to one aspect of the present invention, illustrating the docking of two support frames to the upright creel docking post in a “magazine creeling” configuration.

FIG. 5 is an elevational view of the mobile creel according to one aspect of the present invention, illustrating the docking of four support frames to the upright creel docking post such that the spaced creel mounts of the support frames are operably positioned to extend along a mount axis.

DETAILED DESCRIPTION OF THE INVENTION

The present invention can be understood more readily by reference to the following detailed description, examples, drawing, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a yarn package” can include two or more such yarn packages unless the context indicates otherwise.

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.

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.

In one embodiment, the invention relates to a mobile creel 10 for organizing yarn packages 20 and directing yarn to a carpet manufacturing process. The mobile creel 10 provides flexibility for carpet manufactures in that operators can pre-load portable creels with yarn packages 20 for future runs and move them into position when needed. In one aspect, the mobile creel 10 comprises at least one support frame 100 and an upright creel docking post 200.

In one aspect, and referring to FIG. 1, each support frame 100 of the mobile creel comprises a base 110 having a front portion and a rear portion. In this aspect, the base 110 of each support frame 100 can have a substantially triangular shape. In another aspect, each support frame 100 comprises a plurality of substantially upright support members 130 extending upwardly from the rear portion of the base 110. In a further aspect, each support frame 100 comprises a plurality of spaced creel mounts 150 positioned on at least one of the support members 130. As one will appreciate, each spaced creel mount 150 can be secured to its respective support member 130 by any means known in the art, including, for example and without limitation, welding of the creel mounts 150 to two sides of their respective support members 130. In this aspect, each creel mount 150 can be configured to selectively hold a yarn package 20. It is contemplated that, in one aspect, the creel mount can comprise a conventional creel mount. For example and without limitation, each creel mount 150 can comprise a tempered bent-wire package holder.

In one aspect, and referring to FIG. 2, the upright creel docking post 200 comprises a lower portion and an upper portion. In another aspect, and referring to FIGS. 3 and 4, the front portion of the base 110 can be configured for engagement with the lower portion of the upright creel docking post 200. In a further aspect, each creel mount 150 can be configured so as to be oriented toward a portion of the upright creel docking post 200 after operative engagement of the base 110 by the upright creel docking post. In still a further aspect, each creel mount 150 can be configured so as to be operably positioned to substantially face a portion of the upright creel docking post 200 after operative engagement of the base 110 by the upright creel docking post.

In another aspect, and referring to FIG. 1, the plurality of substantially upright support members 130 comprises two outer support members. In this aspect, the plurality of spaced creel mounts 150 can be mounted on the two outer support members. Optionally, the upright support members 130 can also comprise a central support member. In an additional aspect, the support frame 100 comprises a central gusset 140 attached to the central support member and the base 110.

In an additional aspect, and referring to FIG. 1, the support frame 100 comprises a transport means, such as, for example and without limitation, casters, rollers, skids, or the like, for allowing movement of the support frame relative to the upright creel docking post 200. In one aspect, and without limitation, a plurality of casters 120 can be mounted on a bottom surface of the base. In this aspect, the plurality of casters can comprise at least one lockable caster mounted underneath the rear portion of the base 110, as well as a center pivoting caster mounted underneath the top portion of the base. As one skilled in the art will appreciate, the casters 120 enable the mobile creel to roll along flooring surfaces within a carpet manufacturing plant and the plurality of substantially upright support members 130, coupled with the plurality of casters 120, allows for easy steering of the mobile creel during transfers from one process to another.

In a further aspect, and referring to FIG. 1, the creel mounts 150 can be evenly spaced along the outer support members to create a plurality of spaced levels 170 for securing yarn packages 20. In one aspect, it is contemplated that each level 170 would be substantially horizontal, i.e., transverse to the longitudinal axis of the respective outer support members. For example, eight spaced creel mounts 150 can be positioned on the two outer support members such that there are four levels for securing yarn packages 20, with each level 170 having two spaced creel mounts.

In another aspect, the support frame 100 can comprises a plurality of substantially horizontal creel package separators 160 mounted on the support members 130. It is contemplated that the creel package separators 160 can be configured to divide the levels 170 for securing yarn packages 20. As one will appreciate, the creel package separators 160 help prevent entanglement of yarn packages 20 located on different levels 170 of the mobile creel.

As illustrated in FIG. 2, in one aspect, the lower portion of the upright creel docking post 200 comprises a guide plate 210 configured to receive the base 110 of each support frame 100. In this aspect, the guide plate can have a plurality of slots defined therein that are configured to receive the front portion of each base 110. In another aspect, the lower portion of the docking post 200 can comprise at least one magnet. It is contemplated that the at least one magnet can be configured to maintain the engagement of the front portion of each base 110 with the lower portion of the docking post 200. In an additional aspect, the front portion of each base can also comprise at least one magnet that is configured to attract either a portion of a slot in the guide plate or to be attracted to a magnet positioned on the lower portion of the docking post. It is contemplated that the additional magnets of the docking post can reinforce the engagement of the front portion of each base 110 with the docking post. Optionally, the guide plate 210 or the front portion of the base can comprises a rubber bumper for dampening the impact of the engagement of the support frame 100 by the docking post 200.

In another aspect, and referring to FIG. 2, the upper portion of the upright creel docking post 200 can comprise means for directing at least one path of yarn 30 from the at least one support frame 100 to a selected process, including, for example and without limitation, a carpet tufting machine, a heat setting device and the like. In one aspect, the means for directing at least one path of yarn comprises a series of spaced pre-guide rings 230 that can be positioned along the longitudinal length of the upper portion of the docking post 200. It is contemplated that the pre-guide rings 230 can be configured to receive at least one path of yarn 30 from the at least one support frame 100. As one will appreciate, the pre-guide rings 230 can maintain even tension in the path of yarn 30 so that off-winding yarn harmonics are reduced.

In an additional aspect, the means for directing at least one path of yarn can further comprises a series of spaced ball tension controllers 250 positioned along the longitudinal length of the upper portion of the docking post 200. In one exemplary aspect, the series of spaced pre-guide rings 230 and the series of spaced ball tension controllers 250 can be positioned in an interdigitated relationship. As one will appreciate, the spaced ball tension controllers 250 can be configured to create even tension in the yarn 30 used during carpet manufacturing processes. Known ball tension devices, such as, for example and without limitation, Otto Zollinger (OZ®) ball tension devices, can be used for this purpose. In a further aspect, the means for directing at least one path of yarn comprises a plurality of yarn guides 270 mounted to the upper portion of the docking post 200. In this aspect, the yarn guides 270 can be configured to guide at least one path of yarn into a predetermined yarn formation. Optionally, the yarn guides 270 can be locking yarn guides, such as, for example and without limitation, Yuasa locking yarn guides.

In still another aspect, and referring to FIGS. 3, 4, and 5, the front portion of the base 110 of each support frame 100 can be engaged with the lower portion of the upright creel docking post 200. For example, and without limitation, the mobile creel can have one, two, three, or four support frames in engagement with the docking post 200. As illustrated in FIGS. 4 and 5, it is contemplated that, following the engagement of a support frame 100 with the creel docking post 200, the off-winding yarn end of one yarn package 20 can be tied to the tail of an adjacent yarn package on the same level of the support frame to allow for “magazine creeling,” which creates a continuous path of yarn using multiple yarn packages. It is further contemplated that “magazine creeling” can be expanded by linking yarn packages 20 from adjacent support frames 100 that share a common pre-guide ring 230.

In another embodiment, and referring to FIGS. 3 and 4, the invention relates to a support frame 100 for engagement with an upright docking post 200 of a mobile creel 10 organizing yarn packages 20 and directing yarn to a carpet manufacturing process. In one aspect, the support frame 100 comprises a substantially triangular base 110 having a front portion and a rear portion. In one aspect, the front portion comprises a vertex of the substantially triangular base 110. In this aspect, the front portion of the base 110 can be configured for engagement with the docking post 200. Additionally, in another aspect, the support frame 100 comprises a plurality of substantially upright support members 130 extending upwardly from the rear portion of the base 110. In still another aspect, the support frame 100 comprises a plurality of spaced creel mounts 150 positioned on at least one support member 130 of the plurality of support members. In this aspect, each creel mount 150 can be configured to selectively hold a yarn package 20. Further, each creel mount 150 can be operably positioned to extend along a mount axis. As illustrated in FIG. 4, it is contemplated that the mount axis A of each respective creel mount 150 can substantially bisect the vertex of the front portion of the substantially triangular base 110.

In use, and referring to FIGS. 3, 4, and 5, the mobile creel 10 can be provided to organize yarn packages 20 and direct yarn to a carpet manufacturing process. A yarn package 20 can be secured on at least one spaced creel mount 150 of the plurality of spaced creel mounts. The front portion of the base 110 of at least one selected support frame 100 can be positioned so as to engage the lower portion of the upright creel docking post 200. Further, the yarn of at least one yarn package 20 secured on the at least one selected support frame 100 can be positioned in communication with the means for directing at least one path of yarn from the at least one support frame 100 to a selected process.

Optionally, and referring to FIGS. 3, 4, and 5, the plurality of spaced creel mounts 150 can be evenly spaced along at least two support members 130 of the plurality of substantially upright support members to create a plurality of levels 170 for securing yarn packages 20. In one aspect, the step of securing a yarn package 20 on at least one creel mount 150 further comprises securing at least two yarn packages on respective creel mounts within a selected level for securing yarn packages. In a further aspect, the step of positioning the yarn of at least one yarn package 20 further comprises tying yarn from a first yarn package secured to a first spaced creel mount within the selected level to yarn from a second yarn package secured to a second spaced creel mount within the selected level.

Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.

Claims

1. A mobile creel for organizing yarn packages and directing yarn, the mobile creel comprising:

an upright creel docking post having a lower portion and an upper portion; and

at least one support frame, each support frame comprising: a base having a front portion and a rear portion; a plurality of substantially upright support members extending upwardly therefrom the rear portion of the base; and a plurality of spaced creel mounts positioned thereon at least one support member of the plurality of substantially upright support members, each creel mount configured to selectively hold a yarn package,

wherein the front portion of the base of each support frame is configured for engagement with the lower portion of the upright creel docking post, and wherein each creel mount of the plurality of spaced creel mounts is oriented toward the upright creel docking post.

2. The mobile creel of claim 1, wherein the base of each support frame has a substantially triangular shape.

3. The mobile creel of claim 1, wherein each spaced creel mount of the plurality of spaced creel mounts comprises a tempered bent-wire package holder.

4. The mobile creel of claim 1, wherein the plurality of substantially upright support members comprises two outer support members and a central support member, and wherein the plurality of spaced creel mounts are positioned thereon the two outer support members.

5. The mobile creel of claim 4, wherein each support frame of the at least one support frame further comprises means for allowing the support frame to be moved relative to the upright creel docking post.

6. The mobile creel of claim 4, wherein the means for allowing the support frame to be moved comprises a plurality of casters coupled to a bottom surface of the base.

7. The mobile creel of claim 6, wherein the plurality of casters comprises:

at least one lockable caster mounted underneath the rear portion of the base; and

a center pivoting caster mounted underneath the front portion of the base.

8. The mobile creel of claim 4, wherein the plurality of spaced creel mounts are substantially evenly spaced along the longitudinal length of the outer support members to create a plurality of levels for securing yarn packages, and wherein adjacent creel mounts on the respective outer support members are substantially co-planar.

9. The mobile creel of claim 8, wherein each support frame of the at least one support frame further comprises a plurality of substantially horizontal creel package separators mounted thereon the plurality of substantially upright support members to divide the levels for securing yarn packages.

10. The mobile creel of claim 1, wherein the lower portion of the upright creel docking post comprises a guide plate having a plurality of slots configured to receive the front portion of the base of each support frame.

11. The mobile creel of claim 1, wherein the lower portion of the upright creel docking post comprises at least one magnet, and wherein the at least one magnet is configured to maintain the engagement of the front portion of the base of each support frame with the lower portion of the upright creel docking post.

12. The mobile creel of claim 1, wherein the upper portion of the upright creel docking post comprises means for directing at least one path of yarn therefrom the at least one support frame.

13. The mobile creel of claim 12, wherein the means for directing at least one path of yarn therefrom the at least one support frame comprises a series of spaced pre-guide rings positioned along the upper portion of the upright creel docking post.

14. The mobile creel of claim 13, wherein the means for directing at least one path of yarn therefrom the at least one support frame further comprises a series of spaced ball tension controllers positioned along the upper portion of the upright creel docking post, and wherein the series of spaced pre-guide rings and the series of spaced ball tension controllers are positioned in an interdigitated relationship.

15. The mobile creel of claim 14, wherein the means for directing at least one path of yarn therefrom the at least one support frame further comprises a plurality of yarn guides mounted thereto the upper portion of the upright creel docking post, wherein each yarn guide of the plurality of yarn guides is configured to guide the at least one path of yarn into a predetermined yarn formation.

16. The mobile creel of claim 1, wherein the front portion of the base of each support frame of the at least one support frame is engaged with the lower portion of the upright creel docking post.

17. The mobile creel of claim 16, wherein the at least one support frame comprises a plurality of support frames.

18. The mobile creel of claim 17, wherein the plurality of support frames is selected from a group consisting of two, three, and four support frames.

19. The mobile creel of claim 1, wherein each creel mount of the plurality of spaced creel mounts is operably positioned to substantially face the upright creel docking post.

20. A support frame for engagement with an upright docking post of a mobile creel for organizing yarn packages and directing yarn, the support frame comprising:

a substantially triangular base having a vertex and a rear portion;

a plurality of substantially upright support members extending upwardly therefrom the rear portion of the substantially triangular base; and

a plurality of spaced creel mounts positioned thereon at least one support member of the plurality of substantially upright support members, each creel mount configured to selectively hold a yarn package,

wherein the vertex of the base is configured for engagement with the upright creel docking post, wherein each creel mount of the plurality of spaced creel mounts is operably positioned to extend along a mount axis, wherein the mount axis of each respective spaced creel mount is oriented toward the vertex of the substantially triangular base.

21. A method for organizing yarn packages and directing yarn, the method comprising:

providing a mobile creel, the mobile creel comprising: an upright creel docking post having a lower portion and an upper portion; and a plurality of support frames, each support frame comprising: a base having a front portion and a rear portion; a plurality of substantially upright support members extending upwardly therefrom the rear portion of the base; and a plurality of spaced creel mounts positioned thereon at least one support member of the plurality of substantially upright support members, each creel mount configured to selectively hold a yarn package, wherein the front portion of the base of each support frame is configured for engagement with the lower portion of the upright creel docking post, wherein each creel mount of the plurality of spaced creel mounts is oriented toward the upright creel docking post, and wherein the upper portion of the upright creel docking post comprises means for directing at least one path of yarn therefrom the plurality of support frames;

securing a yarn package thereon at least one spaced creel mount of the plurality of spaced creel mounts;

positioning the front portion of the base of at least one selected support frame of the plurality of support frames in engagement with the lower portion of the upright creel docking post; and

positioning the yarn of at least one yarn package secured thereon the at least one selected support frame in communication with the means for directing at least one path of yarn therefrom the plurality of support frames.

22. The method of claim 21, wherein the plurality of spaced creel mounts are substantially evenly spaced along at least two support members of the plurality of substantially upright support members to create a plurality of levels for securing yarn packages, wherein adjacent creel mounts on the respective support members are substantially co-planar, wherein the step of securing a yarn package thereon at least one spaced creel mount further comprises securing at least two yarn packages thereon respective spaced creel mounts within a selected level of the plurality of levels for securing yarn packages, and wherein the step of positioning the yarn of at least one yarn package further comprises serially tying yarn from a first yarn package secured thereon a first spaced creel mount within the selected level to yarn from a second yarn package secured thereon a second spaced creel mount within the selected level.