UNREELING APPARATUS

Abstract

Apparatus (10 ) configured for the unreeling of strands (34, 36) or ends having filaments are provided. The apparatus include at least one cake (12, 14) formed from at least one end having filaments and mounted for retention. The cake has a hollow central region (22, 28). At least one unreeling device (16, 18) is supported within the hollow central region of the at least one cake. The unreeling device has a head (50), at least one tube, an exit and a passage (38) there through. A take-up apparatus is positioned downstream from the unreeling device. The apparatus is characterized in that the head of the unreeling device has a truncated ogive cross-sectional shape and wherein the apparatus is configured to maintain tension on the strands or ends thereby substantially reducing breakage and substantially reducing the formation of loops, tangles or knots.

Description

BACKGROUND

Strands or ends of newly-formed filaments can be wound into packages (cakes) for use at a later time. The strands or ends of filaments can be unreeled (or payed out) from either the outer surface of the cake or from a hollow inner surface of the cake. In the event the strands or ends of filaments are unreeled from the inner surface of the cake, the strands or ends coming from the inner surface of the cake can be passed through a circular opening of a structure positioned within the interior of the cake. The circular opening of the structure can be configured to allow the strands or ends to be unreeled at a higher speed without incurring loops, tangles, knots or breakages of the strands.

In some instances, the circular opening of the structure is provided in the form of a tube. In other instances, the circular opening of the structure is provided within the form of an opening positioned within a supporting structure. For those instances where a tube is positioned within the interior of the cake, the disproportional size between the diameter of the tube and the internal diameter of the cake can cause mechanical strain on the strands being unreeled resulting in breakage of the strands.

It would be advantageous to provide an improved apparatus for unreeling wound packages of filaments.

SUMMARY

In accordance with embodiments of this invention there are provided apparatus configured for the unreeling of strands or ends having filaments. The apparatus include at least one cake formed from at least one end having filaments and mounted for retention. The cake has a hollow central region. At least one unreeling device is supported within the hollow central region of the at least one cake. The unreeling device has a head, at least one tube, an exit and a passage there through. A take-up apparatus is positioned downstream from the unreeling device. The apparatus is characterized in that the head of the unreeling device has a truncated ogive cross-sectional shape and wherein the apparatus is configured to maintain tension on the strands or ends thereby substantially reducing breakage and substantially reducing the formation of loops, tangles or knots.

Various advantages of this invention will become apparent to those skilled in the art from the following detailed description of the invention, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view, partially in cross-section of an apparatus configured for unreeling glass fibers.

FIG. 2 is a side view in elevation of an unreeling device configured for use within the apparatus of FIG. 1.

FIG. 3 is an enlarged cross-sectional view of a portion of the unreeling device illustrated in FIG. 2.

FIG. 4 is an enlarged front view in elevation of the unreeling device illustrated in FIG. 2.

FIG. 5 is a side view in elevation of a second embodiment of an unreeling device for use within the apparatus of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in 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 be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

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 this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention 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.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

In accordance with embodiments of the present invention, improved apparatus for unreeling wound packages of filaments are provided. It will be understood the term “filaments” refers to fibers, including, but not limited to glass and mineral fibers, produced from molten materials. The term “strand” or “end” as used herein, is defined to mean a single bundle of continuous filaments gathered together in a parallel relationship. The term “cake”, as used herein, is defined to mean a package of wound strands or ends. The term “creel” as used herein, is defined to mean any structure for supporting one or more cakes. The term “ogive” as used herein, is defined to mean having a curved nose, such as similar to that used for a nosecone for a rocket, missile or torpedo.

The description and figures disclose apparatus for unreeling wound packages (cakes) of strands or ends having filaments such as glass fibers and mineral fibers. The apparatus are useful with any material that can be formed into fibers. Also conventional and well-known techniques are not illustrated.

Referring now to the FIG. 1, one example of an apparatus configured for the unreeling of strands or ends is shown generally at 10. In the illustrated embodiment, the apparatus 10 includes a first cake 12, a second cake 14, a first unreeling device 16, and a second unreeling device 18. Generally, the apparatus 10 is configured to withdraw continuous strands or ends from the inside of the first cake 12, pass the strands or ends from the first cake 12 through the unreeling device 16, withdraw continuous strands or ends from the inside of the second cake 14, pass the strands or ends from the second cake 14 through the unreeling device 18, collect and combine the strands or ends from the unreeling devices 16 and 18 thereby forming a roving and collect the roving at a take-up apparatus (not shown).

In the illustrated embodiment, the first and second cakes, 12 and 14, are wound packages of strands or ends having glass filaments. Alternatively, other fibers or filaments can be used. The first cake 12 has a hollow central region 22 defined by a first cake inner surface 25. The hollow central region 22 and the first cake inner surface 25 extend from a first cake front end 24 to a first cake rear end 26. Similarly, the second cake 14 has a hollow central region 28 defined by a second cake inner surface 27. The hollow central region 28 and the second cake inner surface 27 extend from a second cake front end 30 to a second cake rear end 32.

As shown in FIG. 1, the first and second cakes, 12 and 14, are centered about longitudinal axes A and B, respectively. In the illustrated embodiment, the longitudinal axes A and B are substantially parallel to each other. However the longitudinal axes A and B are not required to be parallel to each other.

Referring again to FIG. 1, the first cake 12 has a length LFC and the second cake 14 has a length LSC. In the illustrated embodiment, the lengths LFC and LSC of the first and second cakes 12 and 14 are in a range of from about 450 mm to about 500 mm. In other embodiments, the lengths LFC and LSC can be less than about 450 mm or more than about 500 mm. While FIG. 1 illustrates the lengths LFC and LSC as being substantially the same, it should be appreciated that the lengths LFC and LSC can be different.

As shown in FIG. 1, the first cake 12 has a diameter DFC and the second cake 14 has a diameter DSC. In the illustrated embodiment, the diameters DFC and DSC of the first and second cakes 12 and 14 are in a range of from about 350 mm to about 500 mm. In other embodiments, the diameters DFC and DSC can be less than about 350 mm or more than about 500 mm. While FIG. 1 illustrates the diameters DFC and DSC as being substantially the same, it should be appreciated that the diameters DFC and DSC can be different.

The first and second cakes, 12 and 14, can be secured within the apparatus 10 by any desired structure (not shown). In some embodiments, the structure is a creel (not shown). However, the use of a creel is not necessary for the practice of the invention.

While FIG. 1 illustrates a quantity of two cakes, 12 and 14, it should be appreciated that the apparatus 10 can include any desired quantity of cakes.

As shown in FIG. 1 strands or ends 34, having glass filaments, from the first cake 12 are payed out from the first cake inner surface 25. As the strands or ends 34 are payed out, the strands or ends 34 unwind from various locations along the length of the first cake inner surface 25. For purposes of clarity, some of the various locations of the unwinding strands or ends 34 are shown in FIG. 1 as broken lines. Similarly strands or ends 36, having glass filaments, from the second cake 14 are payed out from the second cake inner surface 27. As the strands or ends 36 are payed out, the strands or ends 36 unwind from various locations along the length of the second cake inner surface 27. Some of the various locations of the unwinding strands or ends 36 in the second cake are shown in FIG. 1 as broken lines.

Referring again to FIG. 1, the payed-out strands or ends 34 pass through a passage 38 formed within the first unreeling device 16. The passage 38 extends the length of the first unreeling device 16. Similarly, the payed-out strands or ends 36 travel through a passage 40 formed within the second unreeling device 18. The first and second unreeling devices, 16 and 18, will be discussed in more detail below.

The payed-out strands or ends, 34 and 36, exit the first and second unreeling devices, 16 and 18 respectively, at an angle and are collected at guide 42. The guide 42 is configured to combine the payed out strands or ends, 34 and 36, thereby forming a roving 44. In the illustrated embodiment, the guide 42 is an eyelet. Alternatively, the guide 42 can be any structure, mechanism or device sufficient to combine the strands or ends, 34 and 36, into a roving 44. While the embodiment shown in FIG. 1 is illustrated as having a quantity of one guide 42, it should be appreciated that any desired number of guides 42 can be used.

As shown in FIG. 1, the payed-out strands or ends 34 exit the first unreeling device 16 thereby forming an exit angle α-1 with the axis A. In the illustrated embodiment, the exit angle α-1 is approximately 90°. Alternatively, the exit angle α-1 can be more or less than approximately 90°. Similarly, the payed-out strands or ends 36 exit the second unreeling device 18 thereby forming an exit angle α-2 with the axis B. In the illustrated embodiment, the exit angle α-2 is approximately 90°. Alternatively, the exit angle α-2 can be more or less than approximately 90°. While FIG. 1 illustrates exits angles α-1 and α-2 as being substantially the same angle, it should be appreciated that exits angles a-1 and a-2 can be different from each other.

Referring again to FIG. 1, the roving 44 is collected downstream from the guide 42 at the take-up apparatus (not shown). In some embodiments, the take-up apparatus is configured to wind the roving 44 into a roving package 20, suitable for future use. Alternatively, the take-up apparatus can be configured to collect the roving 44 for downstream operations. The take-up apparatus can be any desired structure, mechanism or device sufficient to collect the roving 44.

As shown in FIG. 1, the first unreeling device 16 is positioned within the hollow central region 22 of the first cake 12 such that a major axis of the first unreeling device 16 aligns with the longitudinal axis A of the first cake 12. Similarly, the second unreeling device 18 is positioned within the hollow central region 28 of the second cake 14 such that a major axis of the second unreeling device 18 aligns with the longitudinal axis B of the second cake 14. The first and second unreeling devices 16 and 18 are supported in these positions by a rigid member (not shown) that extends from the structure supporting the cakes 12 and 14 to the first and second unreeling devices 16 and 18. The rigid member can have any desired structure.

Referring now to FIG. 2, the first unreeling device 16 is illustrated (while the first and second unreeling devices 16 and 18 are the same or substantially similar to each other, for purposes of simplicity only the first unreeling device 16 is illustrated and described below). Generally, the first unreeling device 16 is configured to maintain consistent tension on the unwinding strands or ends 34 as the strands or ends 34 pass through the first unreeling device 16 thereby preventing slack from forming in the strands or ends 34 prior to passing through the first unreeling device 16. By maintaining consistent tension in the strands or ends 34 and preventing slack from forming, the first unreeling device 16 advantageously is configured to substantially reduce breakage of the strands or ends 34 and reduce the occurrence of knots and loops formed in the strands or ends 34.

The first unreeling device 16 has a length LD1. The length LD1 is configured to be longer than the length LFC of the first cake 12. In the illustrated embodiment, the length LD1 is at least 490 mm corresponding to the lengths LFC and LSC in the range as described above. Referring again to FIG. 1, the length LD1 of the first unreeling device 16 provides that the first unreeling device 16 extends from the first cake front end 24 a minimum distance D1 and extends from the first cake rear end 26 a minimum distance D2. In the illustrated embodiment, the minimum distance D1 is in a range of from about 20 mm to about 50 mm and the minimum distance D2 is in a range of from about 20 mm to about 50 mm.

Referring again to FIG. 2, the first unreeling device 16 includes a head 50, a first tube 52, a second tube 54 and an exit 56. The passage 38 formed within the first unreeling device 16 extends through the head 50, first tube 52, second tube 54 and exit 56.

Referring now to FIG. 3, a portion of the first unreeling device 16 is illustrated. The head 50 of the first unreeling device 16 is configured as the entrance for the strands or ends 34 flowing through the first unreeling device 16. As shown in FIG. 1, the strands or ends 34 can contact a portion of the head 50 as the strands or ends 34 enter first unreeling device 16. As shown in FIG. 3, the head 50 has an ogive cross-sectional shape with a truncated front portion 51. The ogive-shape of the head 50 has a radius R1. The radius R1 is configured to allow strands or ends 34 to enter the first unreeling device 16 from various interior locations of the first cake 12 while maintaining consistent tension on the strands or ends 34. In the illustrated embodiment, the radius R1 is in a range of from about 10 mm to about 20 mm. However, the radius R1 can be less than about 10 mm or more than about 20 mm.

As shown in FIGS. 3 and 4, the head 50 has an outer diameter D3. The outer diameter D3 of the head 50 is sized in relation to the diameter DFC of the first cake 12. In the illustrated embodiment, the outer diameter D3 of the head 50 is 1/10^th the diameter DFC of the first cake 12 resulting in an outer diameter D3 in a range of from about 35 mm to about 50 mm. Alternatively, the outer diameter D3 of the head 50 can be more or less than approximately 1/10^th the diameter DFC of the first cake 12.

Referring again to FIG. 3, the passage 38 within the head 50 of the first unreeling device 16 has a diameter D4. In the illustrated embodiment, the diameter D4 is approximately 8 mm. However, the diameter D4 of the passage 38 can be more or less than approximately 8 mm. In the illustrated embodiment, the passage 38 has a circular cross-sectional shape. However, the passage 38 can have other desired cross-sectional shapes, including the non-limiting example of an ovular cross-sectional shape.

As discussed above, the head 50 is configured such that the strands or ends 34 can contact a portion of the head 50 as the strands or ends 34 enter first unreeling device 16. Accordingly, the head 50 is made of materials providing wear resistance and low friction characteristics. In the illustrated embodiment, the head 50 is made of a metallic material, such as for example brass. However, the head 50 can be made of other desired materials, such as for example ceramic materials.

Referring again to FIG. 3, optionally the head 50 can be removably attached to the first tube 52 thereby allowing replacement of the head 50. In the illustrated embodiment, the head 50 is threadably attached to the first tube 52. However, the head 50 can be attached to the first tube 52 in any desired manner.

Referring again to FIG. 2, the first tube 52 is configured to allow the strands or ends 34 to pass from the head 50 to the second tube 54 while minimizing the frictional effects on the strands or ends 34 traveling through the passage 38. In the illustrated embodiment, the first tube 52 is made of a polymeric material. However, the first tube 52 can be made of other desired materials, such as for example metallic materials.

As shown in FIG. 3, a front end 64 of the first tube 52 is attached to a rear edge 62 of the head 50. The intersection of the front end 64 of the first tube 52 to the rear edge 62 of the head 50 forms tangent points 60. The first tube 52 has an outer surface 66. An angle α-3 is formed between the outer surface 66 of the first tube 52 and a substantially horizontal line C extending from the tangent point 60. As will be explained in more detail below, the angle α-3 is formed as a result of the difference between the diameter D3 of the head 50 and a diameter D5 of the second tube 54. In the illustrated embodiment, the angle α-3 is in a range of from about 2° to about 10°. However, the angle α-3 can be less than about 2° or more than about 10°.

Referring again to FIG. 2, the first tube 52 is connected to the second tube 54 such that the passage 38 extends continuously through the first and second tubes, 52 and 54. The second tube 54 is configured to allow the strands or ends 34 to pass from the first tube 52 to the exit 56 while minimizing the frictional effects of the strands or ends 34 traveling through the passage 38 and further configured to provide structural rigidity to the first unreeling device 16. The second tube 54 can be attached to the first tube 52 in any desired manner.

The second tube 54 has outer diameter D5. In the illustrated embodiment, the outer diameter D5 of the second tube is in a range of from about 12 mm to about 15 mm. Alternatively, the outer diameter D5 of the second tube can be less than about 12 mm or more than about 15 mm.

In the illustrated embodiment, the second tube 54 is made of a metallic material, such as for example brass. However, the second tube 54 can be made of other desired materials, such as for example polymeric materials.

As shown in FIG. 2, the first tube 52 has a length LFT and the second tube 54 has a length LST. In the illustrated embodiment, the lengths LFT and LST are in a range of from about 200 mm to about 300 mm. Alternatively, the lengths LFT and LST can be less than about 200 mm or more than about 300 mm. While the lengths LFT and LST are illustrated in FIG. 2 as being substantially the same length, it should be appreciated that the lengths LFT and LST can be different.

Referring again to FIG. 2, the exit 56 is connected to the second tube 54 such that the passage 38 extends continuously through the exit 56 from the second tube 54. The exit 56 is configured to allow the strands or ends 34 to pass from the second tube 54 through the exit 56 while minimizing the frictional effects of the strands or ends 34 traveling through the passage 38. In the illustrated embodiment, the exit 56 is made of a ceramic material. However, the exit 56 can be made of other desired materials, such as for example metallic materials. The exit 56 can be attached to the second tube 54 in any desired manner.

The exit 56 has an outer diameter D6. In the illustrated embodiment, the outer diameter D6 of the exit 56 is the same as or similar to the diameter D5 of the second tube 54. However, the diameter D6 of the exit 56 can be different from the diameter D5 of the second tube 54.

Referring now to FIG. 5, a second embodiment of an unreeling device 116 is illustrated. Generally, the unreeling device 116 includes a head 150, a first tube 152, a second tube 154, an exit 156, a passage 138 and a tensioning device 180. The head 150, first tube 152, second tube 154, exit 156 and passage 138 are the same as or similar to the head 50, first tube 52, second tube 54, exit 56 and passage 38 illustrated in FIG. 2 and described above. The unreeling device 116 is positioned within the hollow central region of a cake as shown in FIG. 1 and described above.

The tensioning device 180 is configured to absorb occasional severe pulls or tugs from the take-up apparatus (not shown) that can occur when the length difference between the strands or ends is the greatest, such as when the strands or ends are alternately unwound from the front end of the cake to the rear end of the cake. In the illustrated embodiment, the tensioning device 180 is a spring loaded mechanism that is attached to the exit 156 of the unreeling device. Alternatively, the tensioning device 180 can be any structure, mechanism or device sufficient to absorb occasional severe pulls or tugs from the take-up apparatus. Additionally, the tensioning device 180 can be attached to the unreeling device 116 at any desired location. In still other embodiments, the tensioning device 180 can be incorporated into the structure of the unreeling device 116.

The principle and mode of operation of this invention have been described in certain embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope.

Claims

1. An apparatus configured for the unreeling of strands having filaments comprising:

at least one cake formed from at least one strand having filaments and mounted for retention, the cake having a hollow central region,

at least one unreeling device supported within the hollow central region of the at least one cake, the unreeling device having a head, at least one tube, an exit and a passage there through;

a take-up apparatus positioned downstream from the unreeling device;

wherein the head of the unreeling device has a truncated ogive cross-sectional shape; and

wherein the apparatus is configured to maintain tension on the strands thereby substantially reducing breakage and substantially reducing the formation of loops, tangles or knots.

2. The apparatus of claim 1, wherein the cake and the unreeling device have a length, and wherein the length of the unreeling device is longer than the length of the cake.

3. The apparatus of claim 2, wherein the head of the at least one unreeling device extends beyond a front end of the cake and the exit of the at least one unreeling device extends beyond a rear end of the cake.

4. The apparatus of claim 2, wherein the minimum length of the unreeling device is about 490 mm.

5. The apparatus of claim 1, wherein the at least one cake has a diameter (DFC, DSC) and the head of the at least one unreeling device has an outer diameter (D3), wherein the outer diameter (D3) of the at least one unreeling device is sized to be 1/10th the diameter (DFC, DSC) of the at least one cake.

6. The apparatus of claim 5, wherein the outer diameter (D3) of the head of the at least one unreeling device is in a range of from about 35 mm to about 50 mm.

7. The apparatus of claim 6, wherein the passage has a diameter (D4) of approximately 8 mm.

8. The apparatus of claim 1, wherein the head of the at least one unreeling device is removably attached to the at least one tube.

9. The apparatus of claim 1, wherein the head has an rear edge and the at least one tube has an outer surface, wherein the rear edge has at least one tangent point, wherein an angle (α-3) is formed between a horizontal line extending from the at least one tangent point and the outer surface of the at least one tube, and wherein the angle (α-3) is in a range of from about 2° to about 10°.

10. The apparatus of claim 1, wherein there are at least two tubes.

11. The apparatus of claim 10, wherein the second tube has a diameter (D5) in a range of from about 12 mm to about 15 mm.

12. The apparatus of claim 10, wherein the two tubes have the same length.

13. The apparatus of claim 12, wherein the two tubes have a length in a range of from about 200 mm to about 300 mm.

14. The apparatus of claim 1, further including a tensioning device attached to the at least one unreeling device, wherein the tensioning device is configured to absorb occasional severe pulls or tugs from the take-up apparatus that occur when the length difference between the strands is the greatest.

15. The apparatus of claim 14, wherein the tensioning device is a spring loaded mechanism attached to the exit of the at least one unreeling device.