SELVAGE THREAD SYSTEM
A system for manufacturing a scrim material reinforced by a plurality of yarns includes a yarn dispenser to support and space the plurality of yarns in a yarn pattern, a nipping roll including the scrim material for mating to the yarn pattern, forming the scrim, a guide coupled to the yarn dispenser and positioned within the yarn pattern, the guide providing a first retainer for maintaining the yarn pattern, and a selvage thread assembly extending from the guide and coupling the guide to the nipping roll. The selvage thread assembly includes a spindle and a selvage thread having a first end coupled to the spindle and a second end coupled to the nipping roll, the selvage thread positioned within the yarn pattern, providing a second retainer for maintaining the yarn pattern until the yarn pattern is mated to the scrim material.
The present invention relates generally to the field of scrim laying machines, and particularly to a selvage thread system for manufacturing reinforced scrim. Such reinforced scrim may be used in the manufacture of sailcloths, building materials, or other products requiring reinforced sheet material.
Conventional scrim laying machines typically include a fiber dispensing reel that rotates to form a pattern of fibers that comprises the reinforcing portion of the scrim. The fibers are fed from the fiber dispensing reel to a laminating device opposite the reel. The laminating device may include a film or web having an adhesive portion that pulls the fibers from the reel and onto the web, forming the scrim.
Typically, conventional scrim laying machines also include a screw, spring, or other guide near each edge of the fiber dispensing reel for guiding the fibers and maintaining the spacing of the fibers until stabilized by the supporting web. The guides are intended to maintain the spacing of the fibers until the fibers are bonded to the supporting web. However, in some cases, such as when there is limited space near the laminating device or when the width of the laminating device is wider than the width of the scrim being produced, the guides cannot be positioned close enough to the laminating device to maintain a particular pattern of fibers, and the pattern is more difficult to guide or control. In these cases, the scrim produced may not include the desired pattern of fibers, which may result in a higher scrap rate for the scrim product, thus increasing the cost to produce the scrim.
SUMMARYAn embodiment of the present disclosure relates to a system for manufacturing a scrim material reinforced by a plurality of yarns. The system includes a yarn dispenser to support and space the plurality of yarns in a yarn pattern, a nipping roll including the scrim material for mating to the yarn pattern, forming the scrim, a guide coupled to the yarn dispenser and positioned within the yarn pattern, the guide providing a first retainer for maintaining the yarn pattern, and a selvage thread assembly extending from the guide and coupling the guide to the nipping roll.
In this embodiment, the selvage thread assembly includes a spindle coupled to the yarn dispenser, and a selvage thread having a first end coupled to the spindle and a second end coupled to the nipping roll, the selvage thread positioned within the yarn pattern, providing a second retainer for maintaining the yarn pattern until the yarn pattern is mated to the scrim material.
Another embodiment of the present disclosure relates to an apparatus in a scrim forming system for maintaining a yarn pattern during manufacturing of a scrim. The apparatus includes a spindle, a selvage thread coupled to the spindle, a tip coupled to the selvage thread and configured to couple to a guide, a base coupled to the tip, and an arm removably coupled to the base. The selvage thread is configured to provide a retainer for maintaining a yarn pattern for a scrim.
Another embodiment of the present disclosure relates to a method for making a scrim. The method includes providing a yarn dispenser comprising a plurality of yarns spaced to form the yarn pattern, providing a nipping roll comprising a scrim material for mating to the yarn pattern, positioning a first guide within the yarn pattern and orienting the guide substantially perpendicular to the nipping roll, and providing a spindle coupled to the yarn dispenser and a selvage thread coupled to the spindle. The method also includes extending the length of the guide by routing the selvage thread from the spindle to the guide, routing the selvage thread to the nipping roll, and positioning the selvage thread within the yarn pattern, providing tension in the selvage thread by feeding the selvage thread into the nipping roll, and retaining and maintaining the yarn pattern by positioning the selvage thread at the inside edge of the yarn pattern.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, in which:
Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
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The selvage thread assembly 10 also includes a tip 16 that is coupled to the tip 40 of the screw 18. In exemplary embodiments the selvage thread 44 is routed through an opening 46 of the tip 16. In these embodiments, the selvage thread 44 is routed through the tip 16 such that the selvage thread 44 extends from the screw 18 and on the same axis as the screw 18 (i.e. substantially parallel to the screw 18 and substantially perpendicular to the laminating machine 36 and nipping roll 42). The selvage thread 44 is fed into the nipping roll 42, forming a second retainer for the pattern of yarns 28 and effectively extending the length of the screw 18. As the pattern of yarns 28 is fed into the laminating machine 36, the yarn moves laterally toward the tip 16 of the screw 18 to the nipping roll 42. The selvage thread 44 creates an outer perimeter for the scrim, maintaining the spacing of the yarn and the pattern of yarns 28 until the pattern 28 and the selvage thread 44 are stabilized (e.g. bonded, supported, restrained, engaged, etc.) by the supporting web 34. In some embodiments, the selvage thread assembly 10 may include more than one selvage thread 44 in order to provide a more stable perimeter as necessary. In an exemplary embodiment, the selvage thread 44 remains within the scrim, forming an inner perimeter for the scrim. However, in other embodiments the selvage thread 44 portion of the scrim is removed by trimming the edges before the scrim is used or sold. The selvage thread assembly 10 is shown in further detail in
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The selvage thread assembly 10 also includes the tip 16, which is shown in further detail in
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The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.
The construction and arrangements of the selvage thread system, as shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. The order or sequence of any process steps may be varied or re-sequenced according to alternative embodiments.
Various embodiments are described in the general context of method steps, which may be implemented in one embodiment by a program product including computer-executable instructions, such as program code, executed by computers in networked environments. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of program code for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps.
The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.
Claims
1. A system for manufacturing a scrim material reinforced by a plurality of yarns, the system comprising:
- a yarn dispenser to support and space the plurality of yarns in a yarn pattern;
- a nipping roll comprising the scrim material for mating to the yarn pattern, forming the scrim;
- a guide coupled to the yarn dispenser and positioned within the yarn pattern, the guide providing a first retainer for maintaining the yarn pattern;
- a selvage thread assembly extending from the guide and coupling the guide to the nipping roll, the selvage thread assembly comprising: a spindle coupled to the yarn dispenser; and a selvage thread having a first end coupled to the spindle and a second end coupled to the nipping roll, the selvage thread positioned within the yarn pattern, providing a second retainer for maintaining the yarn pattern until the yarn pattern is mated to the scrim material.
2. The system of claim 1, wherein the system comprises a first selvage thread assembly positioned to maintain the yarn pattern at a first side of the nipping roll, and a second selvage thread assembly positioned to maintain the yarn pattern at a second side of the nipping roll.
3. The system of claim 1, wherein the selvage thread assembly comprises a plurality of selvage threads for maintaining the yarn pattern.
4. The system of claim 1, wherein the selvage thread assembly comprises:
- a tip coupled to the selvage thread and coupled to the guide;
- a base coupled to the tip; and
- an arm removably coupled to the base.
5. The system of claim 4, wherein the arm has a curved shape, extending from the base to meet the guide.
6. The system of claim 5, further comprising a release pin for removing and replacing the arm.
7. The system of claim 5, wherein the tip comprises a first opening for receiving the selvage thread and a second opening for routing the selvage thread to the nipping roll.
8. The system of claim 1, wherein the guide is oriented substantially perpendicular to the nipping roll, and the selvage thread is positioned substantially perpendicular to the nipping roll and substantially parallel to the guide.
9. The system of claim 1, further comprising:
- a frame coupled to the yarn dispenser and configured to form the plurality of yarns into the yarn pattern;
- wherein the selvage thread assembly is coupled to the frame.
10. The system of claim 9, wherein the frame comprises a chain.
11. The system of claim 1, wherein the selvage thread is mated to the scrim material and is formed within the scrim.
12. An apparatus in a scrim forming system for maintaining a yarn pattern during manufacturing of a scrim, the apparatus comprising:
- a spindle;
- a selvage thread coupled to the spindle;
- a tip coupled to the selvage thread and configured to couple to a guide;
- a base coupled to the tip;
- an arm removably coupled to the base; and
- wherein the selvage thread is configured to provide a retainer for maintaining a yarn pattern for a scrim.
13. The apparatus of claim 12, wherein the arm has a curved shape, extending from the base to meet the guide.
14. The apparatus of claim 12, further comprising a release pin for removing and replacing the arm.
15. The apparatus of claim 12, wherein the tip comprises a first opening for receiving the selvage thread and a second opening for routing the selvage thread out from the tip.
16. The apparatus of claim 12, wherein the apparatus comprises a plurality of selvage threads for maintaining the yarn pattern.
17. The apparatus of claim 12, wherein the selvage thread extend out from the tip substantially perpendicular to the base.
18. The apparatus of claim 12, wherein the selvage thread forms a portion of the scrim.
19. A method for making a scrim, the method comprising:
- providing a yarn dispenser comprising a plurality of yarns spaced to form the yarn pattern;
- providing a nipping roll comprising a scrim material for mating to the yarn pattern;
- positioning a first guide within the yarn pattern and orienting the guide substantially perpendicular to the nipping roll,
- providing a spindle coupled to the yarn dispenser and a selvage thread coupled to the spindle;
- extending the length of the guide by routing the selvage thread from the spindle to the guide, routing the selvage thread to the nipping roll, and positioning the selvage thread within the yarn pattern;
- providing tension in the selvage thread by feeding the selvage thread into the nipping roll; and
- retaining and maintaining the yarn pattern by positioning the selvage thread at the inside edge of the yarn pattern.
20. The method of claim 19, further comprising:
- mating the selvage thread to the scrim material and forming the selvage thread within the scrim.
Type: Application
Filed: Mar 15, 2013
Publication Date: Sep 18, 2014
Applicant: NORTH SAILS GROUP, LLC (Milford, CT)
Inventor: David P. McGill (Barrington, RI)
Application Number: 13/835,303