Automated apparatus for composite self-twist-yarn braiding

Abstract

An automated apparatus produces braided yarn starting from strands for spinning into yarn. A controller provides the automation. A tension roller holds the plurality of strands in tension. A spinning and/or twisting block has pathways extending through it and each pathway contains one tensioned strand. The spinning and/or twisting block includes air jets operated by valves, each air jet acts on one tensioned strand to a produce a twisted strand within the pathway. A take-up apron receives each twisted strand while maintaining the twist of each twisted strand. A tensioning take-up roll for each twisted strand receives each twisted strand from the take-up apron. A grooved cam with fork guide moves the twisted strand. A ring with booster jets directs a vortex of pressurized air to the twisted strands to produce a braided strand. Finally, a winding machine winds the braided strand received from the ring with booster jets.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. 119(a) to India patent application 2077/MUM/2015, filed 28 May 2015, which is hereby incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to an automated apparatus for composite self-twist-yarn braiding. More particularly, the present invention relates to an automated apparatus for self-twist stable braided yarn while eliminating zero twist (node) in the yarn leading to a continuous interlocked stable yarn in a single contiguous process.

BACKGROUND ART

Spun yarn is made by twisting staple fibers together to make a cohesive thread. It is used into the production of textiles, viz. weaving, knitting, embroidery, sewing, etc. Twisting fibers into yarn is the process called spinning. It can be dated back to the Upper Paleolithic. The yarn spinning was one of the very first processes to be industrialized. In the textile industry, when two or more single strands are combined to produce another strand, the produced strand is called ply strand. As used herein, the term “yarn” and “ply strand” are synonymous. Also, as used herein, a bundle of fibers, a single yarn, and a ply of more than one single yarn are all equivalent to the term “strand” or “strands.”

A spinning machine called “Spinning Jenny” was significant in the beginning of the Industrial Revolution. The ring Spinning Machine dominates the spinning of staple fibers, even today. However, its limitation in production (12 to 20 meters per minute) gave rise to various other yarn making processes in the middle of 19th century, viz. continuous synthetic filament yarn through spinnerets; Spread Tow yarn making technique, non-woven bat yarn making technique, Bobtex yarn making technique where short fibers, bi-component fibers are either handled with non-woven and slitting technique or solvent or binders; film fibrillation yarn making for ropes and tie-strings; open-end spinning (40 to 50 meters per minute production); Air Vortex spinning (Murata & Rieter Spinning Machine with production speed in excess of 500 meters per minute); Self Twist Ply Spinning of two or more strands (Repco Spinning, Rieter Spinning, Saco-Lowell Platt Spinning Machine that produce 240 meters per minute of self-twist plied two, three or four single strands into one strand giving production of 480 meters to 960 meters per minute of single with an advantage of spinning, twisting and plying single strand into two, three or four ply single strand.

CSIRO, an Australian Government corporate entity and wool research organization, held an invention by inventor David Henshaw, that used Self-Twist yarns in the weaving of woolen fabric where S and Z self-twisted ply yarn was subjected to a further twisting operation for successful weaving of woolen fabric. Today Henshaw's invention is licensed to many textile yarn spinning machine manufacturers.

Later, two self-twisted S and Z balanced two fold self-ply cabled yarns were successfully used by CSIRO for Knitting and Hosiery (inventor G. W. Walls) industry.

The success of using self-twist yarn processing for other long staple fibers and textured continuous filament yarn woke up the fiber manufacturing companies like E.I. DuPont, Monsanto and carpet manufacturers like Bigelow Sanford and other textile sectors. They invented their own self-twist yarn producing machinery. Today the economics of Self Twist yarn producing is well accepted.

The conventional methods used for making woolen ply yarn, included following steps: fiber preparation to roving; apron draft and ring spinning; auto wind and clear; assembly wind; 2 for 1 twister; bulking; package dying; rewind and wax.

The method that is used for making self-twist two-ply woolen yarn is: fiber preparation to roving; self-twist spinner; continuous bulking; package dying; rewind and wax.

There are various factors to be considered while twisting yarn: costs in manufacturing self-twist yarn; floor space; and labor and power.

However, using the above apparatuses and methods resulted in yarns with following problems: 1. The yarn so formed using above apparatuses or methods contain a weak spot called zero twist or “node” between the S-twist and Z-twist zones in a continuous strand. 2. The zero twists so produced being large, suffer from periodicity in appearance and stability of twists in the twist zones (S- and Z-twists neutralization). And, 3. There was possibility of streaks in the carpet (repeat continuous appearance of same color showing in a line in a multicolor carpet surface).

To resolve the problem of the node in self-twist plied yarn, several inventors, viz. D. Henshaw, G. W. Walls, Donald E. Hallam, Eric Gilbos and others have made the following attempt: Inserting tuft in the node to stop the twist from running into different twist zones; Tangling fibers at the nodes amongst each other by compressed air or steam piercing or needle punching at the time of node formation; Binding the fibers at the node with chemical binder; Use mechanical pinching of the fibers at the node by narrowing or ultrasonic bonding.

SUMMARY OF INVENTION

An automated apparatus produces braided yarn starting from strands for spinning into yarn. A controller is programmed to control the operation of the automated apparatus. A tension roller holds the plurality of strands in tension. A spinning and/or twisting block has pathways extending through it and each pathway contains one tensioned strand. The spinning and/or twisting block has a plurality of air jets operated by valves, each air jet acts on one tensioned strand to a produce a twisted strand. Preferably, the plurality of air jets is connected to each pathway so as to flow pressurized air into the pathway causing a vortex that twists the strand within. A take-up apron receives each twisted strand from the spinning and/or twisting block while maintaining the twist of each twisted strand. A tensioning take-up roll for each twisted strand receives each twisted strand from the take-up apron. A grooved cam with fork guide for each twisted strand received from the tensioning take-up roll, moves the twisted strand back and forth and up and down. Winding take-up rolls receive each twisted strand guided from the plurality of grooved cams with fork so as to maintain the tension and twists of each said twisted strand. A ring with booster jets directs a vortex of pressurized air to the twisted strands to produce a braided strand. Finally, a winding machine winds the braided strand received from the ring with booster jets.

Technical Problem

Various efforts were made by different inventors to eliminate zero twists in the yarn as discussed above. However, each of them suffers from at least one of the following disadvantages:

The use of an intermittent process to remove zero twists proved impractical;

Ultrasonic bonding and chemical bonding to remove zero twists each caused itching and an uncomfortable feeling to the human body; and

There was no confidence that S-twist and Z-twist would not migrate from their respective twist zones.

Prior efforts to eliminate zero twists failed to eliminate periodicity in the stable yarn.

Thus, there exists an unmet need to produce a continuous interlocked stable composite self-twist yarn with a high degree of confidence that zero twist is eliminated.

Solution to Problem

The solution is to provide an automated apparatus for composite self-twist braided yarn that obviates problems associated with the prior art.

The solution is an automated apparatus for composite self-twist-yarn braiding that eliminates the zero twist and produces a continuous interlocked stable self-twist composite yarn.

The solution is an automated apparatus for composite self-twist-yarn braiding that involves false twist or regular twist (S-twist or Z-twist) in three or more strands and air vortex spinning, twisting, braiding, self-twist plying process wherein twist heat setting or texturing is part of a continuous process or an independent process.

The solution is an automated apparatus for composite self-twist-yarn braiding wherein three or more strands are made as a composite self-twist strand in such a way that the end product does not have nodes at twist reversal. The strands are interlaced or braided or tangled at the node in alternate twist composite fiber assembly as well as in the self-ply no-node composite-fiber assembly structure.

The solution is an automated apparatus for composite self-twist-yarn braiding that may be used in a process for spinning, twisting, plying, cabling, braiding (with the option of twist heat setting or texturing at the self-twisting process of the yarn by providing superheated steam/air at the booster jets instead of compressed air) followed by a last step of winding.

The solution is an automated apparatus for composite self-twist-yarn braiding that involves heat setting the twist and texturing, which is done separately.

The solution is an automated apparatus for composite self-twist-yarn braiding that may be used with any one or combination of staple natural fibers, synthetic fibers, blend of natural and synthetic fibers, continuous multi-filaments and/or monofilament and blend of continuous filament or monofilaments with any staple fibers strand.

The solution is an automated apparatus for composite self-twist-yarn braiding using a combination and permutation of number of natural single strands and synthetic or elastomer single strands, allows manufacture of different percentages of blend of composite self-twisted strand (66%, 50%, 33% or 25% blend) without going through preparatory process of staple fiber blending.

The solution is an automated apparatus for composite self-twist-yarn braiding enables processing of any kind of strand assembly including S-twist alone or Z-twist alone and/or alternate twist single strand into self-twist ply or cable and braided yarn.

The solution is an automated apparatus for composite self-twist-yarn braiding that twines low or high twist staple strands and mono or multi-filament strands into ply or cable braided composite self-twisted strand.

The solution is an automated apparatus for composite self-twist-yarn braiding wherein the obtained composite false twist strands may be used in manufacturing of various products including novelty fabrics, carpets, tapestries, knitting and weaving fabrics and/or texturing staple fiber and/or filament strands.

The solution is an automated apparatus (100) for composite self-twist-yarn braiding wherein the end product is alternate twist strands plied into self-twist S- and Z-twist ply braided strand; or S-twist and S-twist strands plied into self-twist Z-twist plied braided strand; or (c) Z-twist and Z-twist strands plied into self-twist S-twist plied braided strand twist strand.

The solution is an automated apparatus for composite self-twist-yarn braiding that may be used as a unique braiding system for three and more strands.

The solution is an automated apparatus for composite self-twist-yarn braiding that eliminates the use complicated movements of gears for braiding.

The solution is an automated apparatus for composite self-twist-yarn braiding that eliminates the use of spindles and bobbins (source of smaller packages of yarn).

The solution is an automated apparatus for composite self-twist-yarn braiding that is very efficient and economical.

Advantageous Effects of Invention

The yarn produced using the disclosed automatic apparatus is braided at zero twist, providing a yarn and derived fabric that is stable, strong and smooth.

The automatic apparatus may be used for any combination of spinning, twisting, plying, and cabling natural and synthetic staple fibers, continuous multi-filaments and mono-filaments. Cabling is a process of plying already plied pair or pairs of yarns or pairs with singles yarn.

The automatic apparatus may be used to twine low- or high-twist staple yarn and single or multi-filament yarn or any strand created with an air vortex, such as those created by air jet spinning.

Texturing is included in the process or done separately by commercially available strand texturing unit.

By combining natural yarn and synthetic yarn, the automatic apparatus allows one to have 66%, 50%, 33% or 25% blend without going through a preparatory process of staple fiber blending. Enabling such combinations is helpful to producing “athleisure” (snug fit, elastic, moisture absorbing and yet thermal insulating) textiles, medical health related textiles, industrial (aerospace, marine and telecom related) textiles and conventional textiles.

The composite self-twist-yarn braiding produced by the automatic apparatus may be used for manufacturing various products including carpet, tapestry, knitting and weaving fabrics and/or texturing staple and/or filament yarns. It may be used for producing novelty yarn.

The automatic apparatus enables self-twist-yarn braiding three or more yarns without node or zero twist. It uses the principle of interlacing or weaving or braiding the three or more threads while creating alternate twist strands into self-twist S- and Z-twist ply or S-twist and S-twist strands into Z-twist self-twist-yarn braiding or Z-twist and Z-twist strands into S-twist self-twist-yarn braiding, as the case may be, and/or cable.

The automatic apparatus enhances physical properties of the yarn and the end product made from the yarn.

The automatic apparatus gives unique braiding system for three and more strands. The apparatus does not require the use of gears, spindles and bobbins (smaller yarn packages) and their movements for braiding.

The manufacturing of yarn, using the automatic apparatus is very efficient and economical.

Efficiency and economy results from an ability to process three or more strands into a single composite self-ply strand at a production speed typically in excess of 200 meters per minute. The production speed depends upon the number of strands plied or cabled into single strand production. Production speed may be in excess of 200 times number strands plied or cabled into single strand.

Efficiency and economy also results because a package of yarn produced can be considerably larger than that from a conventional ring spinning process, which translates to less time for doffing and donning yarn packages.

Efficiency and economy is attributable to a reduction in required manufacturing floor space for the automatic apparatus compared to existing spinning systems. This is attributable to an automatic apparatus that combines spinning, twisting, plying or cabling, (optional twist heat setting or texturing) and winding (as single process with the same machine) into a single machine.

Efficiency and economy also results from lower power consumption due to reduction in number of processes along with considerable increase in production per unit (200 meters per minute in comparison to 20 meters per minute of ring spinning and 50 meters per minute of open-end spinning.

BRIEF DESCRIPTION OF DRAWINGS

The drawings illustrate preferred embodiments of the tactical telescoping shotgun according to the disclosure. The reference numbers in the drawings are used consistently throughout. New reference numbers in FIG. 2 are given the 200 series numbers. Similarly, new reference numbers in each succeeding drawing are given a corresponding series number beginning with the figure number.

FIG. 1 is a perspective view of a preferred embodiment of the automated apparatus for composite self-twist braided yarn.

FIG. 2 is a top view thereof.

FIG. 3 is a side view thereof.

FIG. 4 is a perspective view of the spinning and/or twisting block of the embodiment of FIG. 1.

FIG. 5 is a perspective view of an alternative embodiment of the spinning and/or twisting block.

FIG. 6 is a front view of another alternate embodiment of the spinning and/or twisting block.

FIG. 7 is a top view of spinning and/or twisting block of FIG. 6.

FIG. 8 is a left side view of spinning and/or twisting block of FIG. 6.

FIG. 9 is a right side view of spinning and/or twisting block of FIG. 6.

FIG. 10 illustrates the combination of three S-twisted strands to produce one Z-twisted yarn using a preferred embodiment of the disclosed apparatus.

FIG. 11 illustrates the combination of three Z-twisted strands to produce one S-twisted yarn using a preferred embodiment of the disclosed apparatus.

FIG. 12 illustrates the combination of four S-twisted strands to produce one Z-twisted yarn using a preferred embodiment of the disclosed apparatus.

FIG. 13 illustrates the combination of four Z-twisted strands to produce one S-twisted yarn using a preferred embodiment of the disclosed apparatus.

FIG. 14 illustrates the combination of three S-twisted strands to produce composite self-twist braided yarn using a preferred embodiment of the disclosed apparatus.

FIG. 15 illustrates the combination of three Z-twisted strands to produce composite self-twist braided yarn using a preferred embodiment of the disclosed apparatus.

FIG. 16 illustrates the combination of four S-twisted strands to produce composite self-twist braided yarn using a preferred embodiment of the disclosed apparatus.

FIG. 17 illustrates the combination of four Z-twisted strands to produce composite self-twist braided yarn using a preferred embodiment of the disclosed apparatus.

FIG. 18 illustrates an irregular frequency of twist in the combination of composite self-twist braided yarns using prior art.

FIG. 19 illustrates a continuous interlocked stable yarn in the combination of composite self-twist braided yarn using a preferred embodiment of the disclosed apparatus for comparison to FIG. 18.

FIG. 20 is a front elevation view of a grooved cam with fork guide.

DESCRIPTION OF EMBODIMENTS

In the following description, reference is made to the accompanying drawings, which form a part hereof and which illustrate several embodiments of the present invention. The drawings and the preferred embodiments of the invention are presented with the understanding that the present invention is susceptible of embodiments in many different forms and, therefore, other embodiments may be utilized and structural, and operational changes may be made, without departing from the scope of the present invention.

The embodiment of the present invention is to provide an automated apparatus for self-twist-yarn braiding for three or more strands to eliminate nodes at zero twist or twist reversal in the yarn by automatic air vortex and braiding leading to a continuous interlocked stable yarn.

The automated apparatus (100) is thus configured to produce braided yarn. The automated apparatus includes a plurality of strands (150, 151, 152, 153) for spinning into yarn; a controller (154) programmed to control operation of the automated apparatus; a tension roller (145) for the plurality of strands, the tension roller (145) being configured to hold the plurality of strands in tension, whereupon each strand in the plurality of strands is then a tensioned strand (156); a spinning and/or twisting block (105) defining a plurality of pathways (e.g., a first pathway (420), a second pathway (421), a third pathway (422), and a fourth pathway (423)) therethrough, each pathway extending between two openings on opposite ends of the spinning and/or twisting block (see FIG. 4 where first opening (401) and second opening (404) define first pathway (420), third opening (405) and fourth opening (408) define second pathway (421), fifth opening (409) and sixth opening (412) define third pathway (422), and seventh opening (413) and eighth opening (416) define fourth pathway (423)), each of said pathways configured to contain one tensioned strand (156); the spinning and/or twisting block (105) comprising a plurality of air jets (e.g., see FIG. 4, at reference numbers 402, 403, 406, 407, 410, 411, 414, 415), each operated by a valve (165), each air jet being configured to act on one tensioned strand (156) to produce a twisted strand of which twisted strand (157) is representative; a take-up apron (110) configured to receive each twisted strand (157) from the spinning and/or twisting block (105) while maintaining the twist of each twisted strand (157); a tensioning take-up roll (115) for each twisted strand (157) configured to receive each twisted strand (157) from the take-up apron (110); a plurality of grooved cams, of which grooved cam (120) is representative, each grooved cam (120) within the plurality of grooved cams includes a fork guide (2005), each grooved cam (120) and fork guide (2005) is configured to guide one twisted strand (157), received from the tensioning take-up roll (115), back and forth and up and down; a plurality of winding take-up rolls (e.g. see FIG. 1, first winding take-up roll (125), second winding take-up roll (126) and third winding take-up roll (127)) configured to receive each twisted strand (157) guided from a grooved cam (120) and fork guide (2005) so as to maintain the tension and twists of each said twisted strand (157); a ring (130) with booster jets (135) configured to direct a vortex of pressurized air to each of twisted strand (157) to produce a braided strand (158); and a winding machine (140) configured to wind the braided strand (158) received from the ring (130) with booster jets (135).

The automated apparatus for producing a self-twist-yarn braiding mainly includes: a plurality of strands (150, 151, 152, 153) for spinning them into yarn; a controller (154), tension rollers (145); spinning and/or twisting block (105); a take-up apron (110); tensioning take-up rolls (115); grooved cam (120) with fork guide (2005), winding take-up rolls (125, 126, 127), a ring (130) with booster jets (135); and a winding machine (140).

Referring to FIG. 1 to FIG. 4, the plurality of strands (150, 151, 152, 153) are fibers used in textile industry to produce yarn. The plurality of strands (150, 151, 152, 153) are used to process them through the automated apparatus (100) for composite self-twist-yarn braiding to produce composite self-twist braided yarn.

The tension roller (145) is placed to receive the plurality of strands (150, 151, 152, 153) for tensioning them to be further processed. The tension roller (145) is a roller that rotates with the help of a motor controlled by a controller (154) determining the speed of rotation of the tension roller (145).

The spinning and/or twisting block (105) is placed after the tension roller (145) to receive the tensioned strands, of which tension strand (156) is representative from the tension roller (145).

As shown in FIG. 4 and FIG. 5, the spinning and/or twisting block (105) includes: a plurality of pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) between first opening (401), second opening (404), third opening (405), fourth opening (408), and fifth opening (413), sixth opening (416)); a plurality of air jets (402, 403, 406, 407, 410, 411, 414, 415); and a valve (165) for each of the plurality of jets. Each valve (165) is preferably operated by a motor (160), which is representative of motors used to control other components. The plurality of air jets is connected to each pathway so as to flow pressurized air into the pathway causing a vortex that twists the strand within. In operation, the controller preferably operates two valves to send pressurized air through four air jets and further operates two other valves to send pressurized air through four other air jets.

The plurality of pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) are channels within the spinning and/or twisting block (105) for passage of strands (150, 151, 152, 153) wherein the present embodiment embodies four pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) for passage of the plurality of strands (150, 151, 152, 153) through the spinning and/or twisting block (105).

The first pathway (420) is a channel within the spinning and/or twisting block (105) between a first opening (401) at one side of the spinning and/or twisting block (105) and a second opening (404) on the opposite side of the spinning and/or twisting block (105) that allows the first strand (150) to pass through in the direction from the first opening (401) to the second opening (404) in one of the embodiments. The second pathway (421) is another channel within the spinning and/or twisting block (105) between a third opening (405) at the one side of the spinning and/or twisting block (105) and a fourth opening (408) on the opposite side of the spinning and/or twisting block (105) that allows the second strand (151) to pass through in the direction from the third opening (405) to the fourth opening (408).

The third pathway (422) is another channel within the spinning and/or twisting block (105) between a fifth opening (409) at the one side of the spinning and/or twisting block (105) and a sixth opening (412) on the opposite side of the spinning and/or twisting block (105) that allows the third strand (152) to pass through in the direction from the fifth opening (409) to the sixth opening (412).

The fourth pathway (423) is another channel within the spinning and/or twisting block (105) between a seventh opening (413) at the one side of the spinning and/or twisting block (105) and a eight opening (d′) on the opposite side of the spinning and/or twisting block (105) that allows the fourth strand (153) to pass through in the direction from the seventh opening (413) to the eighth opening (416).

Not restricting to the number of pathways and respective openings, the spinning and/or twisting block (105) has plurality of pathways (P) and respective openings for the passage of multiple strands (150, 151, 152, . . . , Nth) for making braided yarn wherein the present disclosure includes and illustrates four strands (150, 151, 152, 153) as an embodiment of the invention.

Each of the plurality of pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) is connected to plurality of air jets (402, 403, 406, 407, 410, 411, 414, 415) for through distinct channels for twisting of strand (150 or 151 or 152 or 153) passing through respective pathways (420 or 421 or 422 or 423).

The twisting of the plurality of strands (150, 151, 152, 153) is in clockwise or anticlockwise direction which is facilitated by vortex of pressurized air through the air jet (402, 403, 406, 407, 410, 411, 414, 415), while the strands (150 or 151 or 152 or 153) pass through respective pathways (420 or 421 or 422 or 423). In a preferred embodiment, each of the plurality of pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) is connected to two air jets (402, 403, 406, 407, 410, 411, 414, 415) wherein the first pathway (420) is connected to air jets (402 and 403), the second pathway (421) is connected to air jets (406 and 407), the third pathway (422) is connected to air jets (410 and 411) and the fourth pathway (423) is connected to air jets (414 and 415) wherein further the air jets (402, 403, 406, 407, 410, 411, 414, 415) and the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) are connected through channels in the block facilitating pressurized air from the air jets (402, 403, 406, 407, 410, 411, 414, 415) to pass to the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)).

The air jets (402, 403, 406, 407, 410, 411, 414, 415), the channel and the opening of the channel into the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) are constructed so that the opening of the channel in the pathway is offset on either sides of the pathway (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) as shown in FIG. 2, FIG. 6, FIG. 7 and FIG. 8.

The air jets (402, 406, 410, 414) are connected to the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) such that the channel connecting the air jets (402, 403, 406, 407, 410, 411, 414, 415) and the opening at the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) is offset on one side so as to provide the vortex of pressurized air from one side so as to twist the strands (150 or 151 or 152 or 153) passing through respective pathways (420 or 421 or 422 or 423) in such direction as the vortex of pressurized air moves.

The air jets (403, 407, 411, 415) are connected to the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) such that the channel connecting the air jets (402, 403, 406, 407, 410, 411, 414, 415) and the opening at the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)) is offset on opposite side to the one side so as to provide the vortex of pressurized air from the opposite side so as to twist the strands (150 or 151 or 152 or 153) passing through respective pathways (420 or 421 or 422 or 423) in such opposite direction as the vortex of pressurized air moves.

Optionally, when a single strand (e.g., one of 150 or 151 or 152 or 153) passes through a pathway (420 or 421 or 422 or 423), it is exposed to vortex of pressurized air in two opposite directions at different portions of the strand (150 or 151 or 152 or 153) thereby resulting in twist in one direction in one portion of the strand (150 or 151 or 152 or 153) and in another or opposite direction in another portion of the strand (150 or 151 or 152 or 153) thereby providing twists in two different directions (clockwise and anticlockwise) in a single strand (e.g., one of 150 or 151 or 152 or 153). The twisting is repeated one after the other as the strand (150 or 151 or 152 or 153) passes through the pathway (420 or 421 or 422 or 423). For example, when the strand (150) passes through a first pathway (420), it is exposed to vortex of pressurized air from air jet (402) to get clockwise twist and air jet (403) to get anticlockwise twist at another portion of the strand (150).

In one embodiment, there is a valve (165) for each air jet (402, 403, 406, 407, 410, 411, 414, 415) to control the pressurized air through air jets. A preferred embodiment includes four valves to control the vortex of pressurized air in spinning and/or twisting block (105). The controller (154) is preferably a programmable logic controller (PLC), which controls the duration of pressurized air passed through each of the air jets (402, 403, 406, 407, 410, 411, 414, 415). Preferably, two valves control compressed air to air jets (402, 406, 410, 414) facilitating creation of a vortex of pressurized air in the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)), which in turn facilitate S-twists in the strand (150 or 151 or 152 or 153) passing through it in one direction. Two other valves control compressed air to air jets (403, 407, 411, 415) facilitating creation of a vortex of pressurized air in the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)), which in turn facilitate S-twists in the strand (150 or 151 or 152 or 153) passing through it in another direction.

The controller (154) determines the duration as well as the amount of pressure to be exerted to facilitate twisting through respective air jets (402, 403, 406, 407, 410, 411, 414, 415), as per a pre-defined program. Also, the valves determine the speed of operation of release and terminating the flow of vortex pressurized air into the spinning and/or twisting block (105). The valves controls the speed of the ON and OFF mode of the air jets (402, 403, 406, 407, 410, 411, 414, 415) as per a predetermined program, which determines the frequency of anticlockwise and clockwise vortex in the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)).

In another embodiment of the present invention, the spinning and/or twisting block (105) is placed in a direction so as to receive the tensioned strands, of which tension strand (156) is representative, from the tension roller (145) at the second opening (404) and the fourth opening (408) and the sixth opening (412) and the eighth opening (416) allowing the strands (150 or 151 or 152 or 153) in a tensioned state to pass through the pathways (420 or 421 or 422 or 423) respectively to openings (401, 405, 409, 413, respectively) at the one side of the spinning and/or twisting block (105) from the opposite side of the spinning and/or twisting block (105) implying that the spinning and/or twisting block (105) is so arranged that the first pathway (420) allows the first strand (150) to pass through in the direction from the second opening (404) to the first opening (401), and so on. The positions of the air jets (402, 403, 406, 407, 410, 411, 414, 415) also changes as shown in FIG. 5 thereby changing the twisting pattern in each tensioned strand (156) of the plurality of strands (150, 151, 152, 153).

The take-up apron (110) is placed to receive each twisted strand (157), i.e., the tensioned and twisted plurality of strands (150, 151, 152, 153) exiting the spinning and/or twisting block (105), while maintaining the twists in the twisted strands. The take-up apron (110) takes each twisted strand (157) up without losing the false twist to further pass them to the tensioning take-up rolls (115). A motor facilitates in the mechanism of the take-up apron (110).

The tensioning take-up rolls (115) maintain the twists of each twisted strand (157). The tensioning take-up rolls (115) receive and pass each twisted strand (157) to a grooved cam (120) in the plurality grooved cams. Each twisted strand (157) passes through the fork guide (2005) of a grooved cam (120). A motor controlled by the controller (154) facilitates the rotation of the tensioning take-up rolls (115).

Each grooved cam (120) in the plurality of grooved cams has a fork guide (2005) that enables movement of a strand in the plurality of strands (150, 151, 152, 153) back and forth and up and down for reciprocating the twisted strands on the winding take-up rolls (for example, first winding take-up roll (125), second winding take-up roll (126), and third winding take-up roll (127)).

Preferably, four grooved cams each with a fork guide (2005) are placed in staggered positions to receive a respective twisted strand (157) originating from the strands (150 or 151 or 152 or 153). While holding the twisted strands, the four grooved cams and fork guides maintain the tension and twists of the twisted strands and moves them back and forth and up and down for reciprocating the twisted strands on the winding take-up rolls (for example, first winding take-up roll (125), second winding take-up roll (126), and third winding take-up roll (127)). This results in interlocking the twisted strands and thereby enables braiding. The controller (154) controls the speed and the back and forth and up and down movement of each strand by movement of the fork guide (2005) in the grooved cam (120).

Preferably, the winding take-up rolls include the first winding take-up roll (125), the second winding take-up roll (126), and the third winding take-up roll (127). The winding take-up rolls are placed to receive each twisted strand (157) guided from the plurality of grooved cams and pass each twisted strand (157) between the first winding take-up roll (125) and the second winding take-up roll (126) and then between the second winding take-up roll (126) and the third winding take-up roll (127), all while maintaining tension, twists moving the twisted strands further.

Thus, the second winding take-up roll (126) is configured to roll up each twisted strand (157) half around the second winding take-up roll (126). The third winding take-up roll (127) is configured to pass each twisted strand (157) through the ring (130) with booster jets (135). The speed of rotation of the winding take-up rolls is regulated by the controller (154).

With reference to FIG. 1, the first winding take-up roll (125) receives the reciprocated twisted strands and passes the same between the first winding take-up roll (125) and the second winding take-up roll (126), thereby maintaining the tension and the twists.

The second winding take-up roll (126) winds up the twisted strands half around itself and passes it further between the second winding take-up roll (126) and a third winding take-up roll (127), while rotating. The twisted strands are passed further through ring (130) with booster jets (135). The controller (154) manipulates the speed of the rotation of the winding take-up rolls through a motor (not shown).

The ring (130) with booster jets (135) are placed to provide vortex of pressurized air to the twisted strands with twists and braided portions passing through the ring (130) with booster jets (135) facilitating in self-twisting. The resulting composite self-twist braided yarn is then wound by the winding machine (140). Each vortex of pressurized air is controlled through the valve (165), which in turn is operated or controlled by the controller (154).

The controller (154) operates: one or more motors for rotation of the tension roller (145); each valve (165) for controlling pressures of air jets (402, 403, 406, 407, 410, 411, 414, 415) and ON and OFF modes of the air jets to regulate the twisting of the plurality of strands (150, 151, 152, 153) passing through the spinning and/or twisting block (105); one or more motors, each associated with one of the take-up apron (110), the tensioning take-up rolls (115), the winding take-up rolls (for example, first winding take-up roll (125), second winding take-up roll (126), and third winding take-up roll (127)), and the winding machine (140), the movements of each grooved cam (120) the plurality of grooved cams and each fork guide (2005); and valves associated with booster jets (135), as per the predetermined program.

FIG. 10 is a first example showing three S-twisted strands (1001, 1002, and 1003) combined (plied) to produce a Z-twisted yarn (1005).

FIG. 11 is a second example showing three Z-twisted strands (1101, 1102, and 1103) combined to produce an S-twisted ply strand (1105).

FIG. 12 is a third example showing four S-twisted strands (1201, 1202, 1203 and 1204) combined to produce a second Z-twisted ply strand (1205).

FIG. 13 is a fourth example showing four Z-twisted strands (1301, 1302, 1303 and 1304) combined to produce a second S-twisted ply strand (1305).

These above examples in FIGS. 10-13 are not intended to limit the number of twisted strands (157) to three or four. Twisted yarn may be produced starting with any number of strands. It is also noted that when fork guide (2005) and grooved cam (120) is stationary, according to controller, three singles or four singles will self-twist, as shown in FIG. 10 thru FIG. 13.

FIG. 14 and FIG. 15 illustrate the production of composite self-twist braided yarn. A composite strand, also known as a composite ply strand, composite yarn, or simply yarn, is, for example, a blend of natural and synthetic fibers or same type of fibers of various length in formation of a ply strand, also referred to as yarn. Composite strands can be each strand made of a blend of fibers and/or one strand can be of one type of fiber (e.g., cotton) and another strand can be of another material (e.g., wool or synthetic staple (meaning cut to specific length) or multi-filament).

A composite self-twist braided yarn, also referred to as a composite self-twist braided strand, is a single strand made of three or more composite strands, wherein torque (twist) of each strand is of the same direction, which has a tendency to torque (twist) all the component strands in the opposite direction to form ply strand (this process is called self-twisting) and when the strands (at the same time) interlace/braid with each other, this is then defined as composite self-twist braided strand, also referred to as a composite self-twist braided yarn, and the process and apparatus for producing them are defined herein as composite self-twist strand braiding, or also as composite self-twist yarn braiding.

FIG. 14 shows a first composite self-twist braided ply strand (1405) produced from three S-twisted strands where the first composite self-twist braided ply strand (1405) has an S-twist portion (1401), a braided portion (1402) and a Z-twist portion (1403).

FIG. 15 shows the production of a second composite self-twist braided ply strand (1505) produced from three Z-twisted strands where the second composite self-twist braided ply strand (1505) has a Z-twist portion (1501), a braided portion (1502) and an 5-twist portion (1503).

FIG. 16 shows the production of third composite self-twist braided yarn (1605) produced from four S-twisted strands with an S-twist portion (1601), a braided portion (1602) and a Z-twist portion (1603).

FIG. 17 shows the production of fourth composite self-twist braided yarn (1705) from four Z-twisted strands having a Z-twist portion (1701), a braided portion (1702) and a S-twist portion (1703).

FIG. 18 shows three examples of composite self-twist braided yarn produced using prior art. Below that figure is FIG. 19, which shows two examples of composite self-twist braided yarn produced using a preferred embodiment of the automated apparatus disclosed herein. This line-up allows a comparison. FIG. 18 shows unsuccessful prior art attempts to remove zero twist (1801) from the twisted yarn. FIG. 18 illustrates an irregular frequency (1802) of twist, which results in failure to deliver proper yarn strength, consistency and texture.

FIG. 19 in comparison shows composite self-twist braided yarn produced from three strands (1901) and four strands (1902)) using the automated apparatus (100) for composite self-twist-yarn braiding, as disclosed herein. The yarn shown illustrates proper braiding that eliminates zero twist. It illustrates consistent twists with braided portions in between, resulting in a consistent texture. And, FIG. 19 illustrates a yarn produced having high strength.

The automated apparatus (100) for composite self-twist-yarn braiding effectively eliminates zero twist in the yarn. Such elimination produces to a continuous interlocked stable yarn. Such continuous interlocked stable yarn may be, for example, a three-ply self-twisted yarn with braided portions at the twist reversal of the three strands; or, for example, a four-ply self-twisted yarn with braided portions at the twist reversal of the four strands. Eliminating zero twists and the problems associated thereof and replacing the same by the braided portions imparts strength and smoothness to the yarn produced and to fabric derived therefrom.

The term “strand” used hereinabove includes any type of strands including single or multiple strands, plied or spun or cabled yarns, or pre-treated or untreated yarns.

Method of Using the Automated Apparatus

When the automated apparatus (100) for composite self-twist-yarn braiding is switched ON, the Controller (154) operates the motors controlling rotation of a tension roller (145). The Controller (154) operates each valve (165) controlling pressures of air jets (402, 403, 406, 407, 410, 411, 414, 415) and switches the ON and OFF modes of the air jets to regulate the twisting of the plurality of strands (150, 151, 152, 153) passing through the spinning and/or twisting block (105). One or more motors in turn operate each of the take-up apron (110), the tensioning take-up rolls (115), the winding take-up rolls (for example, first winding take-up roll (125), second winding take-up roll (126), and third winding take-up roll (127))), the winding machine (140), the movements of the plurality of grooved cam with fork guides, and valves associated with booster jets (135), as per the predetermined program.

The tension roller (145) receives the plurality of strands (150, 151, 152, 153) from strand sources. The tension roller (145) passes tensioned strands to the spinning and/or twisting block (105), wherein strand (150) in a tensioned state passes through first pathway (420) of the spinning and/or twisting block (105), strand (151) passes through second pathway (421), the strand (152) passes through the third pathway (422) and the strand (153) passes through the fourth pathway (423).

While the plurality of strands (150, 151, 152, 153) in a tensioned state pass through the pathways (first pathway (420), second pathway (421), third pathway (422), and fourth pathway (423)), they are twisted in one direction by action of a vortex of pressurized air coming from respective air jets (402, 406, 410, 414). Each tensioned strand (156) originating from the plurality of strands (150, 151, 152, 153) is twisted in opposite directions through vortex of pressurized air coming from respective air jet (403, 407, 411, 415).

Each twisted strand (157) originating from the plurality of strands (150, 151, 152, 153), then moves out of the respective openings (404, 408, 412, 416) to be further processed without losing the twist. The portions of the twisted strand (157) that follow the twisted portions are further exposed to the pressurized air coming from air jet (402 and 403) in the same way.

In between, while the portion of the strand (150, 151, 152, or 153) which is 5-twisted by the air jet (402), moves ahead to pass through the portion of pathway where the opening of the channel from the air jet (403) lies, the pressurized air coming from of the air jets (403) is set to stop as it is turned OFF as per pre-determined program based on time allowing the twisted portions to move further and the exposing the trailing portions of the strand (150, 151, 152, 153) to air jets (402, 403, 406, 407, 410, 411, 414, 415) at respective portions for twisting; when the air jets (402, 403, 406, 407, 410, 411, 414, 415) are ON. This facilitates continuous S-twisting of the plurality of strands (150, 151, 152, 153) in the spinning and/or twisting block (105).

The twisted strands originating from the plurality of strands (150, 151, 152, 153) after becoming twisted strands move further to the take-up apron (110) which maintains the twists of the plurality of strands (150, 151, 152, 153). The twisted strands are passed further to the tensioning take-up rolls (115) which further passes them to the plurality of grooved cams and fork guides. Each grooved cam (120) and fork guide (2005) holds a twisted strand (157) each such twisted strand (157) originating from the strands (150 or 151 or 152 or 153). Each grooved cam (120) and fork guide (2005) moves the twisted strand (157) back and forth and up and down for reciprocating the twisted strands on the winding take-up rolls (for example, first winding take-up roll (125), second winding take-up roll (126), and third winding take-up roll (127)) facilitating interlocking and braiding among the twisted strands. The winding take-up rolls maintain the twists and braiding of the twisted strands by passing the twisted strands between the first winding take-up roll (125), the second winding take-up roll (126) and the third winding take-up roll (127) as shown in FIG. 1.

The twisted strands are further passed through ring (130) with booster jets (135) for self-twisting followed by winding of the resulting composite self-twist braided yarn in the winding machine (140).

Having described what is considered the best form presently contemplated for embodying the present invention, various alterations, modifications, and/or alternative applications of the invention will be promptly apparent to those skilled in the art. Therefore, it is to be understood that the present invention is not limited to the practical aspects of the actual preferred embodiments hereby described and that any such modifications and variations must be considered as being within the spirit and the scope of the invention, as described in the above description.

Claims

1. An automated apparatus configured to produce braided yarn, the automated apparatus, comprising:

a plurality of strands for spinning into yarn;

a controller programmed to control operation of the automated apparatus;

a tension roller for the plurality of strands, the tension roller configured to hold the plurality of strands in tension, whereupon each strand in the plurality of strands is then a tensioned strand;

a spinning and/or twisting block defining a plurality of pathways therethrough, each pathway extending between two openings on opposite ends of the spinning and/or twisting block, each of said pathways configured to contain one tensioned strand;

the spinning and/or twisting block comprising a plurality of air jets operated by valves, each air jet in the plurality of air jets being configured to act on one tensioned strand to produce a twisted strand;

a take-up apron configured to receive each twisted strand from the spinning and/or twisting block while maintaining the twist of each twisted strand;

a tensioning take-up roll for each twisted strand configured to receive each twisted strand from the take-up apron;

a plurality of grooved cams, each grooved cam within the plurality of grooved cams includes a fork guide, each grooved cam and fork guide is configured to guide one twisted strand, received from the tensioning take-up roll, back and forth and up and down;

a plurality of winding take-up rolls configured to receive each twisted strand guided from a grooved cam and fork guide so as to maintain the tension and twists of each said twisted strand;

a ring with booster jets configured to direct a vortex of pressurized air to each of twisted strand to produce a braided strand; and

a winding machine configured to wind the braided strand received from the ring with booster jets.

2. The automated apparatus of claim 1, wherein the plurality of air jets is connected to each pathway so as to flow pressurized air into the pathway causing a vortex that twists the strand within.

3. The automated apparatus of claim 1, wherein the controller operates two valves to send pressurized air through four air jets and further operates two other valves to send pressurized air through four other air jets.

4. The automated apparatus of claim 1, wherein the plurality of winding take-up rolls comprises a first winding take-up roll, second winding take-up roll, and a third winding take-up roll;

wherein the first winding take-up roll is configured to receive each twisted strand guided from the plurality of grooved cams and pass each twisted strand between the first winding take-up roll and the second winding take-up roll;

wherein the second winding take-up roll is configured to roll up each twisted strand half around said second winding take-up roll, and further configured to pass each twisted strand between said second winding take-up roll and said third winding take-up roll;

wherein the third winding take-up roll is configured to pass each twisted strand through the ring with booster jets;

wherein a speed of rotation of said plurality of winding take-up rolls is regulated by the controller.

5. The automated apparatus of claim 1, wherein said plurality of strands comprises at least three strands.

6. The automated apparatus of claim 1, wherein the braided strand is selected from the group consisting of: a stable Z-twist ply strand braided from at least three S-twist strands wherein the stable Z-twist ply strand includes composite strands changing their respective positions during braiding while a self-twist process locks each strand's respective position; and at least three Z-twist strands braided into stable 5-twist ply.