Note: Descriptions are shown in the official language in which they were submitted.
BACKGROUND AND OBJFCTS 01 T~IE INVENTION
The present invention relates to the winding of synthetic yarns onto
a cylindrical drum or beam and, in particular, to the prevention of discernable
color bands in fabrics produced from such yarns.
In the mallufacture of synthetic yarn, a spinning solution of melted
polymer is extruded through a spinneret to produce minute filaments which are
twisted or otherwise combined to form a warp yarn or "end". A number of
spinnerets are arranged at a common metier to form a relatively large number of
yarns which are wound onto individual packages, or bobbins. The bobbins can be
of cylindrical or slightly tapered configuration and are rotatably driven below
the spinneret to draw the yarn therefrom.
Once fully wound, the packages are doffed, i.e., removed from the
spinning mechanism, and placed onto a mobile transport unit, and are eventually
taken to a creel at which the yarns are unwound from the packages and wound onto
a common drum or "beam", a step commonly referred to as "beaming". Attention
is directed to United States Patents 2,360,558; 2,578,017; 3,321,153; and
3,744,110 which disclose various beaming operations.
The creel comprises a framework on which a series of tension control
devices, for example whorls or "post-disc" are mounted. The transport units are
positioned alongside the framework such that the respective yarns can be pulled
from the packages, wrapped around the whorls and delivered to the beam without
becoming entangled. That is, an operator individually threads each yarn by
pulling it from the associated package, winding it around the associated whorl
threading it through a respective hole in a guide and eventually attaching it to
the beam. Typically, a large number of yarns are simultaneously unwound at the
creel and wound onto the beam. For example, in one instance, 1172 yarns are
wound, each having been pulled from a respective package at the creel. A beam
~1
g
wound in that fashion thus carries 1172 separate, axially adjacent sections of
wound yarn.
Important1y, it is to be Imderstood that in a typical yarn producing
facility yarns are produced from more than one metier. As a result of conven-
tional beaming techniques, discussed in detail hereafter, it is normal for a
fully wound beam to carry adiacent groups of yarns, each group comprising a con-
siderable number of yarns (e.g., ten) produced at the same metier.
The fully wouncl beam is adapted to be installed in a fabric forming
mechanism such as, for exampleJ a knitting machine which knits a fabric from the
yarns. The yarns which are grouped together on the beam will likely be grouped
together in the fabric. In cases where the yarns are to be dyed, it has been
found that the color or shade of dyed yarns from different metiers may contrast
somewhat. Even yarns from different locations of a given metier, or yarns pro-
duced during different production runs of a given metier may differ in shade
when dyed. Thus, one group of yarns may in the knitted fabric present a differ-
ent appearance from that of an adjacent group of yarns and thus produce a
"banded" or streaked appearance. Such a streaked fabric is unacceptable for
certain products such as wearing apparel, due to its undesirable appearance.
The cause of the different dyeing characteristics of the yarns in-
volves dissimilar conditions (e.g., temperature) existing at the metiers, but
an effective remedy for this problem has yet to be devised. Thus, yarns of dis-
similar dyeing characteristics continue to be produced and wrapped onto a common
beam.
It is known that the "banding" problem can be effectively eliminated
by reading the size of the groups of identical yarns having the same dyeing
characteristics e.g., if such similar yarns are mutually spaced on the beam,
because the contrast in shades of the dyed yarns in the final product is not
readily discernable unless a substantial number of yarns of the same shade are
grouped together. Such intermittent winding or "randomizing" of the yarns on
the beam has heretofore been achieved by creating an intermittent arrangement
of packages at the creel, as described more fully hereafter. Ilowever, this
solution is not practicable. ~or example, it may require that the packages be
manually removed from the transports and reoriented onto another support struc-
ture at the creel. The time and expense of such a procedure is prohibitive;
not only are there many packages involved (e.g., 1172 in some cases) but some
packages are considerably heavy (e.g., 20 pounds).
According to the present invention there is provided apparatus
for winding yarn onto a beam comprising a beam mounted for rotation about its
longitudinal axis, a plurality of first yarn transports, each first transport
supporting a plurality of yarn carrying packages; at least some of the packages
on the first transports being vertically spaced and the yarns thereon being
unwound by the beam and forming first rows of yarns, which first rows are sub-
stantially vertical and laterally spaced, with corresponding yarns in adjacent
first rows being substantially horizontally aligned to form vertically spaced
first sets of yarns the first sets formed exclusively by yarns from the first
transports; a plurality of second yarn transports, each second yarn transport
supporting a plurality of yarn carrying packages; at least some of the packages
on the second transports being vertically spaced and the yarns thereon being
unwound by the beam and forming second rows of yarns, which second rows are
substantially vertical and laterally spaced, with corresponding yarns in
adjacent second rows being substantially horizontally aligned, to form vertically
spaced second sets of yarns; the second sets formed exclusively by yarns from
-- 3 --
the second transl)orts; the first ancl second set of yarns being vertically inter-
mixed such that yarns of differentclyeing characteristics in the first and
second rows are vertically inLc?rposed between one another.
The invention also provides ayparatus for winding yarns onto a beam
compr:ising: a beam mounted for rotation about its longitudinal horizontal axis,
a creel disposed upstream of the beam and including yarn guide means, a
plurality of first mobile yarn transports arranged in horizontal alignment at
the creel, each first transport supporting a plurality of yarn carrying pack-
ages, at least some of the packages on each first transport being vertically
spaced and the yarns thereon being unwound and passed through the guide means to
form first rows of vertically aligned yarns, the first rows being horizontally
spaced, with corresponding yarns in the first rows being horizontally aligned
to form vertically spaced first sets of horizontally aligned yarns traveling
horizontally to the guide means and onto the beam, a second group of second
mobile transports disposed upstream of the first group and horizontally aligned
with the latter, each second transport supporting a plurality of yarn-carrying
packages, at least some of the packages on each second transport being vertically
spaced and the yarns thereon being unwound and passed through the guide means to
form second rows of vertically aligned yarns, the second rows being horizontally
spaced, with corresponding yarns in the second rows being horizontally aligned
to form vertically spaced second sets of horizontally aligned yarns traveling
horizontally to the guide means and onto the beam, the second sets alternating
vertically with the first sets, with the second rows being vertically aligned
with corresponding ones of the first rows to form combined rows of vertically
alternating yarns from the first and second groups of transports, which alter-
nating yarns have different dyeing characteristics, so that no yarn on the beam
is clisposcd immed:iatcly adjaccnt another yarn having the same dyeing characteris-
tics.
I'he present invention yrovides in a method of winding yarns onto a
rotary beam, the method being of the type wherein packages of wound yarns are
placed on vertically spaced supports of a plurality of yarn transports, the yarns
on some transports having different dyeing characteristics than the yarns on
other transports; yarn transports are positioned at a creel; the yarns are
unwound from the packages and wound in longitudinally adjacent relationship onto
a rotating beam, the yarns being guided in rows which are laterally spaced, the
improvement comprising the steps of: providing the rows in first and second
pluralities wherein yarns e;clusively from the first plurality are vertically
spaced and form a series of first rows which are laterally spaced, and yarns
exclusively from the second plurality being vertically spaced and forming a
series of second rows which are laterally spaced; and vertically intermixing
the first and second rows such that yarns in the second rows are vertically
interposed between yarns in the first rows having different dyeing characteris-
tics than the former.
The following is a description by way of example of an embodiment of
the present invention, reference being had to the accompanying drawings in
which:
Figure 1 is a schematic plan view of a prior art arrangement of yarn
transports at a creel only a few of the normal large number of transports being
depicted for clarity;
Figure 2 is a side elevational view of the prior art arrangement
depicted in Figure l;
Figure 3 is a side elevational view of a prior art arrangement of a
3LA~
rotary beam ~isposed downstrcam of the creel depicted in Figures 1 and 2;
Figure 3A is a plan view of the prior art arrangement depicted in
Figure 3;
Figure 4 is a schematic front view of a prior art yarn guide at the
creel;
Figure 5 is a schematic front view of a portion of a beam, depicting
the prior art relationship of yarns wound thereon;
Figure 6 is a schematic front view of a prior art eye-board disposed
downstream of the creel;
Figure 7 is a schematic view similar to Figure 1 of an arrangement of
yarn transports at a creel according to the present invention;
Figure 8 is a schematic side elevational view of the arrangement
depicted in Figure 7;
Figure 9 is a schematic front view of a yarn guide according to the
present invention;
Figure 10 is a schematic front view of a portion of a beam depicting
the relationship of yarns wound thereon in accordance with the present invention;
Figure 11 is a schematic front view of an eye-board according to the
present invention; and
Figure 12 is a schematic side elevational view of the eye-board
according to the present invention.
DETAILED DESCRIPTION
Prior Art
The present invention may best be understood by a comparison thereof
with one prior art system of beaming, depicted in Figures 1 to 6. That system
comprises a creel 20 at which packages or bobbins 22 of yarns are disposed.
.
~ ~ - 6 -
`i9
Ihe crccl is disl)oscd upstrealll of a bc~rfl or rotary drum 21. Ihe packages 22
are mowltc?cl on mobile trallsl)ort, sucll as whc?elc?d transport Imits A, B, C, D,
each of which inclucles a plurality of support spindles on which the packages
are loose]y placecl. One convelltiollal typc of transport unit contains thirty
spindles, fifteen sp:irldles 24 projc!cting from one siclc of the unit and fifteen
spindles 24' projecting from tlle othc?r side.
The spilldles are arrangcd such that the packages are disposed in
staggered relation on each transport unit, with the stagger pattern of adjacent
units being reversed, i.e., a first unit A having a single package (lA) (Figure
2) at top, then two (2A, 3A) therebelow, etc., whereas the next unit B has two
packages (le, 2B) at the top, then one (3B) therebelow, etc. Thus, some
spindles on each tTansport Wlit are vertically spaced. The single top package
lA of the first unit A is aligned horizontally with the two top packages lB,
2B of the next unit B. The units A-D are loaded at the spinning mechanism when
the filled packages from a production rwn of a metier are doffed, i.e.,
removed. In one conventional operation, ninety packages are filled by a metier
during a production run and thus require three transport wnits.
Depicted at the creel 20 are four transport wnits A-D, carrying
packages from different metiers. It will be appreciated that, in practice, it
is customary for many more wnits to be arranged at each creel. For example, in
one known beaming station in which 1172 yarns are wrapped onto a beam, 19 to 20
units would be employed. For the sake of convenience and simplicity in describ-
ing and illustrating the prior art and the present invention, however, only four
wnits are depicted. For further simplicity, only the yarns pulled from one side
of each transport will be explained, since the arrangements at both sides are
identical.
I`he creel compriscs a framework 26 on which are mounted a plurality
of t~nsion colltrol devices such as whorls 28 rotatable about vertical axes and
associated with respective ones oE the packages. Thus, each yarn is manually
unwound from its package and wound aro~md the associated whorl. The whorls may
be provided with conventional means for retarding rotation in order to control
the tension in the yarn.
At the downstream end of the beaming apparatus ~i.e., toward the
beam) there is providcd a guide structure 30 (Figure 4) which includes a
plurality of openings 32. In practice, each yarn is to pass through a respec-
tive one of those openings. Initially, the yarns are threaded manually through
the openings 32 and thereafter through a so-called "eye-board" 34 (Figure 6)
before being affixed to the beam 21. The eye-board 34 contains two identical
sets of apertures 36, 38, each set to receive the yarns from a respective side
of the creel. During this discussion, only the set of apertures 38 will be
described. The apertures contained in the set 38 are identical in number to the
number of yarns drawn from the associated side of the creel, i.e. 60 in the
illustrated embodiment (4 transport units x 15 packages per each side of a
transport unit). Since the packages are arranged on 10 vertically spaced levels,
there are 10 levels of 6 apertures each.
It will be appreciated that the pattern of openings in the guide
member 30 is similar to the pattern of apertures in the eye-board, i.e., 10
levels of 6 apertures. The depiction of the guide member 30 in Figure 4 is
schematic and is intended mainly to show the pattern of openings 32. Typically,
the guide 30 would include conventional means (not shown) for sensing an inter-
ruption (break) in each of the yarns to automatically stop the winding process.
When the beam 21 is rotated the yarns are pulled from the packages
and wrapped around the beam 21. The horizontally aligned group of topmost
packages lA, lB, 2B, lC, lD, and 2D defines a first lcvel or set of yarns
whereas the next lower group of horizontally aligned packages 2A, 3A, 3B, 2C,
3C and 3D defines a second level of yarns, and so on.
The initial yarn at each level, i.e., that farthest from the guide
30, passes through the outermost opening 32 (farthest from the creel) in its
associated level of openings. 'I'hus, the yarn YlA from the top package lA of
the first transport unit A passes around its respective whorl 10 and through an
outermost opening OlA of the top ]evel of openings in the guide 30. Likewise,
the initial yarn Y2A from the next level passes through opening 02A which is
vertically beneath the opening OlA. It will thus be appreciated that all of the
yarns in the outermost vertical row are from the same transport unit A and thus
from the same production run of the same metier. Thus, for the purposes of this
discussion these yarns will be termed "similar yarns" on the assumption that
they possess similar dyeing characteristics.
Importantly, those vertically aligned yarns YlA, Y2A, Y4A, Y5A, Y7A,
Y8A, YlOA, YllA, Y13A, Y14A become grouped alongside one another on the beam,
because the vertical rows of yarns is turned by 90 degrees before engaging the
beam. (The apparatus 49 for supporting and turning the vertical rows of yarns
downstream of the eye-board is conventional and need not be discussed in detail).
Thus, as depicted schematically in Figure 5, a group 50 of yarns YlA, Y2A, Y4A,
Y5A, Y7A, Y8A, YlOA, YllA, Y13A, and Y14A will lie adjacent another group 52 of
yarns on the beam 21. The group 52 contains a mix of yarns from the first and
second transports A and B, i.e., yarns probably from different metiers or
possibly from different production runs from the same metier. The next adjacent
group 54 of yarns will contain only yarns from the second transport B.
When the beam has been fully wound, it is removed and eventually
employed in a fabric producing machine which produces a :Eabric from the yarns.
Thereafter, the fabric may be dyed.
As noted earlier, some yarns may, when dyed, exhibit a different
shade from that of dissimilar yarns from a different metier (or from a different
production run of the same llletier). Thus, assuming that the packages from the
first and second transports A, B are from different metiers (or different pro-
duction runs of the same metie-r or possibly even from different zones of the
same metier during the same production run), the dyeing characteristics of the
first, second and third groups 50, 52, 54 will differ, and the groups, after
dyeing, will likely form readily discernable color "bands" in the fabric.
It will be appreciated that the banding problem might be solved if
it could be assured that all of the yarns on the beam have similar dyeing
characteristics, preferably as a result of being formed during the same produc-
tion run of the same metier. ~-lowever, due to the large number of yarns carried
by the beam (e.g., 1172 in some cases), this is not a practicable solution,
because a typical metier does not produce that many yarns during a given pro-
duction run. Moreover, it is possible that yarns produced at different zones
of the same metier even during the same production run, may exhibit different
dyeing characteristics, thereby defeating such a solution.
Another recognized possibility for alleviating the banding problem
involves a so-called "randomizing" of the yarns on the beam wherein each yarn
(or possibly a group of only a few (2-3) yarns) lies next to a yarn (or few
yarns) from a different metier. Upon being dyed, the dissimilar yarns will be
of different color shades, but such a difference will not be discernable to the
naked eye because similar yarns are no longer combined into large groups (e.g.
4 or more yarns). Thus the "bands" are replaced by a series of alternating non-
discernable lines.
- 10 -
As noted earlier, this solution has been attempted manually, whereby
packages are manually removed from the transport units and placed onto different
units at the creel :in such manner as to assure proper randomizing of the pack-
ages. Thus, the packages from one metier can be intermixed at the creel with
the packages from a different metier to create an intermittent arrangement of
yarns on the beam (e.g., yarns YlA, Y4A, Y7A could have similar dyeing charac-
teristics but different from the dyeing characteristics of yarns Y2A, Y5A,
Y8A). However due to excessive time and costs involved in such a manual trans-
fer of packages, such a practice has not proven to be economically feasible.
Preferred Embodiment of the Invention
In accordance with the present invention, the above-described inter-
mittent arrangement of yarns is achieved without the need for transferring
packages once placed on the transports and without the need for an appreciable
redesigning of the existing creel or transports.
As viewed in Figures 7 and 8, the same transports A, B, C, D are
arranged in the same order as i.n the previously described prior art arrangement.
However, the transports are combined into two groups, i.e., a remote group A, B
and a proximate group C, D. The remote group is termed "remote" in the sense of
preferably being disposed farther upstream from the beam than the "proximate"
group.
A modified guide 62 is provided (Figure 9) the openings of which
form twice the number of levels than in the guide 30 of the prior art arrange-
ment, each level having one-half number of openings than before, i.e. the guide
62 has 20 levels of 3 openings each. A modified eye-board 63 is provided with
the apertive pattern similarly modified.
Yarns exclusively from the proximate transports form a plurality of
rows of yarns designated as "proximate" rows, which proximate rows are laterally
~,~ s~
- 11 -
3~
spaccd alld vertically oricntcd. I:or cx.lmple, a vertical row of yarns YlC, Y2C,
Y4C, Y5C, ctc. passcs through the outc~r vertically aligned row of openings OlC,
02C, OSC, etc. in the guide 62. Ihe next vcrtical row of yarns YlD, Y3C, Y4D,
Y6C, etc. passes through the vertically alignecl row of openings OlD, 03C, 04D,
06C, etc. in tlle guide 62.
The corresponding yarns in the acljacent rows are laterally spaced to
define levels or sets of horizontally aligned yarns, for example, the yarns YlC,
YlD, Y2D form the topmost one of such sets.
In similar fashion, the yarns exclusively from the remote transports
A, B form a plurality of rows, designated as "remote rows", which remote rows
are laterally spaced and substantially vertically aligned.
Ilowever, in contrast to the prior art arrangement, the proximate and
remote rows and sets are vertically intermixed such that yarns in the remote rows
are vertically interposed between yarns in the proximate rows. Preferably, this
is done so that single yarns of the remote rows alternate with single yarns of
the proximate rows, as shown. Thus, for example, remote yarn YlA is disposed
vertically intermediate the proximate yarns YlC and Y2C; remote yarn Y2A is dis-
posed vertically intermediate the remote yarns Y2C and Y4C~ etc. throughout each
row.
By arranging the transports such that the packages on transport A have
different dyeing characteristics than the packages on transport C, it will be
apparent that the intermixed remote and proximate yarns serve to separate one
another in the rows, and thus on the beam.
With more particularity, it will be observed that the uppermost outer
opening OlC of the guide 62 (Figure 9) receives the initial yarn YlC from the
proximate group of transports. The next opening OlA therebeneath receives the
initial yarn YlA from the rcmote group of trallsl)orts. It will be appreciated
that the outermost row of vertically aligned yarns comprises yarns YlC, YlA,
Y2C, Y2A, Y4C, Y4A, Y5C, Y5A, Y7C, Y7A, Y8C, Y8A, YlOC, YlOA, YllC, YllA, Y13C,
Yl3A, Yl4C and Yl4A. Thus each yarn in that vertical row lies vertically
adjacent a yarn from a different transport. Assuming that the transports A and
C carry yarns from different metiers, it is assured that no banding problems will
occur, because each yarn on the beam will lie longitudinally adjacent a yarn
having different dyeing characteristics, as illustrated in Figure 10. Other
means of assuring the presence of different dyeing characteristics in the yarns
may possibly include taking yarns from different production runs of the same
metier or from different zones of the same metier during the same production
run.
It is noted that a space 60 is preferably, but not necessarily,
formed between the proximate and remote groups of transports to provide a tran-
sition zone in which the remote yarns may change levels, so as to become
vertically intermixed with the proximate yarns. In the preferred embodiment
the remote yarns descend one-half level, but it will be appreciated that the
remote yarns could ascend one-half level so as to overlie the associated yarns
in the proximate group.
It is conceivable that transports could be provided which can be
raised or lowered so as to properly relocate the yarn level in that fashion.
Thus, it may not be necessary to form physically spaced remote and proximate
groups of transports.
As noted earlier, it is preferable that the intermixing of remote and
proximate yarns be performed so that no two yarns of the same dyeing characteris-
tics are grouped together on the beam. However, it has been found, in practice,
- 13 -
that two or three or possibly four yarns of the same dyeing characteristics
may be grouped ~oget}ler on the be~n because such a group is not wide enough in
the dyed fabric to create a readily discernable color band. I-lowever, a group of
more than four yarns would probably be too wide to overcome the banding problem.
Also, as noted earlier, it is difficult to obtain yarns which have
the same dyeing characteristics, because of the different conditions which
exist from one metier to the next, or from one production run to the next of the
same metier, or even at different zones of the same metier during a given pro-
duction run. Ilowever, since the present invention relies upon yarns having
different dyeing characteristics, the need for creating universally uniform
conditions at all metiers is alleviated. Yarns of different dyeing characteris-
tics can most conveniently be obtained from different metiers.
In a typical yarn producing olant, many metiers are employed which
operate continuously around the clock and thus result in the availability, at
any given moment, of many filled yarn transports. Thus, it is conceivable that
the present invention can be carried out without concern that associated trans-
ports at the creel will carry yarns of different dyeing characteristics, because
chances are remote that the associated transports, e.g., A and C (i.e.,
"associated" in the sense that the yarns therefrom are to be intermixed~ in
Figure 7 would carry yarns from the same production run of the same metier.
However, precautions can be taken, if desired, to assuredly prevent such an
occurrence.
Thus, it will be appreciated that the present invention greatly
alleviates the banding problem in dyed fabrics without requiring that the pack-
ages be exchanged once placed upon the transports.
The present invention may be embodied in other specific forms without
departing from the spirit or essential characteristics thereof. The presently
- 14 -
LL~3'~
disclosed embod;ments are therefore considered in all respects as illustrative
and not restricti.ve. The scope of the invention is indicated by the appended
claims rather than the foregoing description, and all changes which come within
the meaning and range of e~ui.valency of the claims are therefore intended to be
embraced therein.
