Note: Descriptions are shown in the official language in which they were submitted.
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A STRAND
TECHNICAL FIELD
This invention relates to the production of glass fiber strands, and in the
p~k~ging, dispensing and weaving of yarn for use as a reinforcement or decorative
1 0 material.
BACKGROUND OF THE INVENTION
Mineral fibers are used in a variety of products. The fibers can be used as
reinforcements in products such as plastic matrices, reinforced paper and tape, and woven
products. During the fiber forming and collecting process numerous fibers are bundled
15 together as a strand. Several strands can be gathered together to form a roving used to
reinforce a plastic matrix to provide structural support to products such as molded plastic
products. The strands can also be woven to form a fabric, or can be collected in a random
pattern as a fabric. The individual strands are formed from a collection of glass fibers, or
can be comprised of fibers of other materials such as other mineral materials or organic
20 polymer materials. A protective coating, or size, is applied to the fibers which allows
them to move past each other without breaking when the fibers are collected to forrn a
single strand. The protection of the size allows the strand to be manipulated in various
fabrication processes, such as weaving. Where the fibers are to be used in an industrial
application, the size improves the bond between the strands and the plastic matrix. The
25 size may also include bonding agents which allow the fibers to stick together forming an
integral strand.
Typically, continuous fibers, such as glass fibers, are mechanically pulled
from a feeder of molten glass. The feeder has a bottom plate, or bushing, which has
anywhere from 200 to 10,000 orifices. In the forming process, the strand is wound
30 around a rotating drum, or collet, to form, or build, a package. The completed package
consists of a single long strand. It is preferable that the package be wound in a manner
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which enables the strand to be easily unwound, or paid out. It has been found that a
winding pattern consisting of a series of helical courses laid on the collet builds a package
which can easily be paid out. Such a helical pattern prevents adjacent loops or wraps of
strand from binding together should the strand be still wet from the application of the size
5 material. The helical courses are wound around the collet as the package begins to build.
Successive courses are laid on the outer surface of the package, continually increasing the
package diameter, until the winding is completed and the package is removed from the
collet.
A strand reciprocator guides the strand longitudinally back and forth across
10 the outer surface of the package to lay each successive course. A known strand
reciprocator is the spiral wire type strand oscillator. It consists of a rotating shaft
cont~ining two outboard wires appro~im~ting a spiral configuration. The spiral wires
strike the advancing strand and direct it back and forth along the outer surface of the
package. The shaft is also moved longitudinally so that the rotating spiral wires are
15 traversed across the package surface to lay the strand on the package surface. While
building the package, the spiral wire strand oscillator does not contact the package
surface. Although the spiral wire strand oscillator produces a package that can be easily
paid out, the package does not have square edges. A package having square edges can
have a larger diameter than packages with rounded edges. Also, a square edged package
20 can be stacked during shipping. It is desirable to build cylindrical packages having square
edges and larger diameters.
A known strand reciprocator which produces square edged, cylindrical
packages includes a cam having a helical groove, a cam follower which is disposed within
the groove and a strand guide attached to the cam follower. As the cam is rotated, the
25 cam follower and strand guide move the strand longitudinally back and forth across the
outer surface of the rotating package to lay each successive course. A rotatablecylindrical member, or roller bail, contacts the outer surface of the package as it is being
built to hold the strand laid in the latest course in place at the package edges as the strand
guide changes direction. The contact between the roller bail and the rotating package
30 surface causes the roller bail to rotate, and the speed of the roller bail surface is generally
equal to the speed of the package surface. An alternative version uses the strand guide
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itself to contaet the package and hold down the strand momentarily at the edge of the
package.
To increase produetivity, several paekages are built simultaneously on a
single collet. A separate strand is formed for each package, and a separate strand
5 reciproeator oseillates eaeh strand to build the paekages simultaneously. The strand
reeiproeators are mounted on an arm whieh moves the strand reciprocators away from the
collet as the package radius increases while keeping the roller bails in contaet with the
paekage surfaees. The fiber forming process, including the bushing temperature, is
controlled to keep the fiber diameters constant throughout the collection process, and to
10 keep the package radii of each of the packages increasing at a similar rate.
Process variations do occur, however, resulting in slight variations in
package size along the collet during the collection process. These differences in the
relative radii of the paekages on the collet eause roller bails to oeeasionally leave the
surface of a paekage. When a roller bail loses eontaet with the package surfaee, the
15 rotational speed of the roller bail begins to deerease. As the surfaee of the roller bail
comes back into contact with the package surface the rotational speed of the roller bail
inereases until the surfaee of the roller bail is traveling at the same speed as the surfaee of
the package. Due to bearing frietion and the inertia of the roller bail, the roller bail takes
time to spin back up to speed. While the roller bail is spinning back up to speed, the
20 difference in speed between the paekage surfaee and the roller bail surface eauses the
roller bail to skid against the package surface. The skidding roller bail produces abrasive
forces which can break fibers in the strand if the inertia is too high. In addition, skidding
can oecur during startup as the rotational speed of the collet is increased. Strand fibers
that break tend to separate from the strand as it is wound on the package and wrap around
25 the rotating roller bail, ereating a snarl whieh ean ruin the paekage.
It would be desirable to produce a strand having improved properties for
pae.k~ging, dispensing and weaving.
SUMMARY OF THE INVENTION
Aeeording to this invention there is provided a strand of individual
30 filaments, the strand having a primary eross-sectional shape, and periodic flat spots with a
flat cross-sectional shape which is more elongated than the primary cross-sectional shape.
.
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The strand with the periodic flat spots provides unique properties useful in pi~lc~ging the
strand for shipping to customers. Further, the strand presents advantages in subsequent
fabrication processes such as a weaving process.
The primary cross-sectional shape of the fill yarn preferably has an aspect
S ratio within the range of from about 1:1 to about 6:1, and the flat cross-sectional shape
preferably has an aspect ratio greater than about 6:1. More preferably, the aspect ratio of
the flat cross-sectional shape is greater than about 20:1. Most preferably, the aspect ratio
of the flat cross-sectional shape is within the range of from about 6:1 to about S0: 1. In a
preferred embodiment of the invention, the width of the flat spots is preferably within the
10 range of from about 5 to about 20 times the width of the primary cross-sectional shape.
In a specific embodiment of the invention, the period of the periodic flat
spots is within the range of from about 0.2 to about 6 meters, and more preferably the
period of the flat spots is within the range of from about 0.5 to about 3 meters.
In another preferred embodiment of the invention, the length of the
15 periodic flat spots is within the range of from about O.S to about 10 cm, and more
preferably within the range of from about 1 to about 5 cm.
There has now been developed an improved method of producing a strand
having periodic flat spots and controlling the production process to obtain the desired
qualities in the strand. The method of the invention includes rotating a collet to wind the
20 strand into a package, traversing the strand from end to end of the package so that the
strand is wound in a helical pattern on the package, contacting the package with a roller
bail at edge portions at each end of the package, pressing the package with the roller bails,
thereby causing the strand to flatten as it is wound in the edge portions to create a strand
having periodically occurring flat spots, and controlling the flattening of the strand by
25 controlling the pressure of the roller bails on the package.
In a specific embodiment of the invention, the roller bails are moved away
from the collet during the winding of the strand to accommodate the increase in diameter
of the package. The pressure applied to the package by each of the rollers is preferably
within the range offrom about 2 to about 10 pounds (0.91 to 4.5 kg), and more preferably
30 within the range of from about 3 to about 6 pounds (1.4 to 2.7 kg).
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In another embodiment of the invention, the flattening of the strand is
controlled by controlling the speed of the traverse of the strand. Controlling of the speed
of the traverse of the strand can be used to determine the length of the strand that is
wound onto the package while the strand is in the edge portions, thereby controlling the
S length of the flat spots. The speed of the traverse of the strand can be changed during
winding to control the period of the flat spots. In a specific embodiment of the invention,
the speed of the traverse of the strand is controlled to provide a generally constant period
between flat spots.
In another embodiment of the invention, the strand is traversed by the
10 reciprocation of a strand reciprocator mounted to travel along a helical groove in a
rotating cam, with the helical groove having curved end portions at each end of the cam,
where the speed of the traverse of the strand is controlled by establishing the shape of the
curved end of the helical groove.
There has now been developed an improved method of inserting a fill yarn
15 in an air jet loom weaving process. The fill yarn is propelled with one or more air jets
from the insertion side to the exit side of the loom. The yarn comprises a strand of
individual filaments, the strand having a primary cross-sectional shape and having
periodic flat spots with a flat cross-sectional shape which is more elongated than the
primary cross-sectional shape. The flat spots provide increased drag for propulsion by the
20 air jets.
In a specific embodiment of the invention, the period of the flat spots is
synchronized with the length of fill yarn required for the air jet loom. The flat spots can
be synchronized so that a flat spot passes through the air jet at the beginning of the
propulsion of the fill yarn across the air jet loom, thereby making it easier to propel the
25 fill yarn across the loom. This will enable the loom to operate with a lower overall air jet
pressure.
There has now been developed a woven fabric which provides a unique
appearance by having differentiated yarn in various positions throughout the fabric. The
fabric is comprised of warp yarn and fill yarn, where the fill yarn is a strand of individual
30 filaments, the strand having a primary cross-sectional shape and periodic flat spots with a
flat cross-sectional shape which is more elongated than the primary cross-sectional shape.
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The effect of the flat spots is differentiated fill yarn in the woven fabric. In a specific
embodiment of the invention, the differentiated fill yarn is lighter in color than the
remainder of the fill yarn. In another embodiment of the invention, the differentiated fill
yarn is more reflective than the remainder of the fill yarn.
S The differentiated fill yarn is expected to be wider than the remainder of
the fill yarn, and preferably has an average width which is within the range of from about
125 to about 300 percent of the average width of the remainder of the fill yarn. More
preferably, the differenti~ted fill yarn has an average width which is within the range of
from about 125 to about 175 percent of the average width of the remainder of the fill yarn.
In a preferred embodiment of the invention, the average length of the
differentiated fill yarn is within the range of from about 0.5 to about 10 cm, and more
preferably within the range of from about I to about 5 cm.
In a specific embodiment of the invention, the differentiated fill yarn is
generally randomly spaced throughout the fabric.
In another embodiment of the invention, the differentiated fill yarn is
generally aligned with specific warp yarn to form a longitudinal pattern along the length
of the fabric.
In yet another embodiment of the invention, the differentiated fill yarn
forms a repeating pattern in the fabric.
There has now been developed an improved yarn package which exhibits
improved stability and is capable of being payed out by withdrawing the yarn without
collapse of the package. The package is self supporting and is helically wound. The yarn
in the package comprises a strand of individual filaments, the strand having a primary
cross-sectional shape and periodic flat spots with a flat cross-sectional shape which is
25 more elongated than the primary cross-sectional shape. The package has edge portions
positioned axially at the ends of the package, and the flat spots are positioned in the edge
portions of the package. The package is wound in helical courses, and a size is applied to
the yarn. The size bonds each course to adjacent courses, with the flat spots exhibiting
enhanced bonding over portions of the yarn having the primary cross-sectional shape.
30 The expected average force required to pay out the yarn from the package is within the
range of from about 5 to about 100 grams. Preferably, the package has an axial length
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within the range of from about 8 to about 40 cm and has a diameter within the range of
from about 20 to about 50 cm.
BRTEF DESCRIPTION OF DRAWINGS
Fig. 1 is a schematic view in elevation of apparatus for forming, collecting
5 and winding fiber strands according to the principles of the invention.
Fig. 2 is an enlarged, schematic view in elevation of the strand reciprocator
shown in Fig. 1.
Fig. 3 is a schematic cross-sectional view in elevation of the appaldlus of
Fig. 2, taken along line 3-3.
Fig. 4 is an end view in elevation of a portion of the roller bail assembly of
Fig. 1.
Fig. 5 is a diagrammatic view of an embodiment of the invention in which
several packages are being wound simultaneously.
Fig. 6 is a schematic plan view of the yarn of the invention.
Fig. 7 is a schematic view in elevation of the yarn of the invention.
Fig. 8 is a schematic cross-sectional view of the yarn taken along line 8-8
of Fig. 7.
Fig. 9 is a schematic cross-sectional view of the yarn taken along line 9-9
of Fig. 7.
Fig. 10 is a schematic view in elevation of a package of yarn according to
the invention.
Fig. 11 is a schematic view in elevation of an air jet loom for use with the
method of the invention.
Fig. 12 is a more detailed view of the air jet of loom shown in fig. 1 1.
Fig. 13 is a schematic view of a fabric of the invention in which the
differentiated fill yarn forms a repeating pattern in the fabric.
Fig. 14 is a schematic view of another fabric of the invention in which the
differentiated fill yarn forms a repeating pattern in the fabric.
Fig. 15 is a schematic view of a fabric of the invention in which the
30 differentiated fill yarn is generally aligned with specific warp yarn to form a longitudinal
pattern in the fabric.
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Fig. 16 is a schematic view of a fabric of the invention in which the
differentiated fill yarn is generally randomly spaced throughout the fabric.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS
Figs. 1 and 2 show apparatus for forming, collecting, and winding strands
5 in which fibers 10 are drawn from a plurality of orifices 11 in a bushing 12 and gathered
into a strand 14 by means of a gathering member 16. A size suitable for coating the fibers
can be applied to the fibers by any suitable means, such as size applicator 18. The strand
is wound around a rotating collet 22 to build a cylindrical package 19. The package,
formed from a single, long strand, has a radially outer surface 20 with s~uare edge
10 portions 20a and a central portion 20b between them. The square edge portions 20a form
generally right angles with the package ends 20c. The outer surface of the cylindrical
package is preferably between about 10 cm to about 40 cm long, but may be longer or
shorter depending on the application. The collet is adapted to be rotated about an axis of
rotation 23 by any suitable means such as a motor 24. Any suitable package core material
15 such as a cardboard tube 26 can be disposed on the collet to receive the strand package.
Fig. 2 shows a strand reciprocator 30 which guides the strand 14 laterally
back and forth across the package surface 20 to lay the strand in courses 44 on the
package surface. The strand reciprocator includes a cylindrical cam 32 having a helical
groove 34. The cam is mounted for rotation and preferably made of a hard material, such
20 as stainless steel, but any suitable material can be used. The strand reciprocator further
includes a cam follower 36 that is disposed in the groove 34. The cam follower extends
outwardly from the cam and a strand guide 38 is attached to the end. The cam follower is
preferably made of a plastic or nylon material, but any suitable material can be used. A
notch 40 is formed in the strand guide to hold the strand 14. Rotation of the cam causes
25 the cam follower to follow the helical groove, thereby causing the strand guide to move
laterally across the package surface.
Referring now to Figs. 2 and 3, the strand reciprocator further includes a
roller bail assembly 42 for holding the strand courses 44 in place at the edge portions 20a
of the package surface 20 as the strand guide 38 changes direction. The roller bail
30 assembly includes a pair of spaced apartl or split rollers 46. The rollers have generally
cylindrical edge ends 46a and tapered inner ends 46b. The cylindrical edge ends contact
.
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the package surface at the edge portions 20a. The tapered inner ends extend from the
edge ends towards the central portion of the package surface 20b. The rollers do not
contact the surface of the package at the central portion of the package 20b. Each of the
rollers 46 is independently mounted for rotation by mounts 48. One or more bearings
~ 5 (not shown) are located between the roller bails and the mounts to allow the roller bails to
rotate freely by reducing friction. Although the roller bails are shown as mounted at both
the edge ends and the inner ends, the roller bails may be cantilevered, being mounted at
only one end. Each roller is made from a hard material, such as stainless steel, but any
suitable material may be used. The rollers preferably weigh approximately 50 grams
10 each, but may be heavier or lighter depending on their size and the application. They are
preferably hollow to minimi7.e weight and inertia, but may be solid. Each roller is
preferably about 2 cm long, but they may be longer or shorter depending on the
application.
The split roller bails are preferably coaxial, contacting the package surface
15 along a portion of a line 52 which is generally parallel to the package axis of rotation 23,
although, any suitable orientation of the roller bails may be used. Using 2 cm long roller
bails, the length of contact between the roller bails and the typical package surface will be
approximately 10% to 50% of the length of the outer surface of the package. A longer or
shorter length of contact between the roller bails and the package surface may be used
20 depending on the application.
The package rotates during winding as shown by line 53 in Fig. 4. As the
package builds, the radius 54 increases. To accommodate the increasing package radius,
the strand reciprocator 30 is mounted on an arm 56. To accommodate the increasing
package radius, the arm moves away from the collet along line 63 to keep the proper
25 contact between the surface of the rollers and the package surface and prevent the strand
courses 44a from pulling away from the edge portions 20a of the package surface.Several packages can be built simultaneously on the collet, as shown in
Fig. 5. ~ach package is built by drawing separate strands 14 from separate bushing
sections. The strands are wound around a single collet 22 to form packages 19. A30 separate strand reciprocator, including cam 32, cam follower 36, strand guide 38 and
roller bail assembly 42, is used to build each package. The packages are spaced apart
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along the collet and the strand reciprocators are spaced along the arm 56 in a similar
manner so as to be aligned with the packages.
The winding apparatus operates as follows. The strand reciprocator 30
guides the strand 14 as it is laid on the outer surface of the package. The strand is held by
5 notch 40 in the strand guide 38 and wound around the rotating collet 22 or a package core
26 disposed about the collet. The cam 32 is oriented near the package and rotates about
an axis 33 generally parallel to the package axis of rotation 23. The cam follower is
disposed within the cam groove 34, but is prevented from rotating with the cam. As the
cam rotates, the cam follower is moved laterally by the helical groove in a direction
10 generally parallel to the package axis of rotation 23. The helical groove is continuous,
having curved ends 34a that cause the cam follower to move to the end of the package and
then reverse direction. The strand guide is attached to the cam follower and it traverses
the outer surface of the package, reciprocating back and forth from end to end.
The helical winding pattern of each strand course 44 is formed by
15 reciprocating the strand across the package surface while rotating the package. As the
strand guide approaches the package edge portion 20a, the strand is laid on the package
surface under the roller tapered inner edge 46b. The strand guide continues to move
towards the end of the package 20c and the strand course, shown in phantom at 44a,
moves between the package surface and the cylindrical edge end of the roller which is in
20 contact with the package surface. When the cam follower travels through the curved end
34a of the groove 34, the strand guide 38 changes direction and moves away from the
package edge and towards the central portion of the package 20b. The contact between
the roller bails and the package surface holds the strand course 44a in place at the edge
portions 20a of the package surface, when the strand guide changes direction. By25 preventing the strand courses 44a from pulling away from the package edge portions 20a
as the strand guide moves back towards the center of the package 20b, a cylindrical
package having square edges is built.
The rolling contact between the rollers and the rotating package surface
causes the rollers to rotate. The speed of the roller surface is generally equal to the speed
30 of the package surface and the speed of the strand. When the speeds are equal, there is
little abrasive force between the strand and the roller bails.
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In the multiple package operation, the fiber forming process is controlled
to keep all the packages buiiding, and the package radii increasing, at a similar rate.
However, differences in package radii occur during winding because the diameters of the
strands are not always equal from package to package. Fluctuations in bushing
~ 5 temperatures, and inconsistencies in material properties can change the diarneter of the
fibers, and thus the strands, from package to package. Therefore, one package radius may
temporarily vary from the others until process corrections are made. Current injection is
sometimes used to regulate the temperature of the bushings to control strand diameter.
Differences in the radii of the packages can cause the roller bails to occasionally leave the
10 surface of a package. When a roller loses contact with the package surface, the rotational
speed of the roller begins to decrease. Later, as the surface of the roller comes back into
contact with the package surface, the rotational speed of the roller increases until the
surface of the roller is traveling at the same speed as the surface of the package. Due to
the lower inertia of the split roller bails, the roller bails spin back up to speed more
15 quickly than a single, heavier prior art roller bail which contacts the package surface from
end to end. Since the split roller bails have less inertia, they skid less and produce less
abrasive forces against the strands, and therefore are less likely to break any of the
individual fibers in the strands. In addition, when the collet is accelerating during startup,
the split roller baiis produce less abrasive forces against the strand while they are
20 accelerating and, therefore, break few fibers.
Strand fibers that do break tend to separate from the strand as it is wound
on the package and wrap around the rotating roller bail, creating a snarl which can ruin
the package. The split rollers provide break surfaces which break the snarling, broken
fibers. The rollers include cylindrical portions 46a forming contact surfaces which abut
25 the edge portions 20a of the package surface 20, and tapered portions 46b which do not
contact the package surface. The tapered surfaces extend from the contact surfaces
toward the central portion of the package surface 20b. The ends 46c of the tapered
surfaces 46b form the break surfaces. As the strand guide moves the strand away from
~ the roller 46 towards the central portion 20b of the package surface 20, any broken fibers
30 that have begun to wind around the roller will be broken off from the strand 14. Because
the strand is no longer in contact with a roller over the central portion of the package, the
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broken fibers cling to the main body of the strand due to the size mentioned above, and
the entire strand is wound around the package. By the time the strand reaches the other
roller at the opposite package edge, the broken fibers have been integrated with the strand
and the strand has been wound around the package. The broken fibers do not wrap
5 around the other roller. Although the tapered surface 46b having an edge 46c is shown,
the break surface can also include any surface discontinuity on the roller such as a groove
or shoulder. A discontinuity, or abrupt change in the roller surface will not allow the fiber
to continue to wind around the roller; the fiber will be broken as the strand moves across
the discontinuity. In addition, a knife edge or similar protrusion spaced apart from the
10 roller surface may be used as a break surface. Although it is preferable for the strand not
to contact the roller surface immediately after the snarling fiber has been broken off, it is
not required.
As shown in Figs. 6 and 7, the yarn or strand 68 produced by the winding
apparatus of the invention has periodically occurring flat spots 70 which are created by
15 the pressing of the rollers 46 on the package 20. As the strand is laid onto the rotating
package, the yarn is still wet with the size coating applied by the size applicator 18. After
the size dries, the pressed portions of the strand are retained in the flat shape as the flat
spots shown in Figs. 6 and 7.
The strand, which usual]y has at least 50 and preferably at least 200 glass
20 fiber filaments, has a primary cross-sectional shape 72 which is interrupted by the
periodic flat spots 70. The primary cross-sectional shape will depend on several factors,
including the amount and adhesiveness of the size, the tension of the winding process, and
the number and denier of the filaments in the strand. Typical fiber diameters are within
the range of from about 2.5 to about 13 microns in diameter, and the yardage is typically
25 within the range of from about 2.7 to about 270 tex (grams/km) ( 180,000 to 1,800 yards
per pound). Under normal operating conditions the winding of the strand will produce a
primary cross-sectional shape of the strand which is somewhat flattened or elongated, as
shown in Fig. 8. The primary cross-sectional shape is the shape of the strand between the
flat spots, and preferably the primary cross-sectional shape has an aspect ratio within the
30 range of from about 1: I to about 6:1. The aspect ratio is the long dimension or length L
divided by the short tlimension 1. The flat spots are considerably flatter than the areas of
,
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primary cross-sectional shape, and preferably have a flat cross-sectional shape with an
aspect ratio greater than about 6:1, as shown in Fig. 9. The aspect ratio of the flat spots is
the long dimension or length L' divided by the short dimension 1'. More preferably, the
aspect ratio of the flat cross-sectional shape is greater than about 20:1. A preferred range
5 of the aspect ratio of the flat cross-sectional shape is from about 6:1 to about 50:1. As
shown in Fig. 6, the width of the flat spots 70 is considerably wider than the width of the
area of primary cross sectional shape. It is expected that the width of the flat spots will be
within the range of from about S to about 20 times the width of the primary cross-
sectional shape, although other ratios are possible.
The strand or yarn of the invention, having the periodically occurring flat
spots, results in some unique properties when the strand is applied to or incorporated in
different products or processes. The flat spots are usually evident in some way, such as
being visually evident, thereby providing a distinctive character for the flat spot when
compared to the rem~in(ler of the yarn. Therefore, the flat spots create a different or
15 differentiated yarn where they occur, thereby forming a "differentiated" yarn. For
example, the flat spots in yarn used to make a woven fabric may stand out as being more
reflective in the fabric than the rem~indc.r of the fill yarn, and therefore the effect of the
flat spots is to create threads which are differentiated from the rest.
The strand or yarn having the periodic flat spots can be used for many
20 purposes. One possible use is as a fill yarn for a woven fabric of the type used as a cloth
for reinforcing printed circuit boards. The yarn of the invention can be used to advantage
in numerous industrial applications, where the larger surface area at the flat spots will
exhibit greater bonding with resin matrices. Industrial tapes will require less adhesive to
provide the same adhesion between the glass fiber reinforcement and the resin. Multi-
25 axial nonwoven scrims, which rely on bonding of the fibrous layers where they intersect7
can be made stronger or with a reduced binder content. The yarn of the invention can be
used as input for a chopped strand mat making machine. The yarn can also be used in a
beaming operation. In short, the periodic flatness of the yarn is potentially valuable
anywhere a bond between the yarn and another substance is desirable.
The length of the period P between centers of the flat spots can be
controlled by controlling the length of strand wound on the central portion 20b of the
13
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package, between the edge portions 20a and 20c. This can be accomplished by adjusting
the speed of winding process and the angle of the laydown of the strand on the package.
Smaller wind or laydown angles result in many revolutions of the package between the
ends, and hence a large period P between flat spots. In conventional strand packaging, the
5 wind angle is typically held to a range between about 4 to about 9 degrees, although other
angles are also possible. The wind angle required for stable packages and good runout of
the strand from the package will be a function of the type and weight of the strand, and
the type and amount of size on the fibers. Sharper or greater wind angles cause the strand
to travel quickly from one end to the other, resulting in a short period between flat spots.
10 The wind angle is also affected by the speed at which the strand guide 38 is reciprocated
from end to end of the package. Therefore~ the flattening of the strand can be controlled
by controlling the speed at which the strand is traversed. In a specific embodiment of the
invention the speed of the traverse of the strand is controlled as the package increases in
diameter to provide a constant, fixed period P between flat spots.
As the strand is wound around the package, the package diameter
increases. This will also affect the period P between flat spots since the distance traveled
by the strand around the package would be increased over time. Typical speeds for the
travel of the yarn are within the range of from about 100 to about 1000 meters per minute,
although higher speeds are possible. One method for assuring a constant period is to
20 adjust the wind angle as the package builds to compensate for the increased package
diameter. In a preferred embodiment of the invention, the period of the periodic flat spots
is within the range of from about 0.2 to about 6 meters, and more preferably, the period of
the periodic flat spots is within the range of from about 0.5 to about 3 meters.The length D of the flat spots is somewhat determined by the amount of
25 residence time during which the strand is wound in the edge portions 20a and 20c. This
can be controlled by choosing longer or shorter contact areas for the cylindrical edge ends
46a of the rollers 46, and by providing a longer or shorter curved end path 34a in the
groove 34 of the cam 32. In general, a slower rotational speed for the cam 32 results in a
longer residence time for the strand in the edge portions 20a and 20c. The length of the
30 periodic flat spots is preferably within the range of from about 0.5 to about 10 cm, and
more preferably within the range of from about 1 to about 5 cm.
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The width L' of the flat spots can be controlled by adjusting the pressure of
the rollers 46 on the package. A greater amount of pressure applied to the end portions
20a and 20c will cause a greater flattening. In normal operation the rollers 46 are moved
away from the collet 22 to accommodate the increased package size. The amount of5 pressure exerted on the package by the rollers can be increased by increasing the initial
pressure applied by the rollers and by maintaining the pressure throughout the packaging
process. Also, the pressure can be increased during p~rl~ging by reducing the amount of
backing off by arm 56 during packaging. It is to be understood that various ways can be
used to control the pressure of the roller bails on the package, including a computer
10 controlled motor for moving mounting arm 56 according to a predetermined plan. The
pressure of the rollers can be controlled to produce the desired amount of flatness for the
flat spots.
As shown in Fig. 10, the package 19 is resting on its end and the
periodically flattened strand 68 is being payed out from the interior of the package. The
15 package is free standing, i.e., capable of supporting itself during the unwinding process
without collapsing.
The outside surface 20 of the package is made up of generally curved
central portion 20b and two annular plateaus 74 created at the end portions 20a and 20c
by the flattening effect of the rollers 46. The plateaus are generally parallel to the
20 longitudinal axis 76 of the package in contrast to the gently curving slope of the package
in the central portion 20b. The amount of pressure applied by the rollers will affect the
width of the plateaus. The pressure applied to the package by each of the rollers is
typically within the range of from about 2 to about 10 pounds (0.91 to 4.5 kg), and
preferably within the range of from about 3 to about 6 pounds (1.4 to 2.7 kg).
The flat spots 70 in the strand are positioned exclusively in the end
portions 20a and 20c of the package. The increased surface area of the flat spots affects
the construction of the package by providing increased adhesive contact or bonding
between any particular course of the strand and its adjacent courses of strand. The bond
strength is greater than that of portions of the strand having the primary cross-sectional
30 shape. This increased bonding ability may require adjustment of the amount of size
applied to the strand, or to the adhesive quality of the size. If the bonding of the strand is
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too great, the strand 68 will not be easily payed out from the package. If the bonding is
too loose, the strand being unwound will pay out too easily and may balloon out or
otherwise become entangled. A preferred amount of average tension or force required to
release or pay out the strand is expected to be within the range of from about 5 to about
5 100 grams.
As shown in Figs. 11 and 12, the yarn or strand 68 of the invention can be
used to weave a fabric 78 on a loom 80. The loom can be an air jet loom, as shown, or
can be any other type of loom. The loom is supplied with warp yarn 84, 86 and the strand
68 of the invention is inserted into the fabric as the weft or fill yarn. The operation of
10 looms for making fabric is well known to those skilled in the art. The air jet 82 picks or
propels the fill thread or strand 68 across the loom, between the shed of the upper and
lower warp yarn 84 and 86. The reed 88 beats up or pushes the fill and warp yarntogether to form the fabric, which can be wound or carried away by any suitable means,
such as drum 90. As shown in Fig. 12, the air jet can be supplied with two fill yarn 68
15 and provided witl; separate air input lines 92 so that the fill yarn can be supplied
alternately from nozzles 94. The reed 88 is provided with a series of air jets, not shown,
that assist in carrying the fill yarn across the width of the loom.
The use in an air jet loom of the yarn of the invention, i.e., a yarn having
periodic flat spots, enables the machine to operate more efficiently since the flat spot
20 provides enhanced or increased air drag when subjected to the blast of air from the air jet
nozzle and the air jets on the reed. In a specific embodiment of the invention, the flat
spots are synchronized so that they pass through the air jet at the beginning of the
propulsion of the fill yarn across the loom. It is to be understood that this synchronization
is optional. Although the fabric and weaving process illustrates the yarn of the invention
25 used as a fill yarn, the yarn of the invention can also be used as the warp yarn.
One of the characteristics of the winding apparatus of the invention is that
the contact of the roller bails on the package enables the package to be made with a
relatively large diameter. Also, the ratio of the diameter to the axial length of the
packages can be increased. The axial length of the packages can be any desired length,
30 but is preferably within the range of from about 8 to about 40 cm. The diameter is
preferably within the range of from about 20 to about 50 cm. The increased bonding of
16
. .
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the strand at the end portions of the package provides a more stable package, one that is
more likely to be able to be wound with a relatively short axial length and a relatively
high diameter. This is advantageous in the strand manufacturing process because it lends
itself to making multiple packages which nevertheless contain substantial yardage.
As shown in Fig. 13, the fabric 78 includes warp yarn 84, 86. The fill yarn
includes the portions which are flat spots in the yarn, indicated at 96, as yarn that is
differentiated from the remainder 98 of the fill yarn. The differentiated yarn can be
formed into the fabric in the form of a pattern, as shown. The differentiated yarn differs
from the remainder of the yarn primarily by its visual appearance. For example, the
10 differentiated yarn may be lighter or darker in color than the remainder yarn. The
differentiated yarn may be capable of reflecting more light than the remainder yarn. The
differentiated yarn may be wider than the remainder yarn, and may have an average width
which is within the range of from about 125 to about 300 percent of the average width of
the remainder of the fill yarn, and preferably within the range of from about 125 to about
15 175 percent of the average width of the remainder of the fill yarn. The average length of
the differenti~te~l fill yarn is preferably within the range of from about 0.5 to about 10 cm,
and more preferably within the range of from about l to about 5 cm.
As shown in Fig. 14, the differentiated yarn can form a decorative pattern
in the fabric. Fig. 15 illustrates that the differentiated fill yarn can be generally aligned
20 with specific warp yarn 100 to form a longitudinal pattern along the length of the fabric.
As shown in Fig. 16, the differenti~tecl yarn can be generally randomly spaced throughout
the fabric.
The principle and mode of operation of this invention have been described
in its preferred embodiment. However, it should be noted that this invention may be
25 practiced otherwise than as specifically illustrated and described without departing from
its scope.
INDUSTRIAL APPLICABILITY
The invention can be useful in the packaging, dispensing and weaving of
yarn for use as a reinforcement material.
