FIELD
The present disclosure relates generally to the winding of fibers onto a tube to produce a doff, and more generally to an apparatus for guiding fibers during the winding process.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Reinforcing fibers, such as glass, are used in many common applications. For example, glass fibers can be used in insulation as well as in a variety of polymers for composite material applications. During packaging, the fibers are wound onto a tube to form a doff. The tube typically rotates at high speeds, and the fibers are wound around the tube to quickly form the doff.
Some winding operations include multiple tubes and thus involve the transfer of fibers from one tube to another. Transferring the continuous strand of fiber from one tube to the next in an efficient manner can be challenging at the high rotation speeds as fibers may tend to drift off the tube. When the fibers drift off the tube, a significant amount of manual labor is involved to re-direct/re-wind the fibers onto the tube, which also involves production down-time.
These challenges with winding fibers onto tubes, including winding operations with multiple tubes, are addressed by the present disclosure.
SUMMARY
This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form, a fiber catching device includes a base having an inboard portion and an outboard portion, an external wall extending upwardly from the inboard portion of the base, an outboard hook extending upwardly from the outboard portion of the base and extending to a height above the external wall, and at least one receiver disposed between the external wall and the outboard hook.
In variations of the fiber catching device, which may be implemented individually or in combination: a plurality of protrusions are disposed on the external wall and define a plurality of gaps there between; the gaps further comprise radial gaps arranged progressively closer to a top of the external wall; the gaps further comprise circumferential gaps arranged circumferentially along the external wall; the external wall is angled towards the outboard hook; the receiver is a groove; an inboard hook extends upwardly from the inboard portion of the base; a ridge extends upwardly from the base between the inboard and outboard hooks, wherein the receiver includes an inboard groove disposed between the inboard hook and the ridge, and an outboard groove disposed between the outboard hook and the ridge; the inboard portion of the base defines an inclined edge; the base further comprises opposed circumferential extensions; each of the opposed circumferential extensions comprises at least one aperture configured to receive a mechanical fastener; an internal recess extends radially below the base and is configured to receive an outboard edge of a tube; a ring extends between circumferential end portions of the base; and the base and the ring are a single unitized piece.
In another form of the present disclosure, a fiber catching system includes a tube and a fiber catching device. The fiber catching device includes a base having an inboard portion and an outboard portion, an external wall extending upwardly from the inboard portion of the base, an outboard hook extending upwardly from the outboard portion of the base and extending to a height above the external wall, and at least one receiver disposed between the external wall and the outboard hook, wherein the fiber catching device is configured to direct a continuous fiber into the receiver of the fiber catching device and around an exterior surface of the tube during a fiber winding operation.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
FIG. 1 is a perspective view of a multiple-tube winding system to which the teachings of the present disclosure are applied;
FIG. 2 is a perspective view of a fiber catching device constructed according to the teachings of the present disclosure;
FIG. 3 is a front view of the fiber catching device of FIG. 2;
FIG. 4 is a side view of the fiber catching device of FIG. 2;
FIG. 5 is a top view of the fiber catching device of FIG. 2;
FIG. 6 is a cross-sectional view taken through line 6-6 of FIG. 5;
FIG. 7 is a detail view of an end portion of the fiber catching device of FIG. 2;
FIG. 8 is a perspective view of another form of a fiber catching device according to the teachings of the present disclosure;
FIG. 9 is a front view of the fiber catching device of FIG. 8;
FIG. 10 is a side view of the fiber catching device of FIG. 8;
FIG. 11 is a top view of the fiber catching device of FIG. 8;
FIG. 12 is a perspective view of another form of a fiber catching device according to the teachings of the present disclosure;
FIG. 13 is a perspective view of yet another form of a fiber catching device according to the teachings of the present disclosure;
FIG. 14 is a perspective view of still another form of a fiber catching device according to the teachings of the present disclosure;
FIG. 15 is a perspective view of another form of a fiber catching device according to the teachings of the present disclosure;
FIG. 16 is a perspective view of yet another form of a fiber catching device in according to the teachings of the present disclosure;
FIG. 17 is a cross-sectional view of the fiber catching device of FIG. 16;
FIG. 18 is a perspective view of a fiber catching ring including a ring and a fiber catching device according withe teachings of the present disclosure; and
FIG. 19 is an enlarged perspective view of fibers caught within a fiber catching device according to the teachings of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring to FIG. 1, a fiber winding system is illustrated and generally indicated by reference numeral 10. The fiber winding system 10 generally includes one or more winders 12, onto which tubes 14 are mounted. Strands of continuous fiber 16 are wound onto the tubes 14 to form doffs 18, which are subsequently packaged and used in downstream products/processes. In this exemplary fiber winding system 10, two (2) winders 12 are shown. It should be understood, however, that the teachings of the present disclosure can be applied to fiber winding systems having only one (1) or multiple winders while remaining within the scope of the present disclosure. Further, the strands of fiber 16 in this form are glass, however, it should be understood that other fiber materials, such as by way of example carbon, Kevlar®, and natural fibers, among others, may be used while remaining within the scope of the present disclosure.
As used herein, a “fiber winding operation” is a process by which the fiber 16 is wound about the tube 14 to form the doff 18. The fiber 16 is initially free from the tube 14, e.g., extending from a fiber manufacturing machine (not shown). To wind the fiber 16 about the tube 14, the fiber 16 is directed around an exterior surface of the tube 14 as the tube 14 rotates about the rotatable axis R. To initiate the fiber winding operation, the fiber 16 engages with the tube 14 such that the fiber 16 forms a friction fit with the tube 14, pulling the fiber 16 around and along the exterior surface of the tube 14.
Referring to FIGS. 2-5, a fiber catching device 20 is provided to catch the fiber 16 during the fiber winding operation, and in one form when transferring from one winder 12/tube 14 to the next winder 12/tube 14. In this form, the fiber catching device 20 is generally an arcuate body configured to be secured to an outboard edge 15 of the tube 14. It should be understood that the body may define a shape other than arcuate while remaining within the scope of the present disclosure. The fiber catching device 20 is configured to “catch” and direct the fiber 16 that has been wound onto the tube 14, (illustrated and described in greater detail below), in the direction of rotation as indicated by arrow “R,” and to maintain the fiber 16 on the tube 14 during the fiber winding operation. Further, the fiber catching device 20 together with the tube 14 is also referred to herein as a fiber catching system.
As shown, the fiber catching device 20 includes a base 22 and a receiver, which in this design is in the form of grooves 40/42, described in greater detail below. As used herein, the term “receiver” should be construed to mean any element, feature, or material(s) of the fiber catching device 20 configured to receive the fiber 16. In the form shown, the fiber catching device 20 further includes an internal recess 24 extending radially below the base 22, an inboard hook 26 extending upwardly from the base 22, an outboard hook 28 extending upwardly from the base 22, and a ridge 30 extending upwardly from the base 22 between the inboard and outboard hooks 26, 28. Generally, the base 22 provides structure from which other portions of the body extend and provides a mounting area for the fiber catching device 20. The fiber catching device 20, being curved or arcuate in one form as shown, is designed to fit or slide onto the tube 14, as illustrated and set forth in greater detail below. The body can be formed using a variety of manufacturing methods, such as by way of example, 3D printing/additive manufacturing, casting, and molding, among others. In one form, the fiber catching device 20 is a thermoplastic polymer material formed using a multi-jet fusion additive manufacturing process.
Referring also to FIGS. 6 and 7, the fiber catching device 20 includes a ledge 32 extending radially below the base 22. The ledge 32 and the base 22 define the internal recess 24 therebetween. The fiber catching device 20 further includes an outboard wall 34 connecting the base 22 to the ledge 32. The base 22 has an inclined edge 36 extending downward toward the ledge 32. Thus, a height of the internal recess 24 between the inclined edge 36 and the ledge 32 is less than a height of the remainder of the internal recess 24 and is also less than the thickness of the tube 14. When the fiber catching device 20 is slid onto the tube 14, the tube 14 enters the recess 24, and the tube 14 elastically deforms the inclined edge 36 upward as shown, thereby forming a friction fit therebetween. The fiber catching device 20 is thus partially held onto the tube 14 with compressive force from the elastically deformed inclined edge 36. The fiber catching device 20 is further secured to the tube 14 using stitching (not shown) in one form of the present disclosure. In another form, the fiber catching device 20 may be riveted to the tube 14 or adhesively bonded, among other attachment means.
Referring specifically to FIG. 4, the outboard hook 28 extends to a height above the inboard hook 26. The inboard and outboard hooks 26, 28 are generally curved structures arranged to direct and capture the fiber 16 within the fiber catching device 20. That is, the inboard and outboard hooks 26, 28 are curved such that when the fiber 16 moves up onto the fiber catching device 20, the curved hooks 26/28 hold the fiber 16 within the fiber catching device 20 and inhibit the fiber 16 from moving away from the tube 14. The inboard and outboard hooks 26, 28 are thus generally disposed opposite each other along the base 22 to contain the fiber 16 within the fiber catching device 20 during a winding operation. In one form, the inboard and outboard hooks 26, 28 each have rounded edges 38 that inhibit tearing or breaking of the fiber 16.
The fiber catching device 20 further includes an inboard groove 40 and an outboard groove 42, separated by the ridge 30. In this form, the ridge 30 extends to a height below a top of the inboard hook 26 and a top of the outboard hook 28. The grooves 40, 42 are configured to further capture and maintain, or receive, the fiber 16 within the fiber catching device 20. Therefore, the grooves 40, 42, individually or together, should be considered to be a “receiver” as that term has been defined herein.
As further shown, the inboard hook 26 further includes an angled external wall 48. The angled external wall 48 is configured to face the fiber 16 as the fiber 16 approaches the fiber catching device 20. As the fiber 16 is wound around and moves along the external surface of the tube 14, the angled external wall 48 guides the fiber 16 up onto the fiber catching device 20, up and over the inboard hook 26, and into one of the grooves 40, 42. The external wall 48 is angled relative to the base 22 to direct the fiber 16 into the grooves 40, 42. In other words, the external wall 48 and the base 22 define a nonzero angle such that the external wall 48 extends toward the center of the fiber catching device 20.
Referring back to FIGS. 2, 3, and 5, to further direct the fiber 16 into the fiber catching device 20, and more specifically past the inboard hook 26 and into the grooves 40, 42, the fiber catching device 20 also includes a plurality of protrusions 50 disposed on the angled external wall 48. The protrusions 50 are configured to catch and direct the fiber 16 along the angled external wall 48, past the inboard hook 26, and into one of the inboard groove 40 or the outboard groove 42.
More specifically, and with reference also to FIG. 7, the protrusions 50 in this form include a leading protrusion 52. The leading protrusion 52 is positioned to be the first protrusion 50 that engages the fiber 16 as the tube 14 is rotated during the fiber winding operation. In one form, the leading protrusion 52 includes an angled face 54 that directs the fiber along the angled external wall 48. The protrusions 50 in one form also include rounded edges as shown to reduce the possibility of tearing or breaking the fiber 16. The protrusions 50 are further arranged to direct the fiber 16 progressively closer to a top of the angled external wall 48 through the use of strategically arranged gaps 56.
The gaps 56 are arranged to catch fiber 16 that does not consistently ride up the angled external wall 48 during the fiber winding process. The gaps 56 include radial gaps 58 arranged progressively closer to the top of the angled external wall 48 of the inboard hook 26. The radial gaps 58 are arranged in a radial direction from a bottom of the angled external wall 48 to the top of the angled external wall 48. The gaps 56 further include circumferential gaps 60 arranged circumferentially along the angled external wall 48 of the inboard hook 26. Thus, the radial and circumferential gaps 58, 60 are configured to progressively catch and direct the fiber 16 up along the angled external wall 48. It should be understood that the number and configuration of protrusions 50 and gaps 56 as illustrated and described herein are merely exemplary and a variety of other configurations may be employed while remaining within the scope of the present disclosure. It should also be understood that the angled external wall 48 may be normal or perpendicular to the base 22 rather than being angled while remaining within the scope of the present disclosure.
With reference to FIGS. 8-11, another form of a fiber catching device is illustrated and generally indicated by reference numeral 70. The fiber catching device 70 includes a base 72 extending circumferentially from one end to the other as shown, and the base has an inboard portion 71 and an outboard portion 73. The base 72 further includes an inclined edge 74 at its inboard portion 71, which extends downward as shown. The inclined edge 74 functions similar to the inclined edge previously illustrated and described. The base 72 further comprises opposed circumferential extensions 76 configured to align with a curvature of the tube 14. The inclined edge 74 and the circumferential extensions 76 are configured to inhibit fibers 16 from being caught beneath the base 72 and to direct the fibers 16 into the fiber catching device 70. In one form, the circumferential extensions 76 define optional apertures 78 therein to receive a mechanical fastener (not shown), such as a rivet that joins the fiber catching device 70 to the tube 14. In another form, the fiber catching device 70 may be secured to the tube 14 using stitching. In another form, the fiber catching device 70 may be adhesively bonded to the tube, among other attachment means. It should be understood that these attachment means may be employed individually or in any combination, such as by way of example, rivets and adhesive bonding.
In this form, the fiber catching device 70 includes an inboard hook 80, an outboard hook 82, and a ridge 84 disposed between the hooks 80, 82. The fiber catching device 70 further includes an inboard groove 86 and an outboard groove 88, separated by the ridge 84. In this form, one or more of the grooves 86, 88 define a “receiver” as that term has been defined herein. As described above, the grooves 86, 88 are configured to further capture and maintain the fiber 16 within the fiber catching device 70. More specifically, protrusions 90 on an angled external wall 92 define gaps 94 therebetween, and the protrusions 90 progressively guide the fiber 16 toward the grooves 86, 88. The gaps 94 include radial gaps 96 arranged progressively closer to the top of the angled external wall 92 and circumferential gaps 98 arranged circumferentially along the angled external wall 92. The radial and circumferential gaps 96, 98 are configured to progressively catch and direct the fiber 16 up along the angled external wall 92. And while the angled external wall 92 (and those of other variations illustrated and described herein) is shown angled towards the outboard portion 73, it should be understood that this wall can be normal or perpendicular to the base 72 while remaining within the scope of the present disclosure. Accordingly, the term “external wall” is used to indicate no specific orientation.
Referring now to FIG. 12, another form of a fiber catching device is illustrated and generally indicated by reference numeral 100. The fiber catching device 100 in this form includes a single groove 102 as the “receiver,” which is disposed between an outboard hook 104 and an external wall 106. Similar to the previous variations, the fiber 16 (not shown) is directed along the external wall 106 by protrusions 108 and into the groove 102. The protrusions 108 direct the fiber 16 along the external wall 106, down along a sloped internal wall 110, and into the groove 102. The protrusions 108 in this form are radially aligned with each other and are evenly spaced apart as shown. The protrusions 108 define gaps 112 therebetween, including radial gaps 114 and circumferential gaps 116 along the external wall 106. The gaps 114, 116 are configured to progressively catch and direct the fiber 16 up along the external wall 106.
The fiber catching device 100 also includes a base 118 and circumferential extensions 119, similar to those previously described. While apertures are not specifically illustrated, it should be understood that the circumferential extensions 119 may include one or more apertures as previously described to accommodate fasteners to secure the fiber catching device 100 to the tube 14 (not shown). Other forms of attaching the fiber catching device 100 as set forth herein may also be employed. Further, some or all of the features set forth herein in connection with the various fiber catching devices (e.g., internal recess 24) may be employed with this fiber catching device 100 while remaining within the scope of the present disclosure.
Referring now to FIG. 13, yet another form of a fiber catching device is illustrated and generally indicated by reference numeral 120. The fiber catching device 120 includes protrusions 122 that only have circumferential gaps 124, with no radial gaps or divisions along a length of an external wall 126. Without the radial gaps, the protrusions 122 are continuous along the external wall 126 as shown. Thus, the protrusions 122 guide the fiber 16 up over the external wall 126, along an internal wall 128, and into to a single groove 130. The single groove 130 is thus the “receiver” as that term has been defined herein. Upper portions of the external wall 126 and the internal wall 128 are blended together with a radiused edge 127, which helps to guide the fiber 16 into the single groove 130 and to inhibit snagging of the fiber. The fiber catching device 120 further includes an outboard hook 132, which functions as previously set forth with other variations of the fiber catching device. In another form, this fiber catching device 120 (and all other fiber catching devices illustrated and described herein) may include more than one groove 130 while remaining within the scope of the present disclosure. Further, some or all of the features set forth herein in connection with the various fiber catching devices, may be employed with this fiber catching device 120 while remaining within the scope of the present disclosure.
With reference to FIG. 14, yet another form of a fiber catching device is illustrated and generally indicated by reference numeral 140. In this form, the fiber catching device 140 has no protrusions to guide the fiber 16. Rather, the fiber 16 is guided along an angled external wall 142, down along an internal wall 144, and into a single groove 146. The single groove 146 is thus the “receiver” as that term has been defined herein. This fiber catching device 140 further includes an outboard hook 148, which functions as the other outboard hooks illustrated and described herein. Further, some or all of the features set forth herein in connection with the various fiber catching devices, may be employed with this fiber catching device 140 while remaining within the scope of the present disclosure. Similar features of this fiber catching device 140 that are similar to previously illustrated and described features are omitted for purposes of clarity.
With reference to FIG. 15, another form of a fiber catching device is illustrated and generally indicated by reference numeral 150. In this form, the fiber catching device 150 includes protrusions 152 with circumferential gaps 154 that guide the fiber 16 along an external wall 156. The fiber 16 moves along the external wall 156, over a rounded edge 157, along an internal wall 158, and into a single groove 160. The single groove 160 is thus the “receiver” as that term has been defined herein. The fiber catching device 150 also includes an outboard wall 162 to block the fiber from moving away from the single groove 160. Notably, the outboard wall 162 in this form does not include a hook as with previous forms of the present disclosure. Thus, the outboard wall may be angled inwardly (not shown) to further inhibit the fiber 16 from leaving the fiber catching device 150.
Referring now to FIGS. 16-17, in another form, a fiber catching device 170 includes a base 171, an external wall 172, an outboard hook 174, and a ridge 176 therebetween. The fiber catching device 170 in this form does not have any protrusions on the external wall 172 (although it could in another form of the present disclosure). An inboard groove 178 is disposed between the external wall 172 and the ridge 176, and an outboard groove 180 is disposed between the ridge and the outboard hook 174. In this form, the grooves 178, 180 act as the receivers for the fiber 16.
As further shown, a ramp 182 extends between the inboard groove 178 and the ridge 176. The ramp 182 generally directs the fiber 16 toward the outboard groove 180 if the fiber should leave the inboard groove 178 during the winding operation. And similar to the outboard hooks illustrated and described above, the outboard hook 174 inhibits the fiber 16 from leaving the outboard groove 180. The fiber 16 thus can be received by the inboard groove 178 or the outboard groove 180.
As shown in FIG. 17, the external wall 172 extends to an edge 173, and an internal wall 177 extends down to the inboard groove 178. The internal wall in this form forms an acute angle θ relative to a bottom wall 179 of the inboard groove 178, thereby creating a closed geometry to better retain the fiber 16. It should be understood, however, that the internal wall 177 may be normal, or perpendicular to the bottom wall 179 for improved manufacturability while remaining within the scope of the present disclosure.
It should be understood that some or all of the features set forth herein in connection with the various fiber catching devices may be employed with this fiber catching device 170 while remaining within the scope of the present disclosure. Similar features of this fiber catching device 170 that are similar to previously illustrated and described features are omitted for purposes of clarity.
Referring now to FIG. 18, another form of the present disclosure is a fiber catching ring 190 that includes the fiber catching device 70 described above (or any of the other fiber catching devices illustrated and/or described herein) and a ring 192. The ring 192 is configured to attach to the outboard edge 15 of the tube 14 (FIG. 1). More specifically, the ring 192 has an internal diameter sized to be press fit onto the outboard edge 15 such that the ring 192 is securely attached to, and rotates with, the tube 14 during operation. It should be understood that other features to secure the ring 192 to the tube 14 may be employed while remaining within the scope herein.
In this form, the fiber catching device 70 is integrally formed with the ring 192 to form a single, unitized piece. This unitized piece may be a single material or may be formed of different materials using, by way of example, an additive manufacturing process. In another form, the fiber catching ring 190 is manufactured from an individual ring 192 and an individual fiber catching device 70, as separate parts, which are joined in a secondary operation such as welding, adhesive bonding, mechanical fastening, and combinations thereof. While the fiber catching device 70 is shown generally as the form from FIG. 8, it should be understood that any of the fiber catching devices 20, 100, 120, 140, 150, 170 described above, among others, may be employed with the ring 192 to form a fiber catching ring 190 according to the teachings herein.
Referring now to FIG. 19, in operation, as the fiber 16 approaches the tube 14, the fiber 16 is directed along the exterior surface of the tube 14 towards its outboard edge 15. As the fiber 16 approaches the fiber catching device 20′, and as the fiber 16 is transferred from one winder 12 to the next, the fiber 16 is directed into and “caught” by the fiber catching device 20′. It is within the scope of the disclosure to incorporate any of the other fiber catching devices 70, 100, 120, 140, 150, 170 described above, among others, to catch the fiber 16. It should also be understood that the fiber catching device 20′ illustrated in this figure is secured to the tube 14 using rivets by way of example. This design is thus used to illustrate how the fiber catching device 20 captures fibers 16 and how the design can be secured to the outboard edge 15 of a tube 14. Therefore, this specific design configuration should not be construed as limiting the scope of the present disclosure.
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. For example, the different configuration and pattern of protrusions from one fiber catching device may be combined with another fiber catching device. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
Patent Application
20240294355
