This invention relates to a creel for holding yarn packages in a carpet manufacturing process. More specifically, this invention relates to a highly mobile creel configured for layered storage of yarn packages around a creel docking post in a carpet manufacturing process.
A standard creel has a frame provided with a plurality of vertical rows of holders each adapted to hold a respective bobbin comprised of a tubular core and a mass of filament—yarn or thread—wound on the core. A filament is pulled from each bobbin and guided through a respective eye, whence it passes to a warp or weft system of a loom or the like. A standard creel can hold hundreds and even thousands of bobbins, thus space requirement is a problem. Additionally, conventional creel design requires that the tufting machine be placed out of operation during the times an operator is required to change the bobbins on the creel in order to change yarns. Further, a significant amount of labor is required to successfully relocate a standard creel or to load or unload yarn packages on the creel.
Thus, there is a need in the pertinent art for an easily movable creel having a compact design for securely holding yarn packages. Additionally, there is a need in the pertinent art for a creel that is configured to allow for efficient loading and unloading of yarn packages.
The invention relates to a mobile creel for organizing yarn packages and directing yarn to a carpet manufacturing process. A mobile creel provides flexibility for carpet manufactures in that operators can pre-load mobile creels with yarn packages and roll the mobile creels to a desired location, where the mobile creel can be tied into an existing yarn feed. Due to the mobility of the mobile creel, heavier and larger creel packages can be used so as to extend the runtime between creelings throughout the carpet manufacturing process. Because of these extended runtimes and the decreased need for loading and unloading of creel packages, material-handling labor within a textile plant is significantly reduced.
In one aspect, the mobile creel has at least one support frame and an upright creel docking post. Each support frame of the mobile creel has a base with a front portion and a rear portion. The base of each support frame can have a substantially triangular shape. In another aspect, each support frame has a plurality of substantially upright support members extending upwardly from the rear portion of the base. In a further aspect, each support frame can have a plurality of spaced creel mounts positioned on at least one of the support members. Each creel mount can be configured to selectively hold a yarn package.
In another aspect, the upright creel docking post has a lower portion and an upper portion. The front portion of the base of each support frame can be configured for engagement with the lower portion of the upright creel docking post. In a further aspect, each creel mount can be configured so as to be operably positioned to substantially face a portion of the upright creel docking post after engagement of the base by the upright creel docking post. In one non-limiting example, the creel docking post can simultaneously engage one, two, three, or four support frames.
In an additional aspect, the support frame can have a plurality of casters to enable the mobile creel to be readily moved over flooring surfaces within a carpet manufacturing plant. In a further aspect, the creel mounts can be evenly spaced along the outer support members to create a plurality of levels for securing yarn packages. In another aspect, the support frame can have a plurality of substantially horizontal creel package separators mounted on the support members.
In a further aspect, the lower portion of the upright creel docking post can have a guide plate configured to receive the base of each support frame. In another aspect, the lower portion of the docking post has at least one magnet for maintaining the engagement of the front portion of each base with the lower portion of the docking post. In still another aspect, the upper portion of the upright creel docking post can have means for directing at least one path of yarn from the support frames to a selected process, including, for example and without limitation, a carpet tufting machine or a heat setting. For example and without limitation, the means for directing at least one path of yarn can be, alone or in combination, a series of spaced pre-guide rings, a series of spaced ball tension controllers, a plurality of yarn guides, or the like.
These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:
The present invention can be understood more readily by reference to the following detailed description, examples, drawing, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.
As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a yarn package” can include two or more such yarn packages unless the context indicates otherwise.
Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
In one embodiment, the invention relates to a mobile creel 10 for organizing yarn packages 20 and directing yarn to a carpet manufacturing process. The mobile creel 10 provides flexibility for carpet manufactures in that operators can pre-load portable creels with yarn packages 20 for future runs and move them into position when needed. In one aspect, the mobile creel 10 comprises at least one support frame 100 and an upright creel docking post 200.
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In another aspect, the support frame 100 can comprises a plurality of substantially horizontal creel package separators 160 mounted on the support members 130. It is contemplated that the creel package separators 160 can be configured to divide the levels 170 for securing yarn packages 20. As one will appreciate, the creel package separators 160 help prevent entanglement of yarn packages 20 located on different levels 170 of the mobile creel.
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In an additional aspect, the means for directing at least one path of yarn can further comprises a series of spaced ball tension controllers 250 positioned along the longitudinal length of the upper portion of the docking post 200. In one exemplary aspect, the series of spaced pre-guide rings 230 and the series of spaced ball tension controllers 250 can be positioned in an interdigitated relationship. As one will appreciate, the spaced ball tension controllers 250 can be configured to create even tension in the yarn 30 used during carpet manufacturing processes. Known ball tension devices, such as, for example and without limitation, Otto Zollinger (OZ®) ball tension devices, can be used for this purpose. In a further aspect, the means for directing at least one path of yarn comprises a plurality of yarn guides 270 mounted to the upper portion of the docking post 200. In this aspect, the yarn guides 270 can be configured to guide at least one path of yarn into a predetermined yarn formation. Optionally, the yarn guides 270 can be locking yarn guides, such as, for example and without limitation, Yuasa locking yarn guides.
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Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.
This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/265,607, filed on Dec. 1, 2009, the entire disclosure of which is incorporated by reference herein for all purposes.
Number | Date | Country | |
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61265607 | Dec 2009 | US |