Positive expansion/contraction comb system for wide beam weaving

Abstract

A system for providing improved warp uniformity across the width of the machine, the system including an expansion/contraction comb assembly connected to a synchronized timing system for providing a multiplicity of different expansion zones based upon different threaded zones on the drive rod that become sequentially decreasingly dense from the center of the machine outward. Also the system provides for elimination of floater blocks, which are replaced by drive blocks for deflection control across the width of the machine.

Description

BACKGROUND OF THE INVENTION

[0001] (1) Field of the Invention

[0002] The present invention relates generally to weaving and, more particularly, to an expansion/contraction comb system for improving yarn supply and fabric uniformity across the width of the warping and weaving machines. P (2) Description of the Prior Art

[0003] Typically, warping and weaving processes are subject to the introduction of nonuniformities at various stages. Where nonuniformities are present at an early stage, e.g., at the initial warping process, the nonuniformities and potential defects are multiplied throughout subsequent processes. In particular, warping and weaving on wide machines, such as for manufacturing carpet backing and other wide beam applications like domestic and industrial textiles having warp beams at least about 100 inches wide, the greater the width of the warping and weaving machines, the greater the nonuniformities may be across the width of the machines, which translates into potential defects or at least nonuniformities in the fabric produced thereon.

[0004] Prior art warping and weaving for wide machines commonly employ positive expansion combs that are connected to each other in an articulating manner so as to provide hinged joint sections known as “Nuremberg scissors” for providing improved uniformity controls across the width of the machine. However, the hingedly connected sections of prior art expansion combs do not readily provide adequate control and expansion or contraction compensation across the width of the machine, in particular for wider machines. More particularly, prior art positive expansion combs are known to provide only one or two expansion zones, thereby providing limited expansion and contraction ranges, which improves uniformity only on a very narrow range but which has limited effect on the uniformity for a large range across the machine width. Since positive expansion combs of the prior art use this low number of expansion zones, the amount of contraction or expansion is increased, due to the location and configuration of stationary support blocks, which support the drive box that activates the positive expansion comb assembly. If more multiple timings were to be added to this type of prior art configuration, additional stationary support blocks would be required to support the coupling regions of the threaded drive rod, in particular at the point of coupling of drive rods having different threaded densities. These additional stationary support blocks limit the range of motion of the active, threaded engaged drive blocks, which therefore limits the application of the use of multiple zones.

[0005] Thus, there remains a need for a positive expansion comb assembly having improved uniformity control over a greater width distance for the machine, thereby providing greater uniformity across the entire width of the warp and subsequently the fabric woven therefrom and eliminating substantial multiplicative defects in the finished product.

SUMMARY OF THE INVENTION

[0006] The present invention is directed to a positive expansion/contraction comb system for improving yarn supply and fabric uniformity across the entire width of the warping and weaving machines.

[0007] In the preferred embodiment, the system includes a positive expansion/contraction comb assembly having a comb bed, which secures comb panels that attach to the drive unit for providing an expandable and contractable series of comb panels connected pivotally at respective ends across the width of the machine. The system further includes a synchronized, predetermined timing system having a drive system and expansion/contraction controls for providing a multiplicity of different expansion/contraction zones based upon different threaded zones on the drive rod that become sequentially decreasingly dense from the center of the machine outward.

[0008] The present invention is further directed to a system for providing improved warp uniformity across the width of the machine, the system including a positive expansion/contraction comb assembly connected to a synchronized timing system for providing a multiplicity of different expansion/contraction zones based upon different threaded zones on the drive rod that become sequentially decreasingly dense from the center of the machine outward.

[0009] Thus, the present invention provides improved warp uniformity across the width of the machine via multiple synchronized controlled expansion/contraction zones.

[0010] Accordingly, one aspect of the present invention is to provide a system for providing improved warp uniformity across the width of the machine, the system including a positive expansion/contraction comb assembly connected to a synchronized timing system for providing a multiplicity of different expansion/contraction zones based upon different threaded zones on the drive rod that become sequentially decreasingly dense from the center of the machine outward.

[0011] These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a top view of an expansion/contraction comb base drive unit constructed according to the present invention.

[0013] FIG. 2A is a top view of a positive expansion/contraction comb slasher type assembly according to one embodiment of the present invention.

[0014] FIG. 2B is a front view of the assembly shown in FIG. 2A.

[0015] FIG. 2C is a side view of the assembly shown in FIG. 2A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

[0017] Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1, positive expansion/contraction comb system including a drive unit, generally referenced 10, for improving yarn supply and fabric uniformity across the width of the warping and weaving machines is shown. The positive expansion/contraction system further includes a synchronized, predetermined timing system that includes a drive system 12 for providing expansion and contraction movement in a controlled manner. The drive system includes a threaded drive rod 14 with left hand threads and right hand threads on either side of a center support block 16. The center support block is stationary and is connected to the comb bed at a central region on the center support block; it serves as a center point for the threaded drive rod and drive blocks to initiate and control the expansion and contraction movement of a positive expansion/contraction comb slasher type assembly 18 (shown in FIGS. 2A, 2B, 2C). At predetermined, spaced apart locations along the threaded drive rod 14, a series of stationary support blocks 20 are positioned for separating a multiplicity of different threaded zones 21, 22, 23, and 24, respectively and symmetrically on either side of the center block, on the left (L) and right sides (R); the center block 16 is stationary and connected to the comb bed. The center block connects and corresponds to the center of the comb bed and provides a “back stop” to which collars can be tightened against on the drive rod. The stationary support blocks are stationary and passively support the drive rod and frame at predetermined locations across the width of the machine and provide stabilization of the system, in particular of the frame, which is generally made of angle aluminum (shown in FIG. 2C), and the threaded drive rod, including x- and y-plane or horizontal and vertical stabilization of the expansion/contraction comb assembly. The threaded drive rod 14 is formed of a series of lengths of metal rod attached or bonded together by internally drilling one side, externally “turning” the other side, thereby forming a male/female coupling. These lengths are then connected with roll or spring pins. Support is needed at each of the couplings, which support is provided by the stationary support blocks described hereinabove. The system according to the present invention also includes a squared end 31 and end stationary support blocks 32.

[0018] Furthermore, a series of drive blocks 30 are actively engaged on the threaded drive rod within the respective zones and also serve to prevent deflection of the system within the horizontal or x-plane that runs along the width of the machine as well as providing vertical deflection (deflection out of the x-plane or horizontal) prevention of the comb beds. The drive blocks are attached to the comb bed at a central region of the drive block (shown in FIGS. 2A, 2B and 2C) for driving the expansion and contraction of the comb bed and the comb bed assembly 18 for each of the zones 21, 22, 23, 24 (FIG. 1) and their corresponding threaded density in turns per inch (tpi).

[0019] Additionally, floater blocks (not shown) may be included to provide some additional prevention of deflection in the y-direction or vertical deflection of the comb beds; floater blocks function passively and are not actively engaged by or attached to the threaded drive rod. Note that floater blocks are not required with the present system, and are not preferred for use with it, since the stationary support blocks and the drive blocks provide deflection prevention themselves; hence floater blocks are not shown in the figures. Generally, it is preferred that floater blocks are eliminated entirely and replaced with drive blocks, thereby maximizing control of the system according to the present invention. Also, the drive blocks provide similar deflection control as the floater blocks, while providing the added functional benefit of controlled expansion and contraction of the positive expansion/contraction comb assembly.

[0020] The positive expansion/contraction comb assembly, shown in FIGS. 2A, 2B, 2C, includes comb beds having comb panels 32 and holders 42 constructed, configured, and connected to provide expansion and contraction according to the movement of the threaded drive rod and drive system that controls its movement (shown in FIG. 1). The comb panels each have a first end 34 and a second end 36 that is attached with interlocking pins 38 to an adjacent comb panel. Also, the adjacent comb panels may be linked by male/female fittings as well as interlocking pins for ensuring secured connection. Adjacent links in the comb beds are attached by rivets, or internally threaded shoulder bolts. The comb panels form an expandable series 40 when connected pivotally at locations proximal to the respective first and second ends of adjacent combs, as shown, across the width of the machine. When connected to each other, the comb bed assembly is then connected to the drive block and then to the drive rod at predetermined locations, at least as frequently as the occurrence and location of the threaded drive blocks, described hereinbelow and shown in FIG. 1, for providing a scissor jack movement for expansion and contraction of the comb assembly based on the corresponding threaded drive rod zones to which each section of the comb assembly is attached.

[0021] Furthermore, in a preferred embodiment of the present invention, the cross-links of the comb bed are attached with links having internally threaded shoulder bolts instead of the smushed rivets commonly used in the prior art. While it is still possible to employ the prior art connectors within the comb assembly, the links having internally threaded shoulder bolts provide for an assembly having precision-torqued links, which provides for improved functionality and more precise attachments.

[0022] The expansion and contraction controls are provided by the multiplicity of different threaded zones in the threaded drive rod. The positive expansion/contraction comb assembly is connected to the threaded drive rod as set forth in the foregoing and expands or contracts according to the threaded zone to which each section of the comb assembly is attached across the width of the machine, as shown in FIG. 1, zones 21, 22, 23, 24. Each of the multiplicity of threaded zones is constructed according to a predetermined thread density and orientation. On the left hand side of the machine (L) as viewed from the top view in FIG. 1, the zones are configured and provide for stepped expansion and contraction such that increased movement of the expansion/contraction comb assembly occurs progressively outward from the center block, i.e., each of the multiplicity of zones has a decreasing thread density moving outward from the center block, which is associated with increased expansion or contraction, depending on the rotation of the threaded drive rod. In a preferred embodiment, the timing is providing by a four-section division of the drive rod on either side of the center block; on the left side of the center block a first section 21L provides for a threaded drive rod section at 20 turns per inch (tpi), followed sequentially by decreasing density of rod threading, a second section 22L provides for 15 tpi, a third section 23L provides for 10 tpi, and a fourth section 24L provides for 5 tpi. Correspondingly, on the right side of the center block, symmetrical to the left side are provided, a first section 21R provides for a threaded drive rod section at 20 turns per inch (tpi), followed sequentially by decreasing density of rod threading, a second section 22R provides for 15 tpi, a third section 23R provides for 10 tpi, and a fourth section 24R provides for 5 tpi. For the case of higher or lower density rod threading than illustrated here, there may be requirement for a specialized tap for creating the particular threaded zone, e.g., 2.5 tpi, as no standard threading is currently commercially available for these specifications. Matching and corresponding dies would be required for the external and internal threading. Another preferred embodiment, possibly providing an optimum threading system would provide for a series of threaded regions having 20 tpi, 10 tpi, 5 tpi, and 2.5 tpi, moving from the center block outward on either side of the center block as set forth in the foregoing. This predetermined, synchronized timing system with expansion and contraction controls based on a multiplicity of threaded zones provides for a ratio of 2-to-1 for each section or zone thereby providing more uniform expansion and contraction control across the width of the machine. This embodiment of the present invention set forth hereinabove provides for a four-fold increase in uniformity, which doubles the accuracy across the width of the machine.

[0023] Preferably, the range of expansion and contraction zones is between about three to about six, more preferably about four, as set forth in the figures for the purpose of illustrating the invention. It is understood at the time of the invention that about six zones on either side of the center block may be a limiting point because the area for movement of the expansion and contraction assembly along the threaded drive rod would be limited by the length of each zone and the placement of the support blocks between those zones or sections.

[0024] Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.

Claims

1. A positive expansion/contraction comb system for providing improved warp uniformity across the width of a machine comprising: an expansion/contraction comb assembly having comb panels and holders attached with cross-links to form a series of expandable and contractable comb panels connected pivotally at respective first and second ends across the width of the machine, the assembly connected to a synchronized predetermined timing system including a drive system having a center support block and a series of spaced-apart drive blocks that are actively engaged to a threaded drive rod that extends outwardly from the center block having right hand threading on one side of the center and left hand threading on the other side of the center, whrerein the series of spaced-apart support blocks are positioned at the ends of a multiplicity of threaded zones for providing controlled, tiered expansion and contraction across the width of the machine, wherein the multiplicity of zones is between about three to about six zones on either side of the center block.

2. The system according to claim 1, wherein the multiplicity of zones is between about three to about five zones on either side of the center block.

3. The system according to claim 1, wherein the multiplicity of zones is between about four zones on either side of the center block.

4. The system according to claim 3, wherein the zones provide for threaded drive rod sections having 20 tpi, 15 tpi, 10 tpi, and 5 tpi consecutively from the center block outward on either side of the center block.

5. The system according to claim 1, wherein the multiplicity of zones includes threaded sections of the drive rod that are decreasingly dense from the center block outward.

6. The system according to claim 1, wherein the cross-links are connected by precision-torqued internally threaded shoulder bolts.

7. The system according to claim 1, wherein no floater blocks are used.

8. A positive expansion/contraction comb system for providing improved warp uniformity across the width of a machine comprising: a positive expansion/contraction comb assembly having comb panels which are inserted into a comb bed and attached with cross-links to form a series of expandable and contractable comb panels connected pivotally at respective first and second ends across the width of the machine, the assembly connected to a synchronized predetermined timing system including a drive system having a center support block and a series of spaced-apart drive blocks that are actively engaged to a threaded drive rod that extends outwardly from the center block having right hand threading on one side of the center and left hand threading on the other side of the center, wherein the series of spaced-apart drive blocks are positioned within a multiplicity of threaded zones connected by spaced-apart stationary support blocks, wherein the system provides for controlled, tiered expansion and contraction across the width of the machine without requiring the use of any floater blocks for stabilization, wherein the multiplicity of zones is between about three to about six zones on either side of the center block.