Information
-
Patent Grant
-
6826814
-
Patent Number
6,826,814
-
Date Filed
Monday, September 29, 200320 years ago
-
Date Issued
Tuesday, December 7, 200419 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Stark; Stephen J.
- Miller & Martin PLLC
-
CPC
-
US Classifications
Field of Search
US
- 028 271
- 028 272
- 028 273
- 028 274
- 028 275
- 028 276
- 028 258
- 028 254
- 028 255
- 028 256
- 028 247
- 028 220
- 264 555
- 264 103
- 264 2108
- 264 21114
- 057 333
- 057 350
- 057 403
- 057 908
-
International Classifications
-
Abstract
A texturizer is a base which provides a plurality of inlets directed to stations internal to the base. Each of the stations communicate internal to housings which have inserts therein. Receivers in the inserts receive air from the stations and direct the air towards distal ends of the housings through slots. Prior to reaching the distal ends of the inserts, passages through the inserts direct air to an internal bore in the insert and proximally out the insert bore. The insert bore extends all the way through the insert and through the housing so that yarn is pulled through the housing and crimped preferably at an impingement point in the insert.
Description
FIELD OF THE INVENTION
The present invention relates to a yarn texturizer and a multiple port yarn texturizer having an improved insert construction.
BRIEF DESCRIPTION OF RELATED ART
In the prior art, yarn texturizers generally have inserts which fit within housings in a base. The inserts are comprised of an elongated member having a divergent head which terminates within the housing as shown in FIG.
1
. Air passes around the elongated body. As the air passes by a twist member, rotation is imparted to the air. The spinning air continues about the divergent end where it reverses course and flows into a bore disposed within a convergent section at the distal end of the insert. The housing extends past and over the distal end of the insert to assist in directing the air flow.
Yarn is normally fed through a hollow adjusting screw located above the bore in the insert. The screw extends through the prior art housing. Depending upon the extent to which the screw is inserted or backed out relative to the bore in the insert, the amount of vacuum experienced at the inlet to the bore which is adjusted. One problem with the prior art designs is that operators can unknowingly affect the performance of the yarn set or crimp by moving the screw relative to the bore. Some operators might prefer the screws backed out while other operators may prefer them as tight as possible. While this may not directly affect the operator, it produces a different set in the yarn which can be visible when tufted into a carpet to affect the runability of the downstream processes. Furthermore, the screws can become loose or galled over time thereby affecting the performance of the prior art design. Additionally, since texturizers typically have multiple stations, producing the exact same crimp in the yarn through the various stations may be difficult when each station is manually adjustable.
A second prior art design shown in
FIG. 2
has a similar insert construction but the screw or conical needle as it is often called is connected to a plunger which may be moved by air pressure up and down to assist in threading yarn through the insert and conical needle. Specifically, when the plunger is pushed towards an up position, shown in phantom, the amount of suction into the bore of the insert is significantly less which makes it much easier for the operator to thread up the texturizer station. Once threaded, the plunger may be returned to an operational position. Once again, the moving nature of the conical needle relative to the bore of the insert provides parts which wear over time and are subject to failure. Furthermore, this type of design is normally provided with adjustment parts to allow for the adjustment of the limits of travel of the plunger so that an operator can once again drastically affect the performance of the yarn as it is texturized by the texturizer of the prior art in FIG.
2
.
In both prior art designs air passes around the diverging distal end of the insert from all 360 degrees and then is directed through the bore as the insert narrows from the end to the entrance of the bore as shown. This 360 degree of air coverage provides somewhat of a donut that then narrows about the yarn as shown in
FIG. 1
to then pull it through the bore while also simultaneously performing the crimping and/or setting of the yarn as it passes through the texturizer. While the donut technique obviously works as it has been utilized in the prior art, it is not believed to be the optimum way to direct air through a texturizer to provide the most desirable and consistent crimp to the yarn.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to provide an improved texturizer that does not rely on an adjustment of individual stations or allow operators the opportunity to get stations out of adjustment.
Another object of the present invention is to remove threaded components which could otherwise gall, seize, or be misadjusted.
It is another object of the present invention to provide more consistent running of the product through a texturizer.
It is another object of the present invention to provide better overall runability and increase the efficiency of air-to-yarn concentration.
It is another object of the present invention to reduce the potential maintenance associated with the texturizer.
Accordingly, a texturizer of the presently preferred embodiment of the present invention has at least one station, each station having a housing surrounding an insert. Unlike prior art inserts which typically have a significantly smaller cross section along a majority of the length until the distal end of the insert, the preferred embodiment of the present invention employs an insert having a collar with an outer surface which substantially corresponds with the internal surface of the housing except for a plurality of slots which extend along the inner surface of the housing to provide channels to direct air flow.
Specifically air flows through the slots towards a distal end of the insert. Prior to reaching the distal end of the insert, proximally angled inwardly directed passages direct air from the slots towards the insert bore which extends through the center of the insert along a yarn travel axis. These inwardly directed passages are in communication with the slots so that air proceeds distally towards the distal end of the insert along the slots and then reverses direction towards the proximal end or discharge end of the texturizer insert through the passages. The inwardly directed passages preferably have axes which intersect along the yarn travel axis of the bore at an impingement point. By providing direct impingement at a single point, better overall runability is achieved and more efficient air-to-yarn concentrations achieved. More consistent running of the product is also achieved and less maintenance issues are encountered over the life of the texturizer. Although the preferred embodiment envisions opposing slots symmetrically arranged about the yarn or travel axis, other embodiments then may have three or more slots and may meet at more than one impingement point within the bore axis.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
FIG. 1
shows a cross section portion of a first prior art texturizer port showing an insert located proximately from a hollow conical needle located at the distal end of a housing;
FIG. 2
is a second prior art texturizer cross section portion having a conical needle connected to a plunger moveable with air pressure to provide for easy threading of the insert with yarn;
FIG. 3
is a top perspective view of an assembled texturizer according to the presently preferred embodiment of the present invention;
FIG. 4
is a cross-sectional view taken along the line A—A of
FIG. 3
;
FIG. 5
is a cross-sectional view taken along the line B—B of
FIG. 3
;
FIG. 6
is one of the plurality of housings shown in
FIGS. 3-5
;
FIG. 7
is a side elevational view of an insert taken from the texturizer of
FIG. 3
; and
FIG. 8
is a side plan view of the insert of
FIG. 7
with internal parts shown in phantom.
DETAILED DESCRIPTION OF THE DRAWINGS
In prior art texturizer designs shown in FIG.
1
and
FIG. 2
, pressurized air is directed into a housing
10
from a manifold connected through a base (not shown). As the air proceeded distally towards top end
12
from internal to the housing it passes through vanes
14
which are machined into an insert
16
to impart rotational forces to the pressurized air illustrated as arrows
18
. The swirling air is then be directed about the distal end
20
of the insert
16
which diverges at its distal end along its external surface and then narrows towards a bore
20
as yarn
24
proceeds from the distal end
20
toward the proximal end to the insert
16
. As the arrows
18
(representing air flow) proceed around the distal end
20
, a donut of air is effectively formed which constricts about the yarn
24
to pull it through the bore
22
as well as impart crimp the yarn
24
and thus texturize the yarn
24
as it proceeds through the texturizer.
In the design of
FIG. 1
, an adjustment screw
26
having a bore
28
therethrough is utilized to adjust the amount of vacuum experienced by the yarn
24
as it proceeds into the bore
22
of the insert
16
. Operators are prone to haphazardly adjust the adjusting screw
26
(i.e., some would back it all the way out, some would crank it all the way in). Unfortunately, moving the screw affects the crimp of the yarn
24
which can be observed in finished tufted carpet product. Furthermore, the ability to move the screw relative to the insert can result in galling of the housing or screw threads. Finally, the moving of the threads
30
relative to the housing
10
can become loose over time thereby affecting the quality and/or consistency of the texturized yarn product.
FIG. 2
shows a second prior art design which includes a moveable conical needle
50
relative to insert
52
. Air ports
54
,
56
allow the plunger
58
to be moved to the up position shown in phantom in
FIG. 2
which moves the conical needle
50
distally from the insert
52
. This has been found to be helpful in order to reduce the vacuum quickly to allow yarn to be threaded into the insert. Internal screw adjustments are normally provided to allow for the adjustment of the spacing of the needle
50
from the insert. This design provides further complicated structure and provides more moving parts which could fail over time. Once again, this product design relies upon a ring or donut for the air to be directed around the distal end
60
of the insert
52
towards the bore
62
to texturize yarn.
In both prior art designs, the inserts
16
,
52
have expanding cross sectional surface area across the exterior surface at the distal ends while having narrowing surface areas across internal surfaces proceeding proximally from the distal ends
20
,
60
toward the insert bores.
FIG. 3
illustrates a presently preferred embodiment of the present invention. Texturizers
100
can vary in the number of ports and in the arrangement of air. The specific configuration of air provided from an air supply to the individual housings
102
illustrated in
FIG. 3
is one example. This embodiment of a texturizer
100
is believed to provide sufficient detail to one of ordinary skill in the art to show how other embodiments would also operate.
Treated air is provided through inlets
104
,
106
into texturizer base
108
. Flange
110
is useful in connecting the inlets
104
,
106
to their respective air supplies at a manufacturing facility having the necessary equipment. Bolt holes
112
receive bolts therethrough to connect to the necessary air supply equipment. Air enters the inlets
104
,
106
as shown in FIG.
4
.
As air proceeds into the inlets
104
,
106
it is preferably directed past thermocouple ports
114
,
116
which house thermocouples or other temperature sensors utilized to measure the temperature of the air supply provided into inlets
104
,
106
. In the texturizing yarn it is normally important to maintain the inlet air supply and desired temperature or temperature range since air temperature and pressure both can drastically affect the crimp of the yarn as it leaves the texturizer
100
.
Although many texturizer embodiments provide a single inlet
104
or
106
for a single station, in this embodiment a single inlet
104
or
106
provides each of two stations respectively. Specifically, first inlet
104
provides air to first and second stations
118
,
120
, while second inlet
102
provides air into third and fourth stations
122
,
124
. Plugs
126
,
128
are useful in directing the flow of air to stations internal to the base
108
and simplifying machining processes.
In reference to
FIG. 5
showing texturizer
100
, differences between the presently preferred embodiment of the present invention and the prior art begin to thoroughly distinguish themselves. Since
FIG. 5
is a cross section taken along the center line only the first and second stations
118
,
120
are illustrated since the third and fourth stations
122
,
124
are obscured from view in this cutaway view. As the air proceeds from the respective stations it enters ducts
126
shown in FIG.
6
. These ducts
126
have been machined into the housing
102
and provided for air communication to flow from the inlets
104
,
106
through the respective stations
118
,
120
,
122
,
124
and then through the ducts
126
internal to the housings
102
.
As air passes through the ducts
126
it surrounds the receivers
128
of the respective inserts
136
shown in
FIGS. 7 and 8
. While the air may surround the receivers
128
360 degrees as is done in the prior art, it is channeled through slots
130
disposed in collar
132
so that air can proceed from the receiver
128
through the slots
130
towards the distal end
134
of the respective insert
136
. Instead of reaching the distal end
134
as is done in the prior art while diverging, the air flow is maintained through the respective slots
130
until reaching respective passages
138
.
The passages
138
preferably proceed from a distal exterior portion of the collar
132
of the insert
136
in the slot
130
towards the proximal end
140
. Although the passage
138
is illustrated as being directed about 20 degrees relative to yarn travel axis
142
other relationships between about 10 to about 80 degrees could be utilized. Furthermore, the passages
130
,
132
are preferably symmetrical as illustrated. As yarn is run along the yarn travel axis
142
, it is drawn by the pressure differential caused by the air flow through the passage
138
towards impingement point
144
. The force of the air through the passages
138
contacting the yarn (shown in
FIG. 5
in one of the four inserts) causes the yarn to crimp primarily due to the impingement force at the single impingement point
144
.
Instead of providing a 360 degree circle or donut of air about the yarn, the direction of air through slots and passages
130
,
138
to impingement or pinch point
144
, more efficient air-to-yarn concentration is achieved resulting in more consistent running of product. Furthermore, a lack of moving parts between the distal end
146
and the housing provides an impingement point
144
in which no threaded components can gall, seize, or otherwise be subject to undesirable adjustment by operators. Since there is no operator adjustment provided by the texturizer
100
design, better overall runability is achieved (i.e., as long as the same pressure and temperature are provided through the inlets
104
,
106
and provided with the same yarn inserted at the distal ends
134
of the inserts
136
, a more consistent and high quality output will be discharged from the proximal ends
140
of the inserts
136
.) In fact, runability has been found to increase from about 95% in the prior art texturizers to slightly over 98% through the use of the preferred embodiment.
In the prior art, air would be disposed around a receiver and would be similarly spaced apart from the internal surface of the housing. The insert would remain spaced apart from the housing interior surface until encountering the diverging end of the insert and the distal end of the housing.
In the design in accordance with the presently preferred embodiment, the collar
132
substantially corresponds with the internal surface of the housing
146
except for the slots
130
which allow air to be communicated from the receiver
128
through the slots
130
to the passages
138
. The passages
138
are spaced from the distal end
134
of the insert
136
. An O-ring
150
as shown in
FIG. 5
is installed about groove
152
shown in
FIG. 8
to provide an airtight seal. Caps
154
retain the inserts
136
in the housings
102
. The housings are preferably silver soldered or otherwise attached to the base
108
to the form air tight connections therewith.
Although two slots
130
which oppose the yarn travel axis
142
and extend radially therefrom are illustrated, it is alternatively possible that three or more circumferentially or radially equally spaced passages
138
and slots
130
can be employed. Furthermore these airways may also be symmetrical about the yarn travel axis
142
especially when there are an even number of passages provided. In accordance with this embodiment, the collar
132
separates the slots
130
from one another. In
FIG. 5
, the yarn
156
is shown inserted into the distal end
134
at the insert
136
as it proceeds to the impingement point
144
and is crimped to the desired state and proceeds on out of the proximal end
140
.
A ceramic insert
158
is helpful in preventing the yarn
136
from inadvertently being cut as it passes through the distal end
134
.
As shown in
FIG. 7
, a shank base
160
is located below the receiver
128
. The shank base
160
preferably has an exterior surface
162
which substantially corresponds with the interior surface
146
of the housing
102
so that it effectively forms an air tight seal with the shoulder
164
contacting bottom
166
of the housing
102
. The cap
154
is preferably equipped with internal threads
168
which cooperate with external threads
170
on the housing
102
to secure the insert
136
within the housing
102
.
Numerous alterations of the structure herein disclosed will suggest themselves to those it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
Claims
- 1. A texturizer comprising:a base having a first inlet ducted to a first station; a first housing having a proximal and a distal end, an internal housing bore and a duct intermediate the proximal and distal ends of the first housing, said duct providing fluid communication from the first station to the housing bore; a first insert having a proximal and distal end and an insert bore extending through the first insert along a yarn travel axis, said first insert having a receiver located at least partially in the housing bore at the duct and a collar disposed toward the distal end of the first insert, said collar having at least two slots disposed along an outer surface of the collar, said slots extending distally from the receiver toward the distal end of the first insert, said collar also having passageways corresponding respectively to the slots, said passageways proceeding proximally from the slots into the insert bore to provide fluid communication from the slots to the insert bore.
- 2. The texturizer of claim 1 wherein each of the passageways are similarly angled relative to the yarn travel axis wherein air directed through the passageways meets at an impingement point.
- 3. The texturizer of claim 1 wherein the slots and passageways are circumferentially spaced apart from one another about the collar and separated from one another by the collar.
- 4. The texturizer of claim 1 wherein the distal end of the insert extends at least substantially to the distal end of the housing.
- 5. The texturizer of claim 1 further comprising a seal preventing air flow from the receiver past the distal end of the insert.
- 6. The texturizer of claim 1 wherein the first housing and first insert are respectively, ones of a plurality of similarly constructed housings and inserts connected to the base.
- 7. The texturizer of claim 6 further comprising a second inlet and a second station, said second inlet in fluid communication with the second station, and a second housing of the plurality of housings connected to the base at the second station with a second insert of the plurality of inserts disposed at least partially inside.
- 8. A texturizer comprising:a base having a first inlet ducted to at least one station; a first housing having a proximal and a distal end, an internal housing bore having an internal surface, and a duct intermediate the proximal and distal ends of the first housing, said duct providing fluid communication from one of the at least one stations to the housing bore, said first housing connected to the base; a first insert having a proximal and distal end and an insert bore extending through the first insert along a yarn travel axis, said first insert having a receiver and a collar disposed toward the distal end of the first insert, said collar having an exterior surface substantially adjacent a portion of the internal surface of the housing bore; slots located in the collar extending from the receiver toward the distal end of the collar, said slots spaced apart and separated from one another by the collar, each of said slots having a corresponding passage extending from the respective slot proximally into the insert bore.
- 9. The texturizer of claim 8 wherein the collar has an exterior surface and the slots extend radially inwardly from the exterior surface of the collar.
- 10. The texturizer of claim 8 further comprising a seal intermediate the insert and the housing bore located distally from the slots.
- 11. The texturizer of claim 8 wherein the passages are angled similarly relative to the yarn travel axis.
- 12. The texturizer of claim 8 wherein the housing forms an air tight seal relative to the base, and a shank base is located proximally from the reciever in the housing bore to assist in directing air from the receiver through the slots.
- 13. The texturizer of claim 8 wherein the collar has an outer surface which is received within an inner surface of the housing bore and the slots are disposed along the outer surface of the collar and terminate prior to reaching the distal end of the insert.
- 14. The texturizer of claim 8 wherein the first housing and first insert are respectively ones of a plurality of housings and inserts connected to the base.
- 15. A texturizer comprising:a base having a first inlet ducted to at least one station; a first housing having a proximal and a distal end, an internal housing bore having an internal surface, and a duct intermediate the proximal and distal ends of the first housing, said duct providing fluid communication from one of the at least one stations to the housing bore, said first housing connected to the base; a first insert having a proximal and distal end and an insert bore extending through the first insert along a yarn travel axis, said first insert having a collar with an exterior surface, said first insert located at least partially within the housing bore the insert comprising a receiver located proximate to the duct of the housing; passages extending proximally from the exterior surface of the collar intermediate the proximal and distal end of the insert into the insert bore; and slots communicating the passages with the receiver.
- 16. The texturizer of claim 15 wherein the slots extend from the receiver toward the distal end of the insert and terminate prior to reaching the distal end of the insert.
- 17. The texturizer of claim 15 further comprising a seal intermediate the slots and distal end of the insert, said seal providing a barrier intermediate the outer surface of the collar and the internal surface of the housing bore.
US Referenced Citations (13)