Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
  • B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
  • B65H75/04—Kinds or types
  • B65H75/08—Kinds or types of circular or polygonal cross-section
  • B65H75/10—Kinds or types of circular or polygonal cross-section without flanges, e.g. cop tubes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2701/00—Handled material; Storage means
  • B65H2701/30—Handled filamentary material
  • B65H2701/31—Textiles threads or artificial strands of filaments

Definitions

• the present invention relates to a composite ring spinning tube for ring spinning machines also commonly known as ring bobbin in the textile industry. More particularly, the present invention relates to light weight ring bobbin, which acts as a carrier of the yarn on the ring spinning machines.
• the weight reduction of the ring tubes reduces the payload on the spindle of machine and hence saves energy up to 25 percent of the total energy consumed there.
• Ring bobbins are commonly used in ring spinning machines to wind yarn in on a spinning spindle arrangement. As the ring spinning machines came up in 1900s, the ring bobbins were introduced. Earlier the ring bobbins were made up of wood. As the spinning speeds increased, the take up bobbins format changed. The wood was overtaken by paper with wood bottom bobbins and this was overtaken by thermoplastics over the century. Since the dawn of thermoplastics in 1980s, the plastic spinning tubes have been a standard format for yarn collection/winding on a ring spinning machines and doubling machines. The thermoplastics products are not energy and shape compliant relative to new material, which defray weight without losing the strength.
• thermoplastics have constrained conditions imposed out of its inherent material properties rendering a certain weight of the tube and a specific wall thickness. These give a relatively high payload on the spindle of the ring spinning machine and hence an energy consumption sink. Further, the outer diameter of the ring spinning tube comes from the wall thickness of the thermoplastic bobbins. This determines the yarn content on the tube. Larger the outer diameter of the ring spinning tube, lesser the content it carries. This also has consequential efficiency losses on the ring spinning machine and the next machine of Auto Coner. Industry has struggled for years to cut this load, but with no viable option. [005] Hence what is required is a light weight, thin walled ring spinning tube. [006] Summary of the Invention
• the present invention eliminates all the drawbacks of prior art by providing lightweight composite ring tube which runs on high speed spinning machine and is also further capable of running on the band of super high speeds, thereby increasing the productivity while saving energy.
• the reduced diameter by the microstructure walls of the composite ring tube allows spinning of more yarn which gives higher efficiency on the ring spinning machines and the consequent machine of Auto Coner.
• the invention covers all the three components of the product, viz. the material, structural design and processing steps.
• the invention delivers up to 80% reduction in the weight of the ring spinning tube and up to 20% reduction in the outer diameter of the ring spinning tube against conventional thermoplastic ring bobbins.
• the composite ring tube is a micro mechanical modeling assembly, comprising of a material matrix embedded with epoxy inclusions structured into a cylindrical tube having a top end and a bottom end.
• the geometry of the ring bobbin is such that the outer diameter of top end of composite ring tube is less than the outer diameter of bottom end of the composite ring tube providing a tapered structure to the cylindrical tube.
• the bottom end of the cylindrical tube is a reinforced matrix of prepreg for firmly fitting to the ring spinning spindle.
• the resulting material model is a function of the microstructure that determines the stiffness of the material.
• the wall thickness of cylindrical tube is kept between 0.5 mm to 1 mm, depending upon the sandwich of fibre placements. This material model substantially reduces the weight of the ring tube and permits running the ring spinning machine sat higher speed thereby gaining productivity while saving energy. Further, the reduction in weight of ring tube significantly improves the life of spindle and tape on the ring spinning machine.
• the cylindrical tube of the ring tube is made by optimizing complex set of criteria, which comprises a fiber mesh structure of a carbon yarn sandwiched between a plurality of polyester film skin in a very harmonious way. Then tube is then coated with a resin forming a prepreg. The material selection is tweaked by using a certain fibre denier to get a macroscopic response on the strength of the composite ring spinning tubes.
• the resin used is selected from the group of epoxy resins and has uniform weight over the polyester sheets. The thickness variation of the resin across the polyester film is within +1-3 microns.
• a plurality of layers of prepreg are rolled together on a mould to render a composite ring spinning tube.
• the thickness and strength of the rolled prepreg is maintained to fit on the spindle of ring spinning machine.
• the geometry of the tube is such that the bottom end of the composite ring spinning tube for at least length of 10 millimeters is focally reinforced with additional layers of prepreg to further the flexural rigidity against strong push and pull forces during mounting and removal of the composite ring tubes on the ring spinning machine.
• the weight reduction from the embedded fibre matrix configuration results into a low weight material composite ring spinning tube, ensuring power saving up to 25% on ring spinning machine.
• the wall thickness from the micro mechanical structural design of the composite ring tube is reduced from 2.5 mm to less than 1 mm. This permits 360 degrees of freedom to the spinner to either take more yarn on the composite ring tube, thereby giving higher efficiency on the ring spinning machines. Or reduce the ring diameter and further save on the power.
• FIGURE 1 shows the perspective view of the composite ring tube according to one embodiment of the invention.
• FIGURE 2 shows the orthogonal top view of the composite ring tube according to one embodiment of the invention.
• FIGURE 3 shows the cross sectional view of the composite ring tube according to one embodiment of the invention.
• FIGURE 4 shows the perspective view of TFO tubes according to one embodiment of the invention.
• the composite ring spinning tube viz. ring bobbins is a material matrix embedded with epoxy inclusions, rendered into a geometrical shape of a cylindrical tube having a top end and a bottom end.
• the outer diameter of top end of composite ring tube is less than the outer diameter of bottom end of the composite ring tube providing a tapered structure to the cylindrical tube.
• the bottom end of the cylindrical tube is further reinforced with matrix of layers of prepreg for firmly fitting the ring tube into the spindles of ring spinning machine. This micro modelling mechanical structure reduces the weight of the ring tube and thereby the payload on the spindle drops and saves energy.
• the top 20mm is colored for easy identification and tracking of the yarn spun onto it.
• the microstructure of the composite ensures that the wall thickness of the ring bobbins are rather flimsy and within a range of 0.5 to 1mm, but have the desired flexural rigidity to take the brunt of heavy duty operations. This wall thickness reduction provides 360 degree room for extra yarn spinning onto the Ring Bobbin.
• FIGURE 1 shows the perspective view of the composite ring tube according to one embodiment of the invention.
• the ring tube (100) comprises a cylindrical tube having a top end (110) and a bottom end(130),wherein outer diameter of top end(110) is less than the outer diameter of bottom end(130), providing a tapered configuration to the cylindrical tube.
• These taper ratios are usually in the range of 1 :4 to 1:64, which means for every single length of 4 inches, the outer diameter of the tube reduces by 1mm for a ration of 1 :4.
• the outer diameter of the tube reduces by 1mm for a ration of 1 :4.
• the spindle of the ring spinning machine for all other taper ratios and are function of the spindle of the ring spinning machine.
• the bottom end of the cylindrical tube is reinforced with plurality of layers of prepreg for firmly fitting the ring tube (100) on the spindles of ring spinning machine and to allow high speed operation and auto doffing. Also reinforcing prepreg at the bottom end (130) against strong push and pull forces during mounting and removal of the ring tubes (100) on the ring spinning machine.
• the wall thickness of cylindrical tube is between 0.5 mm to 1 mm, which reduces the weight of the ring tube and allows the ring spinning machines to run at higher speed and increase the productivity while saving energy. The reduction in weight of ring tube significantly improves the life of spindle and tape in the ring spinning machine.
• the top 20mm of the tube is colored for identification of the yarn counts loaded onto the tube.
• the ring tube (100) in the present invention is made of prepreg which is prepared by sandwiching the web of carbon yarns between polyester film skin, coated with fine layer of resin having uniform weight and thickness leading to form prepreg.
• the prepreg is then refrigerated at temperature below 0 degree Celsius and then wound up on a ring tube mould to render into a cylindrical tube.
• the cylindrical tube is cut to the size of the required part to which it is to be fitted on.
• Plurality of layers of prepreg is laid to get the desired strength and thickness.
• the mould is made to the exact shape as the ring spindle of the ring spinning machine, so that it is similar to the shape and size of the spindle of the ring spinning machine, thereby giving the exact fit and tolerances desired for a ring tube.
• the tolerances of fitness are such that the variation across the length is not exceeded more than +/- 0.02mm.
• the cylindrical tubes are removed from the mould and top end colored up to20mm and then wrapped by shrink wrap plastic. The coloring can also be done for the full length of the tube, if so desired.
• the cylindrical tubes are then cured in an oven. The heat shrinks the plastic tape and compresses the layers together.
• the shrink wrap plastic is then peeled off and the cylindrical tubes are further cut and trimmed as per the requirement.
• the cylindrical spinning tubes are then validated for exact fit on the spindle mandrel and for any other visual defect, before being used.
• the choice of the carbon yarn denier and pph of the epoxy determine the flexural strength at break. Thermal processing time and temperatures are the key variables for composite ring tube strength.
• FIGURE 2 shows the orthogonal top view of the composite ring tube according to one embodiment of the invention.
• the outer diameter of top end (110) is less than the outer diameter of bottom end (130) providing a tapered configuration to the cylindrical tube.
• the reduction in the diameter depends upon the kind of spindle on which it is used.
• the tapers are in the ratio of 1 :4 to 1 :64, which means that after every 4 inches of the height of the ring tube, the outer diameter reduces by 1mm and similar for the ratio 1 :64 etc.
• the present invention facilitates spinning of more yarn on the ring tube, which thereby gives higher efficiency on the ring spinning machines and consequently on the next auto coner machines.
• the composite ring tubes can be used for all types of substrates such as cotton, polyester, viscouse, jute, wool, nylon etc.
• FIGURE 3 shows the cross sectional view of the composite ring tube according to one embodiment of the invention.
• FIGURE 4 shows the perspective view of TFO tubes according to one embodiment of the invention.
• the ring spinning tubes can be further applied to all such cylindrical take up tubes used in the textile industry, specially the two for one twisting machines (TFO), ring twisting machines, fiber glass twisting machines etc.
• the cylinder of the bobbin may or may not be tapered in such tubes and is designed as per the design of the take up tube.
• TFO two for one twisting machine
• the wall thickness of the tube dramatically improves up to 10% and gives the extra space for additional yarn payload on the pot of TFO. Thereby allows the user to choose a smaller pot diameter and save hugely on the power cost. It can therefore be applied on broad spectrum of applications like a roving bobbin or cylindrical take up bobbins or dye tubes as per the geometry of the cylinder.
• the material, structural design and the process variables largely remains the same, except the geometry is changed to suit the application.

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• Spinning Or Twisting Of Yarns (AREA)
• Storage Of Web-Like Or Filamentary Materials (AREA)
• Reinforced Plastic Materials (AREA)

Applications Claiming Priority (2)

Publications (1)

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• 2014
  • 2014-02-03 IN IN319DE2014 patent/IN2014DE00319A/en unknown
  • 2014-03-26 EP EP14731356.3A patent/EP3102519A1/en not_active Withdrawn
  • 2014-03-26 WO PCT/IB2014/060156 patent/WO2015114412A1/en active Application Filing
  • 2014-03-26 CN CN201480022433.5A patent/CN105121322A/zh active Pending

Non-Patent Citations (1)

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