JP2023546917A - Defect detection in moving fiber-containing structures - Google Patents

Abstract

Defects in the fiber-containing structure (110) are detected herein using at least one defect detector including a light emitter (115) and a light receiver (130) capable of measuring the cross-sectional diameter of the fiber-containing structure during linear movement. A method and apparatus (100) are disclosed. The cross-sectional diameter is calculated based on the amount of decrease in the amount of light 135 detected by the light receiver relative to the total amount of light (140) transmitted by the projector. Also disclosed herein is a fiber-containing structure subjected to the defect detection method.
[Selection diagram] Figure 3

Description

FIELD OF THE INVENTION This application relates generally to materials technology, and more specifically to the preparation, processing, and detection of fiber-containing structures, such as yarn lines, braided lines, and wirelay structures. More particularly, this application discloses methods and apparatus for real-time detection and characterization of defects in fiber-containing structures in linear motion.

When manufacturing or processing fiber-containing structures such as yarn lines (e.g., multifilament yarns), braided lines (e.g., braided yarns, braided core-sheath structures, etc.) and wirelay structures (e.g., wirelay ropes), For example, defects may occur due to filament breakage or the presence of impurities.

Filament breakage can occur, for example, due to tension, bending, or twisting of the fiber-containing structure. If filament breaks are present on the surface of a fiber-containing structure during in-line processing, these filament breaks can weaken the fiber-containing structure and also separate at various locations along the fiber-containing structure and then re-attach to further May lead to defects. Broken fibers, whether attached to or separated from the original filament, may change shape and increase in size during subsequent in-line processing.

Although the terminology of defects for fiber-containing structures can vary widely in the relevant art, defects due to filament breaks and impurities generally fall into two categories. The first category concerns filament breaks (single filaments or groups of filaments) that extend outward from the surface of the fiber-containing structure as branch-like structures, often referred to as "fluff" or "peeling" defects. The second category consists of broken (separated) fibers or other fibers that adhere to the surface of fiber-containing structures and tend to grow into platform-like structures, often referred to as "pilling" or "slab" defects, during in-line processing. Concerning impurities.

Because defects such as those described above can adversely affect the strength and utility of fiber-containing structures, commercially available products are commonly inspected and often evaluated based on the amount or concentration of defects. Evaluation methods for fiber-containing structures are often performed by humans using magnifying devices such as microscopes, but manual inspection is a tedious process and is not suitable for mass production. Additionally, due to limitations associated with human inspection, real-time corrective interventions to reduce or eliminate the occurrence of defects in human inspection are rarely performed during high-speed manufacturing or processing of fiber-containing structures.

The inventors have recognized that there is a need to discover methods and apparatus that reliably detect defects in fiber-containing structures in linear motion during manufacture or processing. There is also a need for such methods and apparatus for modifying or terminating the manufacture or processing of fiber-containing structures to allow the differentiation and characterization of defects, or to reduce the occurrence of defects.

The following disclosure describes methods and apparatus for detecting defects in linearly moving fiber-containing structures in real time, as well as fiber-containing structures obtained using these methods and apparatus.

Embodiments of the present disclosure are described herein to enable one of ordinary skill in the art to make and use them, and include the following.
(1) One embodiment includes linearly passing a fiber-containing structure through at least one defect detector, and measuring a cross-sectional diameter of at least one of the fiber-containing structures with the defect detector to detect the fiber-containing structure. obtaining at least one diameter signal of diameter versus length of an object, optionally signal processing said diameter signal to obtain at least one signal processed diameter signal, said diameter signal, said signal processed diameter signal or A method for detecting defects in a fiber-containing structure by comparing a combination thereof to at least one reference signal to generate at least one surface defect signal of a surface defect output versus said length of said fiber-containing structure. And,
(a) The defect detector transmits light through the fiber-containing structure with a light projector, detects a silhouette image of the fiber-containing structure with a light receiver, and detects a silhouette image of the fiber-containing structure with a light receiver based on the total amount of light transmitted through the light projector. (b) measuring the cross-sectional diameter of the fiber-containing structure by calculating the cross-sectional diameter based on a decrease in the amount of light generated by the fiber-containing structure; an extrusion device configured to: a braiding machine configured to form the fiber-containing structure; a tensioning assembly configured to apply tension to the fiber-containing structure; a finish applicator configured to apply a coating to the fiber-containing structure, a godet roll assembly configured to draw the fiber-containing structure, a bobbin for the fiber-containing structure; a winding assembly configured to wind a winding assembly, or a combination thereof;
(2) Another aspect relates to a defect-detected fiber-containing structure obtained by performing method (1) above; and (3) another aspect relates to (A) forming a fiber-containing structure. an extrusion device configured to: a braiding machine configured to form the fiber-containing structure; a tensioning assembly configured to apply tension to the fiber-containing structure; and applying a coating to the fiber-containing structure. a finishing applicator configured to, a godet roll assembly configured to draw the fiber-containing structure, a winding assembly configured to wind the fiber-containing structure onto a bobbin, or the like; combination, (B) transmitting light through the fiber-containing structure with a projector, detecting a silhouette image of the fiber-containing structure with a light receiver, and determining the amount of light detected by the light receiver relative to the total amount of light transmitted by the projector; a defect detector configured to measure the cross-sectional diameter of at least one of the fiber-containing structures by calculating the cross-sectional diameter based on the amount of reduction; Comparing one diameter signal, optionally at least one signal-processed diameter signal, or a combination thereof to at least one reference signal to determine at least one of the surface defect output versus the length of said fiber-containing structure. a defect in a fiber-containing structure, the defect detector comprising a processor for obtaining a surface defect signal, the defect detector measuring the at least one cross-sectional diameter while the fiber-containing structure linearly passes the defect detector; The present invention relates to a device for detecting.

Additional objects, advantages, and other features of the disclosure will be set forth in part in the description that follows, and in part will be apparent to those skilled in the art from the following discussion, or can be learned from practice of the disclosure. This disclosure encompasses other embodiments different from those specifically described below, and the details herein may be changed in various ways without departing from this disclosure. In this regard, the description herein is to be understood as illustrative in nature and not as restrictive.

Embodiments of the present disclosure are described in the following specification in consideration of the figures shown below.
FIG. 1A shows a non-twisted, non-braided yarn line formed from a plurality of filaments or filament-containing strands. FIG. 1B shows a braided fiber-containing structure formed of multiple filaments or filament-containing strands that are braided together. FIG. 1C shows a core-sheath fiber-containing structure that includes a core of filaments or filament-containing strands surrounded by a sheath formed of a plurality of filaments or filament-containing strands that are braided together. FIG. 1D shows a wire-lay fiber-containing structure that includes a core of filaments or filament-containing strands surrounded by a wire-stranded cover formed of multiple filaments or filament-containing strands twisted in the same direction. FIG. 2A shows a fiber-containing structure with defects in the form of "fluff" or "peeling" caused by filament breakage. FIG. 2B shows a fiber-containing structure with defects in the form of small "pills" or "slabs" caused by impurities deposited on the surface of the fiber-containing structure. FIG. 2C shows a fiber-containing structure with defects in the form of elongated "pills" or "slabs" caused by the accumulation of impurities deposited on the surface of the fiber-containing structure. FIG. 3 shows a defect detector configured to detect and measure the cross-sectional diameter of a fiber-containing structure. FIG. 4A shows a light projection slit of a defect detector in which a strip of parallel light passes through the light projection slit. FIG. 4B shows the receiving slit of the defect detector with partially blocked collimated light passing through the receiving slit. FIG. 5A shows a receiving slit of a defect detector with collimated light partially blocked by a defect-free portion of the fiber-containing structure passing linearly through the defect detector. FIG. 5B shows a receiving slit of a defect detector in which parallel light is partially blocked by a defect-containing portion of a fiber-containing structure passing linearly through the defect detector. FIG. 6A shows a moving fiber-containing structure with delamination defects caused by filament breaks and shows the location of cross-sectional measurements of the fiber-containing structure occurring at regular intervals. FIG. 6B shows a moving fiber-containing structure with small slab defects caused by deposited impurities and shows the location of cross-sectional measurements of the fiber-containing structure occurring at regular intervals. FIG. 6C shows a moving fiber-containing structure with elongated slab defects caused by accumulated impurities and shows the location of cross-sectional measurements of the fiber-containing structure occurring at regular intervals. FIG. 7 shows an apparatus for manufacturing or processing fiber-containing structures. FIG. 8 shows an apparatus for braiding and detecting fiber-containing structures. FIG. 9 shows a defect detector array with two biaxial defect detectors positioned in series with a fiber-containing structure moving linearly past the defect detector array.

Embodiments of the present disclosure provide various methods for detecting defects in moving fiber-containing structures, apparatus for performing the defect detection methods, and benefits obtained by performing the defect detection methods described herein. Contains fiber-containing structures with detected defects. Certain non-limiting applications of the defect detection methods of the present disclosure are also described herein.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the relevant art. In case of conflict, the present specification, including definitions, will control.

All percentages, parts, ratios, etc. are by weight unless otherwise specified.

When an amount, concentration, or other value or parameter is given as a range or a list of upper and lower limits, this means that any upper and lower values are included, whether or not the range is separately disclosed. It is to be understood that all ranges formed from any pair are specifically disclosed. When a numerical range is stated herein, the range is intended to include the endpoints and all integers and fractions within the range, unless stated otherwise. The scope of this disclosure is not intended to be limited to the particular values recited in defining the range.

The use of "a" or "an" to describe various elements and components herein is merely for convenience and to provide a general meaning of the disclosure. This description should be construed to include one or at least one, and the singular also includes the plural, unless it is clear that it is intended otherwise.

Unless expressly stated to the contrary, "or" and "and/or" refer to inclusive and not exclusive terms. For example, conditions A or B, or A and/or B, are satisfied by one of the following: A is true (or exists) and B is false (or does not exist); is false (or does not exist), and B is true (or exists), both A and B are true (or exist).

As used herein, the terms "about" and "approximately" refer to approximately the same as a reference amount or value, and are to be understood to include ±5% of a given amount or value.

The term "substantially" as used herein, unless otherwise defined, means all or nearly all or most, as understood by one of ordinary skill in the context of use. It is intended to allow for some reasonable variance from 100% that would normally occur in industrial or commercial scale situations.

Throughout this specification, unless otherwise defined and explained, the technical terms and methods employed to determine the relevant measurements refer to ASTM D855/D885M - 10A (2014), published October 2014. , Standard Test Methods for Tire Cords, Tire Cord Fabrics, and Industrial Filament Yarns Made From Man-made Organic-base Fibers.

For convenience, many elements of the various embodiments disclosed herein are discussed separately. Although a list of options may be provided and numerical ranges may be provided, this disclosure should not be considered limited to the separately described list and ranges. Unless stated otherwise, each and every possible combination within this disclosure should be considered expressly disclosed for all purposes.

The materials, methods, and examples herein are illustrative and not intended to be limiting, except as expressly stated. Methods and materials similar or equivalent to those described herein can also be used in the practice of the present disclosure.

<Method for detecting defects in moving fiber-containing structures>
Disclosed herein is a method for detecting defects in a fiber-containing structure that is in linear motion. The term "fiber-containing structure" includes any cord-like structure formed of fibers and/or filaments, such as threadlines, braidlines, wire lays, and core-sheath structures.

1A-1D illustrate examples of fiber-containing structures that can be used in the methods of the present disclosure.

FIG. 1A shows an example of a yarn line cord 5 that includes a plurality of filaments (or filament-containing strands) 10 arranged as a non-twisted, non-braided bundle. FIG. 1B shows an example of a braided line cord 15 that includes a plurality of filaments (or filament-containing strands) 20 arranged as a braided bundle without a central core. FIG. 1C shows a braided cord 25 having a core-sheath structure including a braided sheath 30 formed of a plurality of braided filaments (or braided filament-containing strands) 32 surrounding a core 35 formed of filaments (or filament-containing strands). Give an example. FIG. 1D shows a wire-lay fiber containing core-sheath structure comprising a wire-lay sheath 45 formed of a plurality of braided filaments (or braided filament-containing strands) 50 surrounding a core 55 formed of filaments (or filament-containing strands). A structure 40 is shown.

As explained above, certain defects may occur during manufacturing or processing of fiber-containing structures, for example due to damaged filaments or impurities that may adhere to the fiber-containing structures.

FIG. 2A shows a typical fiber-containing structure 60 with defects 65 in the form of "fluff" or "peeling" caused by filament breakage. Filament breakage may occur, for example, due to stretching, bending, or twisting of the fiber-containing structure. Typically, the broken filaments extend outwardly at an acute angle 70 relative to the direction of travel 75 of the fiber-containing structure 60 in linear motion during processing. However, sometimes the broken filaments extend outward at obtuse angles to the direction of travel of the fiber-containing structure. In some cases, the broken filament includes a leading edge branch 67 (shown in FIGS. 5A and 5B) that extends outwardly at an obtuse angle with respect to the direction of travel, and a trailing edge branch 65 (shown in FIG. 2A) that extends outwardly at an acute angle. It may include two branched structures.

FIG. 2B shows a typical fiber-containing structure 80 with defects 85 in the form of "pills" or "slabs" caused by impurities deposited on the surface of the fiber-containing structure 80. The example of FIG. 2B shows a small (recently introduced) impurity where the "pill" or "slab" attachment point 87 occupies a relatively small area compared to the overall dimensions of the "pill" or "slab". ing.

FIG. 2C shows a typical fiber-containing structure 90 having defects 95 in the form of elongated or enlarged "pills" or "slabs" caused by the accumulation or molding of impurities deposited on the surface of the fiber-containing structure 90. . The example of FIG. 2C shows an elongated or enlarged impurity where the attachment point 97 of the "pill" or "slab" occupies a relatively large area compared to the overall size of the "pill" or "slab."

The defect detection method of the present disclosure uses a defect detector configured to measure a cross-sectional diameter of at least one of a moving fiber-containing structure.

These methods include (1) passing the fiber-containing structure in a straight line through at least one defect detector; (2) measuring the cross-sectional diameter of at least one of the fiber-containing structures with the defect detector to detect the cross-sectional diameter of the fiber-containing structure; obtaining a diameter signal of the diameter versus length of the fiber-containing structure; (3) optionally processing the diameter signal to obtain at least one processed diameter signal; and (4) a diameter signal, a signal. The method may include comparing the processed diameter signal or a combination thereof to at least one reference signal to generate at least one surface defect signal of surface defect power versus length of the fiber-containing structure.

In some embodiments, the defect detector transmits light through the fiber-containing structure with a light emitter, detects a silhouette image of the fiber-containing structure with a receiver, and detects a silhouette image of the fiber-containing structure with a receiver relative to the total amount of light transmitted through the light emitter. The cross-sectional diameter of the fiber-containing structure is measured by calculating the cross-sectional diameter based on the amount of decrease in the amount of light obtained.

FIG. 3 illustrates one embodiment of a defect detector 100 configured to measure the cross-sectional diameter of a fiber-containing structure in linear motion by detecting a silhouette image 105 of the fiber-containing structure 110. It is. In this embodiment, the defect detector 100 includes a light projector 115 including a light source 120 and a lens 125 and a light receiver 130 for detecting the silhouette image 105. The cross-sectional diameter of the fiber-containing structure 110 is calculated based on the amount of decrease in the amount of light 135 detected by the light receiver relative to the total amount of light 140 transmitted by the projector. Optical receiver 130 (i) optionally performs signal processing of diameter signal 145 to obtain a signal-processed diameter signal, and (ii) performs signal processing of diameter signal 145, optionally a signal-processed diameter signal, or a combination thereof. is compared to at least one reference signal 155 to generate a diameter signal 145 that is sent to processor 150 configured to generate at least one surface defect signal 160 of surface defect output versus length of fiber-containing structure 110. do. In the embodiment of FIG. 3, receiver 130 includes an active pixel sensor 165. In the embodiment of FIG.

A variety of light projectors and photodetectors known in the related art can be used in the defect detector of the present disclosure. For example, the emitter can include a laser diode and/or a light emitting diode, and the receiver can include an active pixel sensor. Active pixel sensors used in the photodetectors of the present disclosure may include photodiode image sensors, charge-coupled device (CCD) image sensors, complementary metal oxide semiconductor (CMOS) image sensors, or combinations thereof. can.

The method of the present disclosure can use commercially available equipment that can detect silhouette images of fiber-containing structures in linear motion. For example, the transmission dimension measurement device described in US Patent Application Publication No. 2010/0271638 by Torii et al. can be used as a defect detector in the methods and apparatus of the present disclosure.

The methods of the present disclosure can also use various types of detectors known in the related art that can image the surface of a fiber-containing structure in linear motion. For example, the detection method includes at least one imaging detector capable of imaging a surface of a fiber-containing structure by illuminating the fiber-containing structure with imaging light and receiving a reflected image of the surface of the fiber-containing structure with an imaging receiver. It may also include imaging the surface. Alternatively, the detection methods of the present disclosure may not include imaging the surface of the fiber-containing structure with an imaging detector that receives a reflected image of the surface of the fiber-containing structure.

4A and 4B illustrate how the defect detector of the present disclosure can measure the cross-sectional diameter of a fiber-containing structure.

As explained and illustrated above, defect detector 100 detects fibers by transmitting light 140 through fiber-containing structure 110 with emitter 115 and detecting a silhouette image 105 of fiber-containing structure 110 with receiver 130. Measure the cross-sectional diameter of the containing structure 110, see FIG.

FIG. 4A shows an embodiment in which the light projector 115 includes a light projecting slit 170 through which the transmitted light from the light source 120 passes and becomes a band-shaped collimated light beam 175. FIG. 4B shows an embodiment in which the corresponding light receiver 130 includes a light receiving slit 185 through which the partially blocked collimated light beam 135 passes before being detected by the active pixel sensor 165, for example.

In the illustrations of FIGS. 4A and 4B, a portion of the collimated light beam 175 is blocked by the presence of a defect-free portion 190 of the fiber-containing structure 110 (which is passing linearly through the defect detector 100 at a linear velocity v). However, the amount A ^D of partially blocked parallel light beam 135 detected by receiver 130 is less than the amount A ^T of transmitted parallel light beam 175 transmitted by emitter 115 . The blocked portion of the parallel light beam 135 corresponds to the silhouette image 105 of the fiber-containing structure 110. Thus, the cross-sectional diameter D of the fiber-containing structure 110 is determined by the difference between the amount A ^T of the transmitted parallel light beam 175 and the amount A ^D of the partially blocked parallel light beam 135, ^i.e. -A ^D ).

5A and 5B are diagrams showing how the silhouette image 105 of the fiber-containing structure changes when the defect detector 100 detects a defect.

FIG. 5A shows a defect at time t ₁ when the collimated light beam 175 is partially blocked by a defect-free portion 190 of the fiber-containing structure 110 (passing straight through the defect detector 100 with linear velocity v). The light receiving slit 185 of the detector 100 is shown. As described above, the blocked portion of the parallel light beam 135 corresponds to the silhouette image 105' of the fiber-containing structure 110. Thus, the cross-sectional diameter D ₁ of the defect-free portion 190 at time t ₁ is the difference between the amount of transmitted parallel light beam 175 A ^T and the amount of partially blocked parallel light beam 135 A ^D ₁ , that is, it can be calculated based on D ₁ to (A ^T −A ^D ₁ ).

FIG. 5B shows defect detection at time t ₂ when collimated light beam 175 is partially blocked by defect-containing portion 195 of fiber-containing structure 110 (passing linearly through defect detector 100 with linear velocity v). The light receiving slit 185 of the device 100 is shown. At time _t2 , the interrupted portion of the collimated light beam 200 corresponds to the silhouette image 105'' of the fiber-containing structure 110. In this way, the cross-sectional diameter D ₂ of the defect-containing portion 190 at time t ₂ is the difference between the amount A ^T of the transmitted parallel light beam 175 and the amount A ^D ₂ of the partially blocked parallel light beam 195, i.e. , D ₂ ~(A ^T −A ^D ₂ ).

Since the defect-containing portion 195 illustrated in FIG. 5B contains defects 67 in the form of "fluff" or "peeling" caused by filament breakage, rather more of the parallel light beam 175 than at time _t1 It is cut off at t ₂ . As a result, in this figure, the cross-sectional diameter D ₂ of the defect-containing portion 195 calculated in FIG. 5B is larger than the cross-sectional diameter D ₁ of the defect-free portion 190 calculated in FIG. 5A. In other embodiments, the cross-sectional diameter D ₂ of the defect-containing portion may be smaller than the cross-sectional diameter D ₁ of the defect-free portion of the fiber-containing structure 110. For example, if a portion of a filament break breaks from a fiber-containing structure, the resulting defect-containing portion may have a smaller cross-sectional diameter compared to the corresponding cross-sectional diameter of the defect-free portion of the fiber-containing structure. be.

As explained in more detail below, the measurement of at least one cross-sectional diameter of the fiber-containing structure by the at least one defect detector is performed when the fiber-containing structure passes in a straight line past the defect detector at a linear velocity v. , occurring at regular (time/distance) intervals. The at least one cross-sectional diameter measurement may then occur at a sampling rate ranging from about 1 sample per second to at least 5,000 samples per second. In some embodiments, the sampling rate of at least one of the defect detectors is adjusted such that measurements occur at regular intervals along the length of the fiber-containing structure. The fixed interval over which measurements occur can range from about 10 nm to about 1 cm.

Following the step of measuring at least one cross-sectional diameter of the fiber-containing structure with at least one defect detector and optionally signal processing the diameter signal to obtain at least one signal-processed diameter signal. The disclosed method includes comparing the diameter signal and/or the signal-processed diameter signal to at least one reference signal to generate at least one surface defect signal of surface defect power versus length of the fiber-containing structure. obtain. As explained below, the at least one surface defect signal may be related to the magnitude, slope and/or curvature of the diameter signal.

The surface defect signal may include a magnitude surface defect number signal versus a length of the fiber-containing structure. A size surface defect count signal is generated by comparing the diameter signal to a reference signal of maximum cross-sectional diameter versus length of the fiber-containing structure. A zero magnitude surface defect count occurs when the magnitude of the diameter signal is less than or equal to the maximum cross-sectional diameter at a particular point along the length of the fiber-containing structure. A magnitude surface defect count greater than zero occurs when the magnitude of the diameter signal is greater than the maximum cross-sectional diameter at a particular point along the length of the fiber-containing structure; It can be a positive integer corresponding to the percentage by which the signal magnitude exceeds the maximum cross-sectional diameter.

The surface defect signal may include a graded surface defect count signal of graded surface defect count versus length of the fiber-containing structure. The graded surface defect count signal is generated by comparing the signal-processed diameter signal with a reference signal of the maximum first derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter The signal is obtained by processing the diameter signal to obtain a first derivative of the diameter signal. A sloped surface defect count of zero occurs when the absolute value of the first derivative of the diameter signal is less than or equal to the maximum first derivative of the diameter signal at a particular point along the length of the fiber-containing structure. A sloped surface defect count greater than zero occurs when the absolute value of the first derivative of the diameter signal is greater than the maximum first derivative of the diameter signal at a particular point along the length of the fiber-containing structure; The number of graded surface defects may be a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal that is greater than the largest first derivative of the diameter signal.

The surface defect signal may include a curvature surface defect number signal of curvature surface defect number versus length of the fiber-containing structure. The curvature surface defect count signal is generated by comparing the signal processed diameter signal to a reference signal of the maximum second derivative of the diameter signal versus the length of the fiber-containing structure, where the signal processed The diameter signal is obtained by signal processing the diameter signal to obtain a second derivative of the diameter signal. A zero curvature surface defect count occurs when the absolute value of the second derivative of the diameter signal is less than or equal to the maximum second derivative of the diameter signal at a particular point along the length of the fiber-containing structure. A curvature surface defect number greater than zero occurs when the absolute value of the second derivative of the diameter signal is greater than the maximum second derivative of the diameter signal at a particular point along the length of the fiber-containing structure; The number of curvature surface defects may be a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal that is greater than the largest second derivative of the diameter signal.

The detection methods of the present disclosure may also include identifying and/or classifying defects in the fiber-containing structure based at least in part on the magnitude, slope, and/or curvature of the diameter signal. The detection method of the present disclosure may also include generating a surface defect estimate of the fiber-containing structure based on the magnitude, slope, and/or curvature of the diameter signal.

6A-6C illustrate how variations in the cross-sectional diameter of a defect-containing portion of a fiber-containing structure can be used to count, distinguish, and classify various defects.

FIG. 6A shows locations where cross-sectional measurements of the fiber-containing structure 110 occurring at regular intervals from time t ₁ to t ₈ were made. The fiber-containing structure 110 (which is passing linearly through the defect detector 100 at a linear velocity v) includes a defect-containing portion 195 having defects 65 in the form of "fluff" or "peeling" caused by filament breakage. . In this figure, the cross-sectional diameters calculated at times t ₂ , t ₃ , t ₄ and t ₅ indicate the presence of "fluff" or "peeling" defects 65 caused by filament breakage.

Focusing on the size of the cross-sectional diameter of the fiber-containing structures 110 within the defect-containing portion 195, FIG. 6A shows that (i) the size increases slightly at time t ₃ compared to time t ₂ (time t ₃ (ii) the size at time t ₄ increases more dramatically compared to time t ₂ (the number of surface defects of size slightly greater than zero occurs at time t ₄ ); surface defect number occurs), then (iii) at time t ₅ the magnitude suddenly decreases compared to time t ₄ (zero size surface defect number occurs at time t ₅ ). . This pattern, in which the number of size surface defects suddenly decreases and returns to zero at time _t5 , and the number of size surface defects increases slightly at time _t3 , has one branch (i.e., outward with respect to the direction of travel). It shows the presence of "fluff" or "peeling" defects caused by filament breakage with only trailing branches extending at acute angles (see FIG. 2A).

Focusing on the slope of _the cross-sectional diameter of the fiber _- containing structure ₁₁₀ within the defect-containing portion 195, FIG. (ii) at time _t4 the slope is constant or slightly increased compared to time t3 (a number of tilted surface defects greater than 0 occurs at time _t4 ); (iii) shows that at time t ₅ the slope suddenly decreases compared to time t ₄ (zero slope surface defect count occurs at time t ₅ ); This pattern in which the number of sloped surface defects suddenly decreases and returns to zero at time t ₅ and increases at time t ₃ consists of one branch (i.e., after extending outward at an acute angle with respect to the direction of travel). It shows the presence of "fluff" or "peeling" defects caused by filament breaks that have only marginal branches (see FIG. 2A).

FIG. 6B shows locations where cross-sectional measurements of the fiber-containing structure 110 occurring at regular intervals from time t ₁ to t ₈ were performed. The fiber-containing structure 110 (which is passing in a straight line through the defect detector 100 at a linear velocity v) is in the form of small "pills" or "slabs" caused by impurities deposited on the surface of the fiber-containing structure 110. It includes a defect-containing portion 195 having defects 85 . In this figure, the cross-sectional diameters calculated at times t ₂ , t ₃ , t ₄ and t ₅ indicate the presence of "pill" or "slab" defects 85 caused by impurities.

Focusing on the size of the cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6B shows that (i) the size increases rapidly at time _t3 compared to time _t2 (time _t3 (ii) at time t ₄ the size increases only slightly compared to time t ₃ (at time t 4 the number of surface defects of size significantly greater than zero occurs); (ii) at time t 4 the size increases only slightly compared to time t ₃ ; (slightly increases compared to time t ₃ ), then (iii) at time t ₅ the magnitude suddenly decreases compared to time t ₄ (zero magnitude surface defect count occurs at time t ₅ ) It is shown that. This pattern, in which the number of size surface defects suddenly decreases and returns to zero at time t ₅ and the number of surface defects increases suddenly and strongly at time t ₃ , is due to small "pills" or "slabs" caused by recently introduced impurities. ” indicates the existence of a defect.

Focusing on _the slope of _the cross-sectional diameter of the fiber-containing structures ₁₁₀ within the defect-containing portion 195, FIG. (ii) at time t ₄ the slope decreases to approximately zero compared to time t ₃ (resulting in approximately zero sloped surface defect number at time t ₄ ), and then (iii) It is shown that at time t ₅ the slope returns to zero compared to time t ₄ (zero slope surface defect count occurs at time t ₅ ). This pattern of a sudden decrease in the number of sloped surface defects at time t ₄ and an increase in the number of sloped surface defects at time t ₃ with a decrease in the number of sloped surface defects returning to zero at time t ₅ was recently introduced. Indicates the presence of "pill" or "slab" defects caused by impurities.

Focusing on _the curvature of the cross-sectional diameter of _the fiber- _containing structure 110 in the defect-containing portion 195, FIG. the number of surface defects occurs), (ii) at time t ₄ the curvature decreases to almost zero compared to time t ₃ (the number of curvature surface defects close to zero occurs at time t ₄ ), and then (iii) It shows that at time _t5 the curvature remains zero compared to time _t4 (zero curvature surface defect count occurs at time _t5 ). This pattern of decreasing the number of curvature surface defects to zero at times t ₄ and t ₅ and increasing the number of curvature surface defects at time t ₃ is due to "pill" or "slab" defects caused by recently introduced impurities. It shows its existence.

FIG. 6C shows the locations where cross-sectional measurements of the fiber-containing structure 110 occurring at regular intervals from time t ₁ to t ₈ were made. The fiber-containing structure 110 (which is passing straight through the defect detector 100 at a linear velocity v) is an elongated or enlarged "pill" caused by the accumulation or molding of impurities deposited on the surface of the fiber-containing structure 110. or includes a defect-containing portion 195 having defects 95 in the form of "slabs". In this figure, the cross-sectional diameters calculated at times t ₂ , t ₃ , t ₄ and t ₅ indicate the presence of "pill" or "slab" defects 95 caused by impurities.

Focusing on the size of the cross-sectional diameter of the fiber-containing structures 110 within the defect-containing portion 195, FIG. 6C shows that (i) the size increases slightly at time t ₃ compared to time t ₂ (time t ₃ (ii) at time _t4 the size increases more dramatically compared to time t3 (at time _t4 the number of size-gradient surface defects occurs) (iii) at time t ₅ the size decreases compared to time t ₄ (at time t ₅ the number of surface defects with a _size slightly greater than zero occurrence). This pattern of an increase in the number of size surface defects at time t ₄ followed by a decrease in the number of size surface defects at time t ₅ and a slight increase in the number of size surface defects at time t ₃ may be due to impurity accumulation or molding. It shows the presence of elongated or enlarged "pills" or "slabs" caused by

Focusing on _the slope of the cross-sectional diameter of _the fiber-containing _structure 110 within the defect-containing portion 195, FIG. (a large number of inclined surface defects occurs), (ii) at time t ₄ the slope decreases to approximately zero compared to time t ₃ (an approximately zero number of inclined surface defects occurs at time t ₄ ), and then ( iii) shows that at time t ₅ the slope increases again compared to time t ₄ (the number of sloped surface defects greater than zero occurs at time t ₅ ); This pattern in which the number of sloped surface defects suddenly decreases to about zero at time _t4 , increases at time _t5 , and increases at time _t3 is caused by impurity accumulation and molding. indicates the presence of elongated or enlarged "pills" or "slabs".

Focusing on the curvature of the cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6C shows that (i) the curvature increases at time _t3 compared to time _t2 (greater than zero at time _t3 ); curvature surface defect number occurs), (ii) at time t ₄ the curvature decreases to approximately zero compared to time t ₃ (approximately zero curvature surface defect number occurs at time t ₄ ), and then (iii ) shows that at time t ₅ the curvature increases again compared to time t ₄ (the number of curvature surface defects greater than zero occurs at time t ₅ ). This pattern in which the number of curvature surface defects suddenly decreases to about zero at time t ₄ and increases at time t ₅ with an increase in the number of curvature surface defects at time t ₃ is caused by impurity accumulation or shaping. Indicating the presence of a resulting elongated or enlarged "pill" or "slab" defect.

In general, the ability to distinguish and classify various defects in a fiber-containing structure passing linearly through at least one defect detector can be improved by increasing the sampling rate of the measurements. Thus, for example, if the number of measurement intervals is doubled so that 16 measurements are taken over the same length of the fiber-containing structure 110 in FIGS. 6A-6C, the pattern described above can be detected with higher resolution; The ability to distinguish and classify different defects could be improved.

In some embodiments, the defect detection method may include the additional step of changing the linear velocity of the fiber-containing structure based on the surface defect signal. For example, in order to increase the measurement interval, the linear velocity of the fiber-containing structure can be reduced, thereby increasing the sensitivity and the ability to distinguish and classify various defects. In this regard, the defect detection method of the present disclosure can measure the linear velocity of a fiber-containing structure using at least one velocity meter. In some embodiments, the fiber-containing structure may linearly pass the at least one defect detector at a linear velocity of at least 300 meters per minute, while in other embodiments the linear velocity is at least 300 meters per minute. It may be less than 10 centimeters. In some embodiments, for example, when the fiber-containing structure is a braided fiber-containing structure or a stranded wire fiber-containing structure with a textured surface, the fiber-containing structure The at least one detector may be passed linearly at a linear velocity of less than a meter per minute to at least 1 meter per minute.

In some embodiments, the defect detection method can include the additional step of varying the sampling rate of measuring at least one cross-sectional diameter based on the surface defect signal. For example, the sampling rate can be increased to increase the number of measurement intervals, thereby increasing sensitivity and improving the ability to distinguish and classify various defects.

With respect to the reference signal used to generate various surface defect signals (e.g., based on cross-sectional diameter size, slope and/or curvature), the reference signal is constant along the length of the fiber-containing structure. The reference signal may be a variable reference signal that varies at one or more points along the length of the fiber-containing structure, or a combination thereof.

At least one of the defect detectors includes at least one roller, at least one extrusion device configured to form a fiber-containing structure, at least one braiding machine configured to form a fiber-containing structure, at least one tensioning assembly configured to apply tension to the fiber-containing structure; at least one finishing applicator configured to apply a coating to the fiber-containing structure; and at least one finishing applicator configured to stretch the fiber-containing structure. and at least one godet roll assembly, at least one winding assembly configured to wind the fiber-containing structure onto a bobbin, or a combination thereof. Other equipment commonly used to handle, process, and/or measure fiber-containing structures may also be placed in series with the defect detector of the present disclosure.

FIG. 7 shows an apparatus for manufacturing or processing fiber-containing structures, in which a plurality of defect detectors 205, 206, 207, 208, 209 and 210 (or a defect detector array as described below) is located with tension assembly 215, finishing applicator 220, godet roll assembly 225, and take-up assembly 230. In this example, the fiber-containing structure 110 is passed from the bobbin or upstream process 235 through the tension assembly 215, which is located in series with the surrounding defect detectors 205 and 206, onto the first roller 240 and then to the surrounding defect detectors 205 and 206. on the second roller 245 through the finishing applicator 220 located in series with the detectors 207 and 208 and then on the third roller 250 through the godet roll assembly 225 located in series with the defect detector 209. Above, it then passes linearly to take-up assembly 230, which includes dancer arm 255, traverse guide assembly 260, and finishing bobbin 265. Upstream steps 235 may include, for example, extrusion, winding, or braiding steps to produce fiber-containing structure 110.

The detection method of the present disclosure can include forming a fiber-containing structure by an extrusion process, and at least one of the defect detectors is located in series with the extrusion device. The detection method of the present disclosure may also include forming a fiber-containing structure by a braiding process, where at least one of the defect detectors is located in series with the braiding machine. The defect detector may be located within the braiding device, for example between the at least one carrier bobbin (or carrier guide) and the winding shaft.

The detection method of the present disclosure includes changing the operation of an extrusion device, a braider, a tensioning assembly, a finishing applicator, a godet roll assembly, a take-up assembly, a linear speed, or a combination thereof based on a surface defect signal. It can also be included. For example, if the method detects an increase in surface defect output starting immediately downstream of the finishing applicator 220, by reducing the linear velocity v of the fiber-containing structure or by changing the operating parameters of the finishing applicator 220. The finishing applicator operation can be modified to reduce surface defect output.

Defect detector arrays that include at least two defect detectors located in series can also be used in the methods of the present disclosure. FIG. 8 shows that a defect detector array 270 is located downstream of a braiding machine 275 and upstream of a downstream process 280, such as a tensioning assembly 215, a finishing applicator 220, a godet roll assembly 225, and/or a take-up assembly 230. An embodiment is shown below. In the example of FIG. 8, defect detector array 270 includes two defect detectors 285 and 290 located in series. In some embodiments, the defect detectors of the defect detector array can be rotated relative to each other by a detector offset angle such that different silhouette images of the fiber-containing structure are detected by at least two detectors. Detector offset angles can range from 1° to less than 360°.

Defect detectors of the present disclosure can include multi-axis defect detectors that can simultaneously measure multiple cross-sectional diameters of a fiber-containing structure from various directions.

In one embodiment, a two-axis defect detector includes two light emitters to transmit light onto the fiber-containing structure and two light receivers to detect a silhouette image of the fiber-containing structure. The two projectors may include a projector A for transmitting light A to a surface A of the fiber-containing structure and a projector B for transmitting light B to a surface B of the fiber-containing structure. The two light receivers can include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure. In this scenario, emitter A is optically aligned with receiver A, and emitter B is optically aligned with receiver B. Light projector A and light projector B rotate relative to each other by a light projector offset angle, and light receivers A and light receiver B rotate relative to each other by a light receiver offset angle. In some embodiments, the emitter offset angle and receiver offset angle may independently range from 5° to 175°.

FIG. 9 shows a defect detector array 295 including two biaxial defect detectors α 300 and β 305 mounted in series with respect to a fiber-containing structure 110 moving the defect detector array 295 at a linear velocity v. ing. The two two-axis defect detectors α300 and β305 each include a light emitter A310 and a light emitter B315, and a light receiver A320 and a light receiver B325. Emitter A310 is optically aligned with receiver A320, and emitter B315 is optically aligned with receiver B325. In biaxial defect detector α300, projector A310 and projector B315 rotate relative to each other by a projector offset angle ΔΦ _α (where ΔΦ _α =Φ ¹ _α −Φ ² _α ). In the biaxial defect detector β305, the projector A310 and _the projector B315 are rotated relative to _each other by a projector offset angle _ΔΦβ , where _ΔΦβ = ^Φ1β − ^Φ2β .

In the embodiment of FIG. 9, biaxial defect detectors α 300 and β 305 are also offset relative to each other by a detector offset angle of approximately 90° and are set apart by a linear separation distance d 330. In some embodiments, the detector offset angle may range from 1° to less than 360°. In some embodiments, the linear separation distance d may range from about 1 mm to about 100 mm. Other embodiments of the present disclosure may use a defect detector array having at least three defect detectors located in series.

<Fiber-containing structure>
The present disclosure also relates to fiber-containing structures obtained by the defect detection methods disclosed herein. As explained above, fiber-containing structures can include core-sheath structures having yarn lines, braided lines, or braided or twisted sheaths. The yarn line may have a twist level of less than 10 turns per meter, or less than 1 turn per meter.

As used herein, the term "core-sheath structure" refers to a cord-like structure having a jacket of braided strands that at least partially surrounds a central core. Figures 1C and 1D show core-sheath structures with braided and wire-stranded sheaths, respectively.

The fiber-containing structures of the present disclosure have a shape-controlled (flattened ) may include a core-sheath structure with a jacket. Examples of such shape-controlled core-sheath structures include those described in U.S. Provisional Application No. 63/044,418, filed June 26, 2020, the entire content of which is incorporated by reference. Incorporated herein.

The fiber-containing structures of the present disclosure may also include braided cords of varying cross-sectional area. Such braided cords with varying cross-sectional areas include those described in U.S. Provisional Application No. 63/069,182, filed August 24, 2020, the entire contents of which are incorporated herein by reference. Incorporated into the specification.

In some embodiments, the surface coverage of the braided sheath over the core is at least 85%. In other embodiments, surface coverage may range from about 25% to about 100%. In still other embodiments, the surface coverage may exceed 100% such that adjacent strands at least partially overlap each other. In some embodiments, surface coverage may range from about 25% to about 150%. For example, surface coverage may range from about 50% to about 125%, or about 75% to about 110%, or about 85% to about 105%, or about 90% to about 100%.

Some core-sheath structures have surface coverage significantly less than 100% (due to the presence of intentional gaps) or (due to overlapping jacket strands). ) may significantly exceed 100%. Such embodiments may be used, for example, if it is beneficial to obtain a jacket with a higher surface roughness (due to the presence of gaps or protrusions) or (due to the presence of overlapping strands). This may be advantageous if additional protection of the wick is desired.

The pick number of the braided sheath in the relaxed state (ie, the natural resting state with no tension applied to the core-sheath structure) may range from 30 to 3000 filament unit intersections per meter. In other embodiments, the pick count of the braided sheath is between about 30 and 3000 crosses per meter, or between about 50 and about 2000 crosses per meter, or between about 50 and 1000 crosses per meter at rest. It may range over a range.

The number of strands (ends) in the braided sheath is determined by the requirements of the core-sheath construction and the capabilities of the braiding device. Strand counts from 3 to over 200 can be used depending on the particular application. In some embodiments, the number of strands (ends) of the braided sheath may range from 4 to 96 ends, while in other applications, a number of strands (ends) limited to about 24 ends may be appropriate. For example, the number of strands (ends) of the core-sheath structures of the present disclosure can range from 4 to 24 ends, or 4 to 16 ends, or 4 to 12 ends, or 4 to 8 ends, or 4 to 6 ends. For medical applications, the core-sheath structures of the present disclosure often range from 4 to 24 ends.

The braid angle of the relaxed braided sheath generally ranges from about 5° to about 85°. In other embodiments, the braid angle of the S and Z strands of the relaxed braided sheath is about 5° to about 60°, or about 10° to about 75°, or about 15° to about 60°, or about It may range from 20° to about 45°, or from about 5° to about 45°.

The selection of the braid angle can have a significant impact on the properties of the core-sheath structure used as the fiber-containing structure of the present disclosure. For example, reducing the braid angle tends to improve the modulus and/or strength of the resulting core-sheath structure due to the load-bearing fibers of the jacket (sheath) being more aligned with the direction of the load. . Also, selection of the braid angle can be used to control core and jacket load sharing. In some embodiments, a balance of core and jacket (sheath) load sharing is important to obtain a core-sheath structure with optimal tensile strength and durability.

The fiber-containing structure of the present disclosure includes a core and a braided sheath of strands surrounding the core, the braided sheath including strands having a braid angle of 5 degrees or more in a relaxed state and a braid angle of 5 degrees or more in a relaxed state. Mention may be made of core-sheath constructions in which the angled strands include at least one strand of shaped filament. These core-sheath structures are untwisted strands in which the shaped filament strands have a twist level of less than one turn per meter, and in which the shaped filament strands have a cross-sectional aspect ratio measured at the braided sheath. at least 3:1, the thickness of at least a portion of the braided sheath ranges from about 20 to about 200 μm, and/or the braided sheath contains synthetic fibers having a tensile strength of greater than 12 cN/dtex. be able to.

The core-sheath structures of the present disclosure include at least one twist level in which the braided sheath has a twist level of less than 0.75 turns per meter, or less than 0.5 turns per meter, or less than 0.25 turns per meter. Embodiments include two strands of untwisted shaped filaments.

In some embodiments, the cross-sectional aspect ratio of the shaped strand filament ranges from 3:1 to 50:1, or from 3:1 to 20:1, or from 4:1 to 15:1. or ranging from 5:1 to 10:1. In other embodiments, the shaped filament strands have a cross-sectional aspect ratio of about 3:1 to about 50:1 (about 68-98% ellipticity), or about 4.1:1 to about 50:1 (about 68-98% ellipticity). 75.5% to 98% ellipticity), or 5.6:1 to 50:1 (approximately 82% to 98% ellipticity), or 8:1 to 22.2:1 (approximately 87% ellipticity). .5 to 95.5%).

The thickness of at least a portion of the braided sheath may range from about 16 μm to about 250 μm, or from about 40 μm to about 200 μm, or from about 50 μm to about 175 μm, or from about 60 μm to about 150 μm, or from about 50 μm to about 125 μm.

The fiber-containing structures of the present disclosure can include synthetic fibers having a tensile strength greater than 12 cN/dtex. The synthetic fibers may have a tensile strength of at least 13 cN/dtex, or at least 15 cN/dtex, or at least 20 cN/dtex. In some embodiments, the synthetic fibers included in the braided sheath can have a tensile strength ranging from 13 cN/dtex to 50 cN/dtex, or from 15 cN/dtex to 45 cN/dtex.

In addition to synthetic fibers having a tensile strength of greater than 12 cN/dtex, the fiber-containing structures of the present disclosure can also be used with other synthetic and non-synthetic fibers having a tensile strength ranging from about 1 cN/dtex to about 30 cN/dtex. May include filaments. For example, some fiber-containing structures may include at least one synthetic fiber with a tensile strength of greater than 12 cN/dtex and at least one synthetic or non-synthetic fiber with a tensile strength of less than 12 cN/dtex.

The fiber-containing structures of the present disclosure can also have a maximum (outer) diameter ranging from about 15 μm to about 20 mm. In other embodiments, the outer diameter may range from about 20 μm to about 8 mm, or from about 30 μm to about 5 mm, or from about 50 μm to about 3 mm, or from about 50 μm to about 1 mm.

A wide variety of core sizes can also be used in the core-sheath structures of the present disclosure. For example, the maximum diameter of the wick can range from about 10 μm to about 20 mm. In other embodiments, the maximum diameter of the wick may range from about 15 μm to about 10 mm, or from about 25 μm to about 5 mm, or from about 50 μm to about 1 mm, or from about 50 μm to about 500 μm.

The core-sheath structures of the present disclosure can use not only monofilament cores, but also twisted or non-twisted cores. In some embodiments, the wick consists of at least two wick strands twisted together at a twist level of greater than 0 to 1600 turns per meter. The number of core strands included in a twisted or untwisted core can range from 1 to 500; the twist level of cores or core strands used to produce multi-strand cores can range from 1 to 1600 revolutions per meter. obtain. Combinations of twisted, untwisted, and/or braided filaments can also be used to manufacture the core in the core-sheath structures of the present disclosure.

Embodiments of the present disclosure include core-sheath structures that include a round core having a circular cross-section and a braided sheath comprised of shaped strands, wherein the shaped strands have a flattening factor of about 0.05 to about 0.45. Covers a range of. In other embodiments, the flattening factor may range from about 0.1 to about 0.35, or from about 0.10 to about 0.30, or from about 0.1 to about 0.25.

In some embodiments, the core in the core-sheath structure is a surface-treated core. For example, the surface of the core component may be corona-treated or plasma-treated prior to application of the braided sheath. Such treatments can create surface imperfections or modifications that enhance contact (surface interaction) between the core and the inner surface of the braided sheath, further enhancing the interaction between the core and the braided sheath.

Another aspect of the present disclosure relates to the proportion of shaped strands used in braided fiber-containing structures. In some embodiments, all of the strands used in the braiding process are shaped strands, while in other embodiments only a portion of the strands used in the braiding process are shaped strands. For example, in some embodiments, the S strands that are braided in the left-hand direction are all shaped strands, whereas the Z strands that are braided in the right-hand direction are all shaped strands that do not undergo a shaping step that occurs prior to the braiding step. strands that are not strands, and vice versa. In still other embodiments, only a portion of one or both of the S-strands and Z-strands may be shaped strands. Embodiments of the present disclosure include only one shaped strand in the braided sheath, or all (100%) shaped strands in the braided sheath, or between one shaped strand and 100% shaped strands in the braided sheath. core-sheath structures comprising any combination of the following.

The fiber-containing structures of the present disclosure include at least one shaped strand of filaments having a cross-sectional aspect ratio of at least 3:1 and at least one shaped strand having a cross-sectional aspect ratio of less than 2:1. Also included are core-sheath structures that are hybrid jackets that include strands of filaments. For example, in some embodiments, the braided sheath has at least one strand of shaped filaments having a cross-sectional aspect ratio of at least 3:1 and a twist level of greater than 0 to 1600 turns per meter. A hybrid jacket comprising at least one twisted (unshaped) strand of filament. As explained above, twisted filament bundles (i.e., twisted strands) are stiffer and more difficult to form than untwisted filament bundles.

Core-sheath structures used as fiber-containing structures of the present disclosure include, in addition to left-handed S strands and right-handed Z strands, the core-sheath structures have a braid angle of less than 5° in the relaxed state. Mention may also be made of triaxially braided sheaths comprising directional strands. In some embodiments, the triaxially braided sheath may include at least one shaped longitudinal strand that is shaped by forming at least one of the longitudinal strands prior to braiding of the plurality of strands. For example, the triaxially braided sheath of the present disclosure may include one shaped longitudinal strand, all shaped longitudinal strands, or any combination therebetween in addition to the S and Z strands.

The fiber-containing structures of the present disclosure may include additional components such as lubricants, fibers, surface-coated filaments, or combinations thereof. Lubricants used in the fiber-containing structures of the present disclosure can include at least one of lubricating filaments and lubricating fibers. Surface coated filaments can include crosslinked or non-crosslinked silicone polymers as a surface coating.

The fiber-containing structures of the present disclosure can have linear mass densities ranging from about 30 denier to about 10,000 denier. In other embodiments, the linear mass density of the core-sheath structure is from about 40 denier to about 4500 denier, or from about 50 denier to about 4000 denier, or from about 100 denier to about 3000 denier, or from about 70 denier to about 2000 denier. , or from about 80 denier to about 1500 denier, or from about 90 denier to about 1000 denier.

The fiber-containing structures of the present disclosure can include organic fibers. The chemical composition of the fibers included in the fiber-containing structures of the present disclosure can be any high performance polymer known to provide a combination of high tensile strength, high toughness, and low creep, to name just a few. To name a few, liquid crystalline polyester filaments, aramid filaments, copolymer aramid filaments, polyetheretherketone filaments, poly(p-phenylenebenzobisoxazole) (PBO) filaments, ultra-high molecular weight polyethylene filaments, high modulus polyethylene filaments, polypropylene filaments, It can be selected from, but is not limited to, polyethylene terephthalate filaments, polyamide filaments, high strength polyvinyl alcohol filaments, polyhydroquinone diimidazopyridine (PIPD) filaments, and combinations thereof.

Polyhydroquinone diimidazopyridine (PIPD) filament fibers are based on polymers of the following repeating units:

The fiber-containing structures of the present disclosure include liquid crystal polyester filaments, aramid filaments, copolymer aramid filaments, polyetheretherketone filaments, poly(p-phenylenebenzobisoxazole) filaments, ultra-high molecular weight polyethylene filaments, high modulus polyethylene filaments, It can include at least one selected from polypropylene filaments, polyethylene terephthalate filaments, polyamide filaments, polyhydroquinone diimidazopyridine filaments, and high strength polyvinyl alcohol filaments. In other embodiments, at least two of these materials may be included in the fiber-containing structure.

In some embodiments, the fiber-containing structure can include at least one fiber selected from liquid crystal polyester fibers, aramid fibers, PBO fibers, ultra-high molecular weight polyethylene fibers, and high strength polyvinyl alcohol fibers. In other embodiments, the shaped and/or unshaped strands of the braided sheath can be selected from liquid crystal polyester fibers and aramid fibers, especially liquid crystal polyester fibers.

The core-sheath structures of the present disclosure, in some embodiments, include liquid crystalline polyester filaments, aramid filaments, copolymer aramid filaments, polyetheretherketone filaments, poly(phenylenebenzobisoxazole) filaments, ultra-high molecular weight polyethylene filaments, It can include at least one selected from the group consisting of polypropylene filaments, high modulus polyethylene filaments, polyethylene terephthalate filaments, polyamide filaments, and high strength polyvinyl alcohol filaments.

Examples of the polymerized unit include those shown in Table 1.

Regarding the polymerized units shown in Table 1 above, the number of Y substituents is equal to the maximum number of substitutable positions in the ring structure, and each Y is independently a hydrogen atom, a halogen atom (e.g., a fluorine atom, a chlorine atom, bromine atom, iodine atom, etc.), alkyl groups (e.g., alkyl groups having 1 to 4 carbon atoms such as methyl, ethyl, isopropyl, or t-butyl), alkoxy groups (e.g., methoxy, ethoxy group, isopropoxy group, n-butoxy group, etc.), aryl group (e.g. phenyl group, naphthyl group, etc.), aralkyl group [benzyl group (phenylmethyl group), phenethyl group (phenylethyl group), etc.], aryloxy It represents a group (eg, phenoxy group, etc.), an aralkyloxy group (eg, benzyloxy group, etc.), or a mixture thereof.

Liquid crystal polyester fibers can be obtained by melt spinning liquid crystal polyester resin. Spun fibers may be further heat treated to improve mechanical properties. Liquid crystalline polyesters may be composed of repeating polymerized units derived from, for example, aromatic diols, aromatic dicarboxylic acids, and aromatic hydroxycarboxylic acids. The liquid crystalline polyester may optionally further include polymerized units derived from aromatic diamines, aromatic hydroxyamines, and/or aromatic aminocarboxylic acids.

More specific polymerized units will be explained using the structures shown in Tables 2 to 4 below.

When the polymerized unit in the formula is a unit that can represent a plurality of structures, two or more units can be used in combination as the polymerized unit constituting the polymer.

In the polymerized units in Table 2, Table 3, and Table 4, n is an integer of 1 or 2, and each unit n=1 and n=2 may exist alone or in combination. , Y ₁ and Y ₂ each independently represent a hydrogen atom, a halogen atom (e.g., fluorine atom, chlorine atom, bromine atom, iodine atom, etc.), an alkyl group (e.g., methyl group, ethyl group, isopropyl group, or t - butyl groups), alkoxy groups (e.g. methoxy, ethoxy, isopropoxy, n-butoxy, etc.), aryl groups (e.g. phenyl, naphthyl) group), aralkyl group (benzyl group (phenylmethyl group), phenethyl group (phenylethyl group), etc.), aryloxy group (e.g., phenoxy group, etc.), aralkyloxy group (e.g., benzyloxy group, etc.), or It may be a mixture of. Among these groups, Y is preferably a hydrogen atom, a chlorine atom, a bromine atom, or a methyl group.

Z in (14) of Table 3 can include a divalent group represented by the following formula.

In some embodiments, the liquid crystal polyester may be a combination containing a naphthalene skeleton as a polymerized unit. In particular, it may contain both polymerized units derived from hydroxybenzoic acid (A) and polymerized units derived from hydroxynaphthoic acid (B). For example, the unit (A) may be a formula (A), and the unit (B) may be a formula (B). From the viewpoint of improving melt moldability, the ratio of unit (A) to unit (B) is 9/1 to 1/1, preferably 7/1 to 1/1, more preferably 5/1 to 1/1. It may be within the range of

The sum of polymerized units (A) and polymerized units (B) may be, for example, about 65 mol% or more, or about 70 mol% or more, or about 80 mol% or more, based on total polymerized units. In some embodiments, the braided sheath can include a liquid crystalline polyester comprising about 4 to about 45 mol% of polymerized units (B) in the polymer.

The melting point used herein is the main absorption peak temperature measured and observed by a differential scanning calorimeter (DSC) (for example, "TA3000" manufactured by Mettler) in accordance with the test method of JIS K7121. Specifically, 10 to 20 mg of the sample was used in the above DSC device, and after the sample was sealed in an aluminum container, nitrogen was flowed as a carrier gas at a flow rate of 100 cc/min, and the endotherm was heated at a rate of 20°C/min. Measure the peak. Depending on the type of polymer, if a clear peak does not appear in the first DSC measurement, increase the temperature at a heating rate (or heating rate) of 50°C/min to a temperature 50°C higher than the expected flow temperature, and then After completely melting at this temperature for 3 minutes, it is further cooled down to 50°C at a cooling rate (or cooling rate) of -80°C/min. Thereafter, the endothermic peak can be measured at a heating rate of 20° C./min.

Commercially available LCPs included in the braided sheath of the present disclosure include Vectran (registered trademark) HT Black manufactured by Kuraray Co., Ltd., Vectran (registered trademark) HT manufactured by Kuraray Co., Ltd., Sciberas (registered trademark) manufactured by Toray Industries, Inc. Examples include monofilament manufactured by Zeus Corporation and Zexion (registered trademark) manufactured by KB Seiren Co., Ltd.

Liquid crystalline polyesters can be used alone or in combination in the core-sheath structures of the present disclosure.

According to the present invention, "aramid fiber" means a polyamide fiber having high heat resistance and high strength and having a molecular skeleton composed of aromatic (benzene) rings. Aramid fibers can be classified into para-aramid fibers and meta-aramid fibers depending on their chemical structure, and para-aramid fibers are preferably included in some braided sheaths of the present disclosure.

Examples of commercially available aramid fibers and copolymer aramid fibers include para-aramid fibers, such as Kevlar® manufactured by E.I. du Pont de Nemours and Company, Heraclon® manufactured by Colon Industries, and Teijin Corporation. and meta-aramid fibers such as Nomex® from E.I. du Pont de Nemours and Company and Conex® from Teijin Limited.

When included in the fiber-containing structures of the present disclosure, aramid fibers can be used alone or in combination. In some embodiments, the filaments included in the fiber-containing structure can include copolymer aramid filaments. For example, in some embodiments, the fiber-containing structure comprises copolyparaphenylene/3,4'-oxydiphenylene terephthalamide filaments.

This material is conventionally called Technora® and is available from Teijin Limited.

Polyparaphenylenebenzobisoxazole (poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers are commercially available as Zylon (registered trademark) AS and Zylon (registered trademark) HM manufactured by Toyobo Co., Ltd. .

The fiber-containing structures of the present disclosure can also be formed from polyetheretherketone (PEEK) materials, such as Victrex(TM) PEEK polymer. In some embodiments, the use of high dpf PEEK polymers as a component of the fiber-containing structure may impart improved tensile properties to the fiber-containing structure.

The ultra-high molecular weight polyethylene fibers used in some fiber-containing structures of the present disclosure may be about 5.0, or about 7.0, or about 10, or about 30, or about 28, or about 24 dL/g. may have an intrinsic viscosity in the range of . When the intrinsic viscosity of the "ultra-high molecular weight polyethylene fiber" is in the range of about 5.0 to about 30 dL/g, fibers with good dimensional stability can be obtained.

The weight average molecular weight of the "ultra high molecular weight polyethylene fiber" is about 700,000, or about 800,000, or about 900,000 to about 8,000,000, or about 7,000,000, or about 6 ,000,000. When the weight average molecular weight of the "ultra high molecular weight polyethylene fiber" is in the range of about 700,000 to about 8,000,000, high tensile strength and elastic modulus can be obtained.

Because it is difficult to determine the weight average molecular weight of "ultra-high molecular weight polyethylene fibers" using the GPC method, the following mentioned in "Polymer Handbook, 4th Edition, Chapter 4 (John Wiley, published in 1999)" According to the formula, the weight average molecular weight can be determined based on the above intrinsic viscosity value.
Weight average molecular weight = 5.365 x 10 ⁴ x (intrinsic viscosity) ^1.37

In some embodiments, it may be preferred that the repeating units of the "ultra high molecular weight polyethylene fiber" substantially include ethylene. However, in addition to homopolymers of ethylene, copolymers of ethylene and small amounts of other monomers such as α-olefins, acrylic acid and derivatives thereof, methacrylic acid and derivatives thereof, vinylsilane and derivatives thereof are used. There are cases where it is possible. The polyethylene fibers may have a partially crosslinked structure. The polyethylene fibers may also be a blend of high-density polyethylene and ultra-high molecular weight polyethylene, a blend of low-density polyethylene and ultra-high molecular weight polyethylene, or a blend of high-density polyethylene, low-density polyethylene, and ultra-high molecular weight polyethylene. The polyethylene fibers may be a combination of two or more types of ultra-high molecular weight polyethylenes having different weight average molecular weights, or two or more types of polyethylenes having different molecular weight distributions.

Commercially available "ultra-high molecular weight polyethylene fibers" include Dyneema (registered trademark) SK60, Dyneema (registered trademark) SK, Izanas (registered trademark) SK60, and Izanas (registered trademark) SK71 manufactured by Toyobo Co., Ltd., and Honeywell Corporation. Examples include Spectra Fiber 900 (registered trademark) and Spectra Fiber 1000 manufactured by Manufacturer.

These "ultra high molecular weight polyethylene fibers" can be used alone or in combination.

The performance and properties of the fiber-containing structures of the present disclosure can be modified and controlled by applying finishing compositions to the core and/or braided sheath. For example, the fiber-containing structure can include filaments, fibers or strands with a coating of crosslinked silicone polymers or non-crosslinked silicone polymers or long chain fatty acids. Suitable long chain fatty acids include stearic acid.

Application of crosslinkable silicone polymers can provide beneficial performance improvements in the tensile strength of the fiber-containing structures of the present invention.

Generally, there are three crosslinking reaction methods available for preparing silicone resins: 1) peroxide curing, in which thermal activation of polymerization occurs under the formation of peroxide free radicals, 2) tin salt or titanium alkoxide catalysts. 3) addition reaction chemistry catalyzed by platinum or rhodium complexes that can be initiated by temperature or light.

The cross-linked silicone coating increases the moisture resistance of the coated strands and also increases the lubricity of the strands, coatings that may be necessary to overcome frictional interactions when the core-sheath structure is subjected to longitudinal stress. Compared to unbraided structures, braided structures react more efficiently.

Coating compositions of the present disclosure can be applied using surface application techniques known to those skilled in the art. These surface application techniques can include simple pumping of the finishing solution through a finishing guide where the fibers are brought into contact with the finishing solution, which is carried to the fiber bundle by capillary action. Alternatively, other techniques can include spraying, rolling, or dip coating techniques such as dip coating. Subsequent treatment of the fibers to which the finishing solution has been applied can include contact with a roller or rollers to solidify the finishing solution and/or to influence the degree of crosslinking of the finishing formulation. The roller(s) may or may not be heated. The coating composition can then be cured to cause crosslinking of the crosslinkable silicone polymer. If heat curing is used, the temperature may be about 20°C, about 50°C, or about 120°C to about 200°C, or up to about 170°C, or up to about 150°C. The curing temperature can be determined by the thermal stability properties of the filament, fiber or strand and the actual crosslinking system used.

The resulting degree of crosslinking can be controlled to impart varying degrees of flexibility or other surface properties to the filaments, fibers or strands. The degree of crosslinking can be determined by the method described in US Pat. No. 8,881,496, where the coating is extracted with a solvent that dissolves the monomer but does not dissolve the crosslinked polymer. The degree of crosslinking can be determined by the difference in weight before and after extraction.

The degree of crosslinking may be at least about 20%, or at least about 30%, or at least about 50%, based on the total weight of the coating. The maximum degree of crosslinking may be about 100%. The weight of the crosslinked coating may be from about 1% to about 20%, or from about 10%, or from about 5% by weight, based on the total weight of the filaments, fibers or strands.

In some embodiments, the maximum cross-sectional diameter of the fiber-containing structure can range from about 15 μm to about 20 mm. In other embodiments, the maximum diameter may range from about 20 μm to about 5 mm, or from about 30 μm to about 4 mm, or from about 40 μm to about 3.5 mm, or from about 50 μm to about 3 mm, or from about 50 μm to about 2 mm. The average cross-sectional diameter of the fiber-containing structure can range from about 20 μm to about 10 mm.

The fiber-containing structures of the present disclosure can be designed to meet a variety of properties, such as cut strength. In some embodiments, the cutting strength is at least 15 cN/dtex. In other embodiments, the cutting strength of the cord may range from about 4 cN/dtex to about 40 cN/dtex, or from about 13 cN/dtex to about 31 cN/dtex, or from about 15 cN/dtex to about 26 cN/dtex.

Fiber-containing structures of the present disclosure include tension members useful in a variety of applications, including medical cords. For example, fiber-containing structures of the present disclosure include sutures, catheter navigation cables and assemblies, steering cables and assemblies, device deployment control cables and assemblies, and torque and tension transmission cables and assemblies, to name a few. Can be mentioned.

Fiber-containing structures of the present disclosure can include cords having a linear mass density of about 30 denier to about 10,000 denier. In other embodiments, the linear mass density is about 40 denier to about 4500 denier, or about 50 denier to about 4000 denier, or about 100 denier to about 3000 denier, or about 70 denier to about 2000 denier, or about 80 denier. It can range from about 1500 denier, or from about 90 denier to about 1000 denier.

<Device for detecting defects in moving fiber-containing structures>
The present disclosure also relates to an apparatus for detecting defects in a moving fiber-containing structure. Such apparatus includes: (A) the extrusion device configured to form a fiber-containing structure; the braiding machine configured to form the fiber-containing structure; and a device configured to apply tension to the fiber-containing structure. the tensioning assembly configured to , the finishing applicator configured to apply a coating to the fiber-containing structure, the godet roll assembly configured to stretch the fiber-containing structure, the fiber-containing structure the winding assembly configured to wind an object onto a bobbin, or a combination thereof; (B) transmitting light through the fiber-containing structure with a projector and detecting a silhouette image of the fiber-containing structure with a receiver; and configured to measure the cross-sectional diameter of at least one of the fiber-containing structures by calculating the cross-sectional diameter based on the amount of decrease in the amount of light detected by the light receiver with respect to the total amount of light transmitted by the light emitter. and (C) comparing at least one diameter signal obtained from said defect detector, optionally at least one signal-processed diameter signal, or a combination thereof, with at least one reference signal. is configured to obtain at least one surface defect signal of a surface defect output versus a length of the fiber-containing structure; A defect detector may include a processor that measures the at least one cross-sectional diameter.

The apparatus of the present disclosure operates as described in the above method and can be modified in accordance with the above subject matter.

<Embodiment>
Embodiment [1] of the present disclosure includes linearly passing a fiber-containing structure through at least one defect detector, measuring a cross-sectional diameter of at least one of the fiber-containing structures with the defect detector, and measuring the cross-sectional diameter of the at least one defect detector. obtaining at least one diameter signal of diameter versus length of a fiber-containing structure, optionally signal processing said diameter signal to obtain at least one signal processed diameter signal; and said diameter signal, said signal. Comparing the processed diameter signal or a combination thereof to at least one reference signal to generate at least one surface defect signal of a surface defect output versus the length of the fiber-containing structure. The defect detector transmits light to the fiber-containing structure using a light projector, detects a silhouette image of the fiber-containing structure using a light receiver, and detects a silhouette image of the fiber-containing structure with a light receiver, and detects a total amount of light transmitted by the light receiver with respect to a total amount of light transmitted through the light projector. measuring the cross-sectional diameter of the fiber-containing structure by calculating the cross-sectional diameter based on the amount of decrease in the amount of light obtained by forming the fiber-containing structure; a braiding machine configured to form the fiber-containing structure; a tensioning assembly configured to apply tension to the fiber-containing structure; and a tensioning assembly configured to apply a coating to the fiber-containing structure. a finishing applicator configured to draw the fiber-containing structure, a godet roll assembly configured to draw the fiber-containing structure, a winding assembly configured to wind the fiber-containing structure onto a bobbin, or a combination thereof. Concerning the way in which it is located.

Embodiment [2] of the present disclosure relates to the method of embodiment [1], wherein said fiber-containing structure linearly passes said at least one defect detector at a linear speed of at least 300 m/min.

Embodiment [3] of the present disclosure provides that the fiber-containing structure is a braided fiber-containing structure or a fiber-containing structure made of twisted wires, and the fiber-containing structure is Embodiments [1] and [2] relate to the method of linearly passing through at least one detector.

Embodiment [4] of the present disclosure provides that the fiber-containing structure is a non-braided fiber-containing structure having a twist level of less than 1 turn per meter, wherein the fiber-containing structure is a braided fiber-containing structure. , or the method of embodiments [1] to [3], wherein the fiber-containing structure is a fiber-containing structure made of twisted wires.

Embodiment [5] of the present disclosure relates to the method of embodiments [1] to [4], wherein the fiber-containing structure is a core-sheath structure comprising a core and a braided sheath of strands surrounding the core.

Embodiment [6] of the present disclosure is a cord in which the fiber-containing structure has a core-sheath structure including a braided sheath surrounding a core, and the braiding angle of the braided sheath in a relaxed state is about 5° to about 85°. The present invention relates to the methods of embodiments [1] to [5], which cover the range of.

Embodiment [7] of the present disclosure is a cord in which the fiber-containing structure has a core-sheath structure including a braided sheath surrounding a core, and the number of picks of the braided sheath in a relaxed state is 6 to 3 per meter. 000 filament unit intersection, relates to the method of embodiments [1] to [6].

Embodiment [8] of the present disclosure is a cord in which the fiber-containing structure has a core-sheath structure including a braided sheath surrounding a core, and the number of strands (ends) of the braided sheath is 3 to 24 ends. The present invention relates to the methods of embodiments [1] to [7].

Embodiment [9] of the present disclosure relates to the method of embodiments [1] to [8], wherein the fiber-containing structure is a cord having a wire lay structure including a non-braided sheath surrounding a core.

Embodiment [10] of the present disclosure relates to the method of embodiments [1] to [9], wherein the fiber-containing structure includes organic fibers.

Embodiment [11] of the present disclosure relates to the method of embodiments [1] to [10], wherein the fiber-containing structure comprises synthetic fibers having a tensile strength of greater than 12 cN/dtex.

Embodiment [12] of the present disclosure provides that the fiber-containing structure is a liquid crystal polyester filament, an aramid filament, a copolymer aramid filament, a polyether ether ketone filament, a poly(p-phenylenebenzobisoxazole) filament, an ultra-high molecular weight Embodiments [1] to [1] comprising at least one selected from the group consisting of polyethylene filaments, high modulus polyethylene filaments, polypropylene filaments, polyethylene terephthalate filaments, polyamide filaments, polyhydroquinone diimidazopyridine filaments, and high strength polyvinyl alcohol filaments. 11].

Embodiment [13] of the present disclosure relates to the method of embodiments [1] to [12], wherein the fiber-containing structure comprises synthetic fibers and at least one of a lubricant, staple fibers, and a surface coating.

Embodiment [14] of the present disclosure relates to the method of embodiments [1]-[13], wherein the fiber-containing structure is a cord having a linear mass density of about 30 to about 10,000 denier.

Embodiment [15] of the present disclosure relates to the method of embodiments [1] to [14], wherein the maximum cross-sectional diameter of the fiber-containing structure ranges from about 20 μm to about 10 mm.

Embodiment [16] of the present disclosure relates to the method of embodiments [1] to [15], wherein the average cross-sectional diameter of the fiber-containing structure ranges from about 20 μm to about 10 mm.

Embodiment [17] of the present disclosure further includes forming the fiber-containing structure by an extrusion process, and at least one defect detector is located in series with the extrusion device, embodiments [1] to Regarding the method of [16].

Embodiment [18] of the present disclosure further includes forming the fiber-containing structure by a braiding process, and embodiment [1], wherein at least one of the defect detectors is located in series with the braiding machine. Regarding the method of ~[7].

Embodiment [19] of the present disclosure further includes forming the fiber-containing structure by a braiding process, and the defect detector array is configured such that the fiber-containing structure passes linearly through the defect detector array. in series with the braiding machine, the defect detector array including at least two of the defect detectors in series, the at least two of the defect detectors being arranged in series with the fiber-containing rotated relative to each other by a detector offset angle such that different silhouette images of a structure are detected by the at least two of the detectors, the detector offset angle ranging from 1° to less than 360°; The present invention relates to the methods of embodiments [1] to [18].

Embodiment [20] of the present disclosure relates to the method of embodiment [19], wherein said defect detector array includes at least three of said defect detectors located in series.

Embodiment [21] of the present disclosure relates to the method of embodiments [19] and [20], wherein the separation distance between the at least two of the defect detectors in the defect detector array ranges from 1 mm to 100 mm. .

In embodiment [22] of the present disclosure, the defect detector includes two light projectors for transmitting light to the fiber-containing structure and two light receivers for detecting a silhouette image of the fiber-containing structure. The two projectors include a projector A for transmitting light A to the surface A of the fiber-containing structure, and a projector B for transmitting the light B to the surface B of the fiber-containing structure. the two light receivers include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure; Emitter A is optically aligned with the receiver A, the emitter B is optically aligned with the receiver B, and the emitter A and the emitter B are rotated relative to each other by an emitter offset angle; Embodiments [19] to [1], wherein the light receiver A and the light receiver B are rotated relative to each other by a receiver offset angle, and the light emitter offset angle and the light receiver offset angle range from 5° to 175°. 21].

Embodiment [23] of the present disclosure relates to the method of embodiments [1]-[22], wherein at least one of said defect detectors is located in series with said tensioning assembly.

Embodiment [24] of the present disclosure relates to the method of embodiments [1] to [23], wherein at least one of said defect detectors is located in series with said finishing applicator.

Embodiment [25] of the present disclosure relates to the method of embodiments [1]-[24], wherein at least one of said defect detectors is located in series with said godet roll assembly.

Embodiment [26] of the present disclosure relates to the method of embodiments [1] to [25], wherein at least one of said defect detectors is located in series with said winding assembly.

Embodiment [27] of the present disclosure relates to the method of embodiments [1] to [26], wherein at least one of said defect detectors is located in series with at least one roller.

Embodiment [28] of the present disclosure provides that the measurement of the fiber-containing structure comprises at least two of the defect detectors located adjacently in series together as a defect detector array; The method of embodiments [1] to [27], wherein the detector offset angle between adjacently located defect detectors in the array ranges from 1° to less than 360°.

Embodiment [29] of the present disclosure provides that the measurement of the fiber-containing structure comprises at least three of the defect detectors located adjacently in series together as a defect detector array; The method of embodiments [1] to [28], wherein the detector offset angle between adjacently located defect detectors in the array ranges from 1° to less than 360°.

Embodiment [30] of the present disclosure provides that the defect detector is configured to measure at least two cross-sectional diameters of the fiber-containing structure, wherein the offset angle between the at least two cross-sectional diameters is between 5° and The present invention relates to the method of embodiments [1] to [29], which are multi-axis defect detectors having a range of 175°.

In embodiment [31] of the present disclosure, the defect detector includes two light projectors for transmitting light to the fiber-containing structure and two light receivers for detecting a silhouette image of the fiber-containing structure. The two projectors include a projector A for transmitting light A to the surface A of the fiber-containing structure, and a projector B for transmitting the light B to the surface B of the fiber-containing structure. The two light receivers include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure, Emitter A is optically aligned with the receiver A, the emitter B is optically aligned with the receiver B, and the emitter A and the emitter B are rotated relative to each other by an emitter offset angle; Embodiments [1] to [2], wherein the light receiver A and the light receiver B rotate relative to each other by a receiver offset angle, and the emitter offset angle and the receiver offset angle range from 5° to 175°. 30].

Embodiment [32] of the present disclosure relates to the method of embodiments [1] to [31], in which the light projector includes a laser diode or a light emitting diode.

Embodiment [33] of the present disclosure relates to the method of embodiments [1] to [32], wherein the light receiver is an active pixel sensor.

Embodiment [34] of the present disclosure is embodiment [1], wherein the light receiver is an active pixel sensor including a photodiode image sensor, a charge-coupled device (CCD) image sensor, or a complementary metal oxide semiconductor (CMOS) image sensor. ] to [33].

Embodiment [35] of the present disclosure further includes imaging the surface of the fiber-containing structure with at least one imaging detector, the imaging detector illuminating the fiber-containing structure with imaging light and imaging the fiber-containing structure. The present invention relates to the method of embodiments [1] to [34], in which the surface is imaged by receiving a reflected image of the surface with a receiver.

Embodiment [36] of the present disclosure further includes imaging a surface of the fiber-containing structure with at least one imaging detector, wherein the imaging detector illuminates the fiber-containing structure with imaging light and captures an image. imaging the surface by receiving a reflected image of the surface with a receiver; at least one of the imaging detectors includes the extrusion device, the braiding machine, the tensioning assembly, the finishing applicator, the godet roll assembly; The method of embodiments [1] to [35], being located in series with said winding assembly, or said combination thereof.

Embodiment [37] of the present disclosure is the embodiment [1] to [36] in which the method does not include imaging the surface of the fiber-containing structure with an imaging detector that receives a reflected image of the surface. Regarding the method.

Embodiment [38] of the present disclosure relates to the method of embodiments [1]-[37], wherein said measurement of said at least one cross-sectional diameter occurs at a sampling rate of at least 5,000 samples per second.

Embodiment [39] of the present disclosure provides that the measurement of the at least one cross-sectional diameter occurs at a sampling rate, and the sampling rate of the at least one of the defect detectors is such that the measurement occurs at a sampling rate of the length of the fiber-containing structure. The methods of embodiments [1] to [38] are arranged to occur at regular intervals along the length of the substrate, and wherein the regular intervals range from 10 nm to 1 cm.

Embodiment [40] of the present disclosure relates to the method according to embodiments [1] to [39], further comprising generating a surface defect evaluation of the fiber-containing structure based on the surface defect signal.

Embodiment [41] of the present disclosure includes embodiments [1] to [40] in which the at least one surface defect signal includes a magnitude surface defect number signal versus a magnitude surface defect number signal of the length of the fiber-containing structure. ], wherein the size surface defect count signal is generated by comparing the diameter signal with a reference signal of maximum cross-sectional diameter versus the length of the fiber-containing structure; A zero magnitude surface defect count occurs when the magnitude of the diameter signal is less than or equal to the maximum cross-sectional diameter at a particular point along the length of the fiber-containing structure; A magnitude surface defect number greater than zero occurs when the maximum cross-sectional diameter at the particular point along the length of the structure is greater than the maximum cross-sectional diameter, and the greater than zero magnitude surface defect number occurs when the diameter signal is greater than the maximum cross-sectional diameter. is a positive integer corresponding to a percentage above said maximum cross-sectional diameter.

Embodiment [42] of the present disclosure relates to the method of embodiment [41], further comprising generating a surface defect assessment of the fiber-containing structure based at least in part on the size surface defect count signal. .

Embodiment [43] of the present disclosure further comprises classifying defects included in the fiber-containing structure based at least in part on the size surface defect count signal. ] Regarding the method.

Embodiment [44] of the present disclosure provides embodiments [1] to [43], wherein the at least one surface defect signal includes a sloped surface defect count signal versus a sloped surface defect count signal of the length of the fiber-containing structure. ], wherein the sloped surface defect count signal is compared with the signal-processed diameter signal and a reference signal of the maximum first derivative of the diameter signal versus the length of the fiber-containing structure. wherein the processed diameter signal is obtained by processing the diameter signal to obtain a first derivative of the diameter signal, and wherein the absolute value of the first derivative of the diameter signal is A sloped surface defect count of zero occurs when the maximum first derivative of the diameter signal at a particular point along the length of the fiber-containing structure is less than or equal to the absolute value of the first derivative of the diameter signal. a value greater than the maximum first derivative of the diameter signal at the particular point along the length of the fiber-containing structure, a sloped surface defect number greater than zero occurs, and the slope greater than zero occurs. The number of surface defects is a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal that is greater than the maximum first derivative of the diameter signal.

Embodiment [45] of the present disclosure relates to the method of embodiment [44], further comprising generating a surface defect assessment of the fiber-containing structure based on the graded surface defect count signal.

Embodiment [46] of the present disclosure further comprises classifying defects included in the fiber-containing structure based at least in part on the slope surface defect count signal. Regarding the method.

Embodiment [47] of the present disclosure provides embodiments [1] to [46], wherein the at least one surface defect signal includes a signal of the number of curvature surface defects versus the number of curvature surface defects of the length of the fiber-containing structure. ], wherein the curvature surface defect count signal is compared with the signal-processed diameter signal and a maximum second derivative of the diameter signal versus a reference signal of the length of the fiber-containing structure. wherein the processed diameter signal is obtained by processing the diameter signal to obtain a second derivative of the diameter signal, and wherein the absolute value of the second derivative of the diameter signal is A zero curvature surface defect count occurs when the maximum second derivative of the diameter signal at a particular point along the length of the fiber-containing structure is less than or equal to the second derivative of the diameter signal. A curvature surface defect number greater than zero occurs when the absolute value is greater than the maximum second derivative of the diameter signal at the particular point along the length of the fiber-containing structure, and the curvature greater than zero The number of surface defects is a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal that is greater than the maximum second derivative of the diameter signal.

Embodiment [48] of the present disclosure relates to the method of embodiments [1] to [47], further comprising generating a surface defect evaluation of the fiber-containing structure based on the curvature surface defect count signal.

Embodiment [49] of the present disclosure further comprises classifying defects included in the fiber-containing structure based at least in part on the curvature surface defect count signal. Regarding the method.

Embodiment [50] of the present disclosure relates to the method of embodiments [1] to [49], wherein the reference signal is a constant reference signal that is constant along the length of the fiber-containing structure.

Embodiment [51] of the present disclosure provides embodiments [1] to [50], wherein the reference signal is a variable reference signal that changes at one or more points along the length of the fiber-containing structure. ] Regarding the method.

Embodiment [52] of the present disclosure relates to the method of embodiments [1]-[51], further comprising measuring the linear velocity of the fiber-containing structure using at least one velocimeter.

Embodiment [53] of the present disclosure provides that, based on the surface defect signal, the extrusion device, the braiding machine, the tensioning assembly, the finishing applicator, the godet roll assembly, the take-up assembly, or a combination thereof. The method of embodiments [1] to [52] further includes changing the operation of the method.

Embodiment [54] of the present disclosure relates to the method of embodiments [1]-[53], further comprising changing the linear velocity of the fiber-containing structure based on the surface defect signal.

Embodiment [55] of the present disclosure relates to the method of embodiments [1] to [54], further comprising changing the sampling rate of the at least one cross-sectional diameter measurement based on the surface defect signal.

Embodiment [56] of the present disclosure relates to the method of embodiments [1] to [55], further comprising classifying defects included in the fiber-containing structure based on the at least one surface defect signal. .

Embodiment [57] of the present disclosure relates to a fiber-containing structure obtained by the method of embodiments [1] to [57].

Embodiment [58] of the present disclosure relates to a fiber-containing structure obtained by the method of embodiments [1] to [56], wherein the fiber-containing structure is a yarn line or a braided line. .

Embodiment [59] of the present disclosure is a fiber-containing structure obtained by the method of embodiments [1] to [56], wherein the fiber-containing structure has a twist level of less than 10 turns per meter. It relates to a structure that is a yarn line.

Embodiment [60] of the present disclosure is a fiber-containing structure in which a defect has been detected obtained by the method of embodiments [1] to [56], wherein the detected fiber-containing structure in which the defect has been detected is It relates to a structure that is a core-sheath structure with a braided or twisted sheath.

Embodiment [61] of the present disclosure provides (A) an extrusion device configured to form a fiber-containing structure, a braiding machine configured to form the fiber-containing structure, and a a tensioning assembly configured to apply tension; a finishing applicator configured to apply a coating to the fiber-containing structure; a godet roll assembly configured to stretch the fiber-containing structure; a winding assembly configured to wind a structure onto a bobbin, or a combination thereof; (B) a projector for transmitting light through the fiber-containing structure and a receiver for detecting a silhouette image of the fiber-containing structure; and configured to measure the cross-sectional diameter of at least one of the fiber-containing structures by calculating the cross-sectional diameter based on the amount of decrease in the amount of light detected by the light receiver with respect to the total amount of light transmitted by the light emitter. and (C) comparing at least one diameter signal obtained from said defect detector, optionally at least one signal-processed diameter signal, or a combination thereof, with at least one reference signal. is configured to obtain at least one surface defect signal of a surface defect output versus a length of the fiber-containing structure; The defect detector includes a processor for measuring the at least one cross-sectional diameter.

Embodiment [62] of the present disclosure relates to the apparatus of embodiment [61], wherein the fiber-containing structure passes linearly past the at least one defect detector at a linear speed of at least 300 m/min.

Embodiment [63] of the present disclosure provides that the fiber-containing structure is a braided fiber-containing structure or a fiber-containing structure made of twisted wires, and the fiber-containing structure moves at a linear speed of at least 1 m/min. Concerning the device of embodiments [61] and [62], passing linearly through one detector.

Embodiment [64] of the present disclosure provides that the fiber-containing structure is a non-braided fiber-containing structure having a twist level of less than 1 turn per meter, wherein the fiber-containing structure is a braided fiber-containing structure. , or the device of embodiments [61] to [63], wherein the fiber-containing structure is a fiber-containing structure made of twisted wires.

Embodiment [65] of the present disclosure relates to the device of embodiments [61] to [64], wherein the fiber-containing structure is a core-sheath structure comprising a core and a braided sheath of strands surrounding the core.

Embodiment [66] of the present disclosure is a cord having a core-sheath structure in which the fiber-containing structure includes a braided sheath surrounding a core, wherein the braid angle of the braided sheath in a relaxed state is from about 5° to about 85°. The present invention relates to the apparatus of embodiments [61] to [65], which range in scope.

Embodiment [67] of the present disclosure is a cord in which the fiber-containing structure has a core-sheath structure including a braided sheath surrounding a core, and the number of picks of the braided sheath in a relaxed state is 6 to 3 per meter; 000 filament unit intersection, the device of embodiments [61] to [66].

Embodiment [68] of the present disclosure is a cord in which the fiber-containing structure has a core-sheath structure including a braided sheath surrounding a core, and the number of strands (ends) of the braided sheath is 3 to 24 ends. This relates to the apparatus of embodiments [61] to [67].

Embodiment [69] of the present disclosure relates to the device of embodiments [61]-[68], wherein the fiber-containing structure is a cord having a wirelay structure including a non-braided sheath surrounding a core.

Embodiment [70] of the present disclosure relates to the device of embodiments [61] to [69], wherein the fiber-containing structure includes organic fibers.

Embodiment [71] of the present disclosure relates to the device of embodiments [61] to [70], wherein the fiber-containing structure comprises synthetic fibers having a tensile strength of greater than 12 cN/dtex.

Embodiment [72] of the present disclosure provides that the fiber-containing structure is a liquid crystal polyester filament, an aramid filament, a copolymer aramid filament, a polyether ether ketone filament, a poly(p-phenylenebenzobisoxazole) filament, an ultra-high molecular weight Embodiments [61] - comprising at least one selected from the group consisting of polyethylene filaments, high modulus polyethylene filaments, polypropylene filaments, polyethylene terephthalate filaments, polyamide filaments, polyhydroquinone diimidazopyridine filaments, and high strength polyvinyl alcohol filaments. Regarding the device of [71].

Embodiment [73] of the present disclosure relates to the device of embodiments [61]-[72], wherein the fiber-containing structure comprises synthetic fibers and at least one of a lubricant, staple fibers and a surface coating.

Embodiment [74] of the present disclosure relates to the device of embodiments [61]-[73], wherein the fiber-containing structure is a cord having a linear mass density of about 30 to about 10,000 denier.

Embodiment [75] of the present disclosure relates to the device of embodiments [61] to [74], wherein the maximum cross-sectional diameter of the fiber-containing structure ranges from about 20 μm to about 10 mm.

Embodiment [76] of the present disclosure relates to the device of embodiments [61]-[75], wherein the average cross-sectional diameter of the fiber-containing structure ranges from about 20 μm to about 10 mm.

Embodiment [77] of the present disclosure relates to the apparatus of embodiments [61] to [76], wherein at least one of the defect detectors is located in series with the extrusion device.

Embodiment [78] of the present disclosure relates to the apparatus of embodiments [61] to [77], wherein at least one of the defect detectors is located in series with the braiding machine.

Embodiment [79] of the present disclosure includes a defect detector array located in series with the braiding machine, and the fiber-containing structure passes linearly through the defect detector array, according to embodiment [61] The apparatus of [78], wherein the defect detector array includes at least two of the defect detectors located in series, and wherein the at least two of the defect detectors are connected to the fiber-containing structure. rotated relative to each other by a detector offset angle such that different silhouette images of the detectors are detected by the at least two of the detectors, the detector offset angle ranging from 1° to less than 360°; Regarding equipment.

Embodiment [80] of the present disclosure relates to the apparatus of embodiment [79], wherein said defect detector array includes at least three of said defect detectors located in series.

Embodiment [81] of the present disclosure is the apparatus of embodiments [79] and [80], wherein the separation distance between the at least two of the defect detectors in the defect detector array ranges from 1 mm to 100 mm. Regarding.

In embodiment [82] of the present disclosure, the defect detector includes two light projectors for transmitting light to the fiber-containing structure and two light receivers for detecting a silhouette image of the fiber-containing structure. The two light projectors include a projector A for transmitting light A to the surface A of the fiber-containing structure, and a projector B for transmitting the light B to the surface B of the fiber-containing structure. the two light receivers include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure; Emitter A is optically aligned with the receiver A, the emitter B is optically aligned with the receiver B, and the emitter A and the emitter B are rotated relative to each other by an emitter offset angle; Embodiments [79] to [79], wherein the light receiver A and the light receiver B are rotated relative to each other by a receiver offset angle, and the emitter offset angle and the receiver offset angle range from 5° to 175°. 81].

Embodiment [83] of the present disclosure relates to the apparatus of embodiments [61]-[82], wherein at least one of said defect detectors is located in series with said tensioning assembly.

Embodiment [84] of the present disclosure relates to the apparatus of embodiments [61]-[83], wherein at least one of said defect detectors is located in series with said finishing applicator.

Embodiment [85] of the present disclosure relates to the apparatus of embodiments [61]-[84], wherein at least one of said defect detectors is located in series with said godet roll assembly.

Embodiment [86] of the present disclosure relates to the apparatus of embodiments [61] to [85], wherein at least one of said defect detectors is located in series with said winding assembly.

Embodiment [87] of the present disclosure relates to the apparatus of embodiments [61] to [86], wherein at least one of said defect detectors is located in series with at least one roller.

Embodiment [88] of the present disclosure provides that at least two of the defect detectors are located adjacently in series together as a defect detector array, and the defect detectors are located adjacently in the defect detector array. Embodiments [61] to [87], wherein the detector offset angle between the two ranges from 1° to less than 360°.

Embodiment [89] of the present disclosure provides that at least three of the defect detectors are located adjacently together in series as a defect detector array, and the defect detectors are located adjacently in the defect detector array. The present invention relates to the apparatus of embodiments [61] to [88], wherein the detector offset angle between the detectors ranges from 1° to less than 360°.

Embodiment [90] of the present disclosure provides that the defect detector is configured to measure at least two cross-sectional diameters of the fiber-containing structure, wherein the offset angle between the at least two cross-sectional diameters is between 5° and The present invention relates to the apparatus of embodiments [61] to [89], which are multi-axis defect detectors having a range of 175°.

In embodiment [91] of the present disclosure, the defect detector includes two light projectors for transmitting light to the fiber-containing structure and two light receivers for detecting a silhouette image of the fiber-containing structure. The two light projectors include a projector A for transmitting light A to the surface A of the fiber-containing structure, and a projector B for transmitting the light B to the surface B of the fiber-containing structure. the two light receivers include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure; Emitter A is optically aligned with the receiver A, the emitter B is optically aligned with the receiver B, and the emitter A and the emitter B are rotated relative to each other by an emitter offset angle; Embodiments [61] to [61], wherein the light receiver A and the light receiver B are rotated relative to each other by a receiver offset angle, and the emitter offset angle and the receiver offset angle range from 5° to 175°. 90].

Embodiment [92] of the present disclosure relates to the apparatus of embodiments [61] to [91], wherein the light projector includes a laser diode or a light emitting diode.

Embodiment [93] of the present disclosure relates to the device of embodiments [61] to [92], wherein the light receiver is an active pixel sensor.

Embodiment [94] of the present disclosure is the embodiment [94], wherein the light receiver is an active pixel sensor consisting of a photodiode image sensor, a charge-coupled device (CCD) image sensor, or a complementary metal oxide semiconductor (CMOS) image sensor. 61] to [93].

Embodiment [95] of the present disclosure further includes (D) an imaging detector configured to image the surface of the fiber-containing structure, the imaging detector detecting the fiber-containing structure with imaging light. The present invention relates to the apparatus of embodiments [61] to [94], which images the surface by illuminating the surface and receiving a reflected image of the surface with an imaging receiver.

Embodiment [96] of the present disclosure further includes (D) an imaging detector configured to image a surface of the fiber-containing structure, the imaging detector illuminating the fiber-containing structure with imaging light. , imaging the surface by receiving a reflected image of the surface with an imaging receiver, and at least one of the imaging detectors includes the extrusion device, the braiding machine, the tensioning assembly, the finishing applicator, and the godet roll. The apparatus of embodiments [61] to [95] is located in series with an assembly, said winding assembly, or said combination thereof.

Embodiment [97] of the present disclosure relates to the apparatus of embodiments [61] to [96], which does not include imaging the surface of the fiber-containing structure with an imaging detector that receives a reflected image of the surface.

Embodiment [98] of the present disclosure relates to the apparatus of embodiments [61]-[97], wherein the defect detector makes measurements of the at least one cross-sectional diameter occurring at a sampling rate of at least 5,000 samples per second. .

Embodiment [99] of the present disclosure provides that the defect detector makes measurements of the at least one cross-sectional diameter that occur at a sampling rate, and the at least one sampling rate of the defect detector is such that the measurements occur at a sampling rate of the fiber-containing structure. The device according to embodiments [61] to [98], arranged to occur at regular intervals along said length of the object, said regular intervals ranging from 10 nm to 1 cm.

Embodiments [100] of the present disclosure provide that the at least one surface defect signal includes a size surface defect number versus size surface defect number signal of the length of the fiber-containing structure [61] to [99] , wherein the magnitude surface defect count signal is generated by comparing the diameter signal with a reference signal of maximum cross-sectional diameter versus the length of the fiber-containing structure; A zero magnitude surface defect count occurs when the magnitude of the diameter signal is less than or equal to the maximum cross-sectional diameter at a particular point along the length of the fiber-containing structure; A magnitude surface defect number greater than zero occurs when the maximum cross-sectional diameter at the particular point along the length of the object is greater than the magnitude of the diameter signal. is a positive integer corresponding to a percentage above said maximum cross-sectional diameter.

Embodiment [101] of the present disclosure is provided in embodiments [61] to [100], wherein the at least one surface defect signal includes a sloped surface defect count signal versus a sloped surface defect count signal of the length of the fiber-containing structure. ], wherein the sloped surface defect count signal is compared with the signal-processed diameter signal and a reference signal of the maximum first derivative of the diameter signal versus the length of the fiber-containing structure. wherein the processed diameter signal is obtained by processing the diameter signal to obtain a first derivative of the diameter signal, and wherein the absolute value of the first derivative of the diameter signal is A sloped surface defect count of zero occurs when the maximum first derivative of the diameter signal at a particular point along the length of the fiber-containing structure is less than or equal to the absolute value of the first derivative of the diameter signal. a value greater than the maximum first derivative of the diameter signal at the particular point along the length of the fiber-containing structure, a sloped surface defect number greater than zero occurs, and the slope greater than zero occurs. For the device, the number of surface defects is a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal that is greater than the maximum first derivative of the diameter signal.

Embodiment [102] of the present disclosure provides embodiments [61] to [101], wherein the at least one surface defect signal includes a signal of the number of curvature surface defects versus the number of curvature surface defects of the length of the fiber-containing structure. ], wherein the curvature surface defect count signal compares the signal-processed diameter signal with a maximum second derivative of the diameter signal versus a reference signal of the length of the fiber-containing structure. wherein the processed diameter signal is obtained by processing the diameter signal to obtain a second derivative of the diameter signal, and wherein the absolute value of the second derivative of the diameter signal is A zero curvature surface defect count occurs when the maximum second derivative of the diameter signal at a particular point along the length of the fiber-containing structure is less than or equal to the second derivative of the diameter signal. A curvature surface defect number greater than zero occurs when the absolute value is greater than the maximum second derivative of the diameter signal at the particular point along the length of the fiber-containing structure, and the curvature greater than zero For the device, the number of surface defects is a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal that is greater than the maximum second derivative of the diameter signal.

Embodiment [103] of the present disclosure relates to the apparatus of embodiments [61]-[102], wherein the reference signal is a constant reference signal that is constant along the length of the fiber-containing structure.

Embodiment [104] of the present disclosure provides embodiments [61] to [103], wherein the reference signal is a variable reference signal that changes at one or more points along the length of the fiber-containing structure. ] regarding the device.

Embodiment [105] of the present disclosure relates to the apparatus of embodiments [61] to [104], further comprising a speedometer configured to measure the linear velocity of the fiber-containing structure.

The previous description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the embodiments disclosed herein will be readily apparent to those skilled in the art, and the general principles defined herein may be modified without departing from the spirit and scope of the invention. can be applied to embodiments and applications. Accordingly, the invention is not limited to the embodiments shown, but is accorded the widest scope consistent with the principles and features disclosed herein. In this regard, a particular embodiment within this disclosure may not exhibit all of the advantages of the invention broadly considered.

100 Defect detector 105 Silhouette image 110 Fiber-containing structure 115 Emitter 120 Light source 125 Lens 130 Light receiver 135 Light amount 140 Total light amount 145 Diameter signal 150 Processor 155 Reference signal 160 Surface defect signal 165 Active pixel sensor

Claims (21)

passing the fiber-containing structure linearly through at least one defect detector;
measuring a cross-sectional diameter of at least one of the fiber-containing structures with the defect detector to obtain at least one diameter signal of diameter versus length of the fiber-containing structures;
optionally signal processing the diameter signal to obtain at least one signal-processed diameter signal; and comparing the diameter signal, the signal-processed diameter signal, or a combination thereof to at least one reference signal. generating at least one surface defect signal of a surface defect output versus the length of the fiber-containing structure;
The defect detector transmits light through the fiber-containing structure using a light projector, detects a silhouette image of the fiber-containing structure using a light receiver, and calculates the amount of light detected by the light receiver relative to the total amount of light transmitted by the light projector. measuring the cross-sectional diameter of the fiber-containing structure by calculating the cross-sectional diameter based on the amount of decrease in;
At least one of the defect detectors includes an extrusion device configured to form the fiber-containing structure, a braiding machine configured to form the fiber-containing structure, and a device configured to apply tension to the fiber-containing structure. a tensioning assembly configured to apply a tensioning force to the fiber-containing structure; a finishing applicator configured to apply a coating to the fiber-containing structure; a godet roll assembly configured to stretch the fiber-containing structure; a winding assembly configured to wind a bobbin, or a combination thereof. 2. The method of claim 1, further comprising forming the fiber-containing structure by an extrusion process, wherein at least one of the defect detectors is located in series with the extrusion device. 2. The method of claim 1, further comprising forming the fiber-containing structure by a braiding process, wherein at least one of the defect detectors is located in series with the braider. further comprising forming the fiber-containing structure by a braiding process,
a defect detector array is positioned in series with the braiding machine such that the fiber-containing structure passes linearly through the defect detector array;
the defect detector array includes at least two of the defect detectors located in series;
the at least two of the defect detectors are rotated relative to each other by a detector offset angle such that different silhouette images of the fiber-containing structure are detected by the at least two of the defect detectors;
4. The method of claim 3, wherein the detector offset angle ranges from 1° to less than 360°. 5. The method of claim 4, wherein the defect detector array includes at least three of the defect detectors located in series. The defect detector includes two light projectors for transmitting light to the fiber-containing structure and two light receivers for detecting a silhouette image of the fiber-containing structure,
The two floodlights include a floodlight A for transmitting light A to the surface A of the fiber-containing structure, and a floodlight B for transmitting light B to the surface B of the fiber-containing structure,
The two light receivers include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure,
The light emitter A is optically aligned with the light receiver A, the light emitter B is optically aligned with the light receiver B,
The light projector A and the light projector B rotate relative to each other by a light projector offset angle, and the light receiver A and the light receiver B rotate relative to each other by a light receiver offset angle,
A method according to any preceding claim, wherein the emitter offset angle and the receiver offset angle range from 5° to 175°. The defect detector is configured to measure at least two cross-sectional diameters of the fiber-containing structure, such that the offset angle between the at least two cross-sectional diameters ranges from 5° to 175°. A method according to any one of claims 1 to 6, which is a defect detector. further comprising imaging a surface of the fiber-containing structure with at least one imaging detector;
the imaging detector images the surface by illuminating the fiber-containing structure with imaging light and receiving a reflected image of the surface with an imaging receiver;
at least one of the imaging detectors is located in series with the extrusion device, the braider, the tensioning assembly, the finishing applicator, the godet roll assembly, the take-up assembly, or a combination thereof; The method according to any one of claims 1 to 7. the at least one surface defect signal includes a magnitude surface defect number signal versus a magnitude surface defect number signal of the length of the fiber-containing structure;
the size surface defect count signal is generated by comparing the diameter signal and a reference signal of maximum cross-sectional diameter versus the length of the fiber-containing structure;
a zero magnitude surface defect count occurs when the magnitude of the diameter signal is less than or equal to the maximum cross-sectional diameter at a particular point along the length of the fiber-containing structure;
A magnitude greater than zero surface defect count occurs when the magnitude of the diameter signal is greater than the maximum cross-sectional diameter at the particular point along the length of the fiber-containing structure; 9. A method according to any preceding claim, wherein the number of surface defects is a positive integer corresponding to the percentage by which the magnitude of the diameter signal exceeds the maximum cross-sectional diameter. the at least one surface defect signal includes a sloped surface defect count versus sloped surface defect count signal of the length of the fiber-containing structure;
the graded surface defect count signal is generated by comparing the signal-processed diameter signal with a maximum first derivative of the diameter signal versus a reference signal of the length of the fiber-containing structure; the signal-processed diameter signal is obtained by signal-processing the diameter signal to obtain a first derivative of the diameter signal;
a sloped surface defect count of zero when the absolute value of the first derivative of the diameter signal is less than or equal to the maximum first derivative of the diameter signal at a particular point along the length of the fiber-containing structure; occurs,
a sloped surface greater than zero when the absolute value of the first derivative of the diameter signal is greater than the maximum first derivative of the diameter signal at the particular point along the length of the fiber-containing structure; a number of defects occurs, and the number of sloped surface defects greater than zero is a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal that is greater than the maximum first derivative of the diameter signal. , the method according to any one of claims 1 to 8. the at least one surface defect signal includes a curvature surface defect count versus curvature surface defect count signal of the length of the fiber-containing structure;
the curvature surface defect count signal is generated by comparing the signal processed diameter signal and a maximum second derivative of the diameter signal to a reference signal of the length of the fiber-containing structure; the signal-processed diameter signal is obtained by signal-processing the diameter signal to obtain a second derivative of the diameter signal;
a zero curvature surface defect count when the absolute value of the second derivative of the diameter signal is less than or equal to the maximum second derivative of the diameter signal at a particular point along the length of the fiber-containing structure; occurs,
the surface of curvature being greater than zero when the absolute value of the second derivative of the diameter signal is greater than the maximum second derivative of the diameter signal at the particular point along the length of the fiber-containing structure; a number of defects occurs, and the number of curvature surface defects greater than zero is a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal that is greater than the maximum second derivative of the diameter signal. , the method according to any one of claims 1 to 8. 12. The method of any one of claims 1 to 11, further comprising measuring the linear velocity of the fiber-containing structure using at least one velocimeter. further comprising altering operation of the extrusion device, the braider, the tensioning assembly, the finishing applicator, the godet roll assembly, the take-up assembly, or a combination thereof based on the surface defect signal; The method according to any one of claims 1 to 11. (A) an extrusion device configured to form a fiber-containing structure, a braiding machine configured to form the fiber-containing structure, and a tensioning assembly configured to apply tension to the fiber-containing structure; a finishing applicator configured to apply a coating to the fiber-containing structure; a godet roll assembly configured to stretch the fiber-containing structure; and a godet roll assembly configured to wind the fiber-containing structure onto a bobbin. a winding assembly, or a combination thereof;
(B) transmitting light through the fiber-containing structure with a light projector, detecting a silhouette image of the fiber-containing structure with a light receiver, and reducing the amount of light detected by the light receiver relative to the total amount of light transmitted by the light projector; (C) a defect detector configured to measure the cross-sectional diameter of the at least one fiber-containing structure by calculating the cross-sectional diameter of the at least one fiber-containing structure based on the Comparing the diameter signal, optionally at least one signal-processed diameter signal, or a combination thereof to at least one reference signal to determine the surface defect output versus the length of the fiber-containing structure. An apparatus comprising a processor configured to obtain a signal, the defect detector measuring the at least one cross-sectional diameter while the fiber-containing structure passes linearly through the defect detector. 15. The apparatus of claim 14, wherein at least one of the defect detectors is located in series with the extrusion device. 15. The apparatus of claim 14, wherein at least one of the defect detectors is located in series with the braiding machine. a defect detector array positioned in series with the braiding machine, the fiber-containing structure passing linearly through the defect detector array;
the defect detector array includes at least two of the defect detectors located in series;
the at least two of the defect detectors are rotated relative to each other by a detector offset angle, and different silhouette images of the fiber-containing structure are detected by the at least two of the defect detectors;
17. The apparatus of claim 16, wherein the detector offset angle ranges from 1° to less than 360°. Apparatus according to any one of claims 14 to 17, wherein the defect detector array comprises at least three of the defect detectors located in series. The defect detector includes two light projectors for transmitting light to the fiber-containing structure and two light receivers for detecting a silhouette image of the fiber-containing structure,
The two light projectors include a projector A for transmitting light A to a surface A of the fiber-containing structure, and a projector B for transmitting light B to a surface B of the fiber-containing structure,
The two light receivers include a light receiver A for detecting a silhouette image A of the fiber-containing structure and a light receiver B for detecting a silhouette image B of the fiber-containing structure,
The light emitter A is optically aligned with the light receiver A, the light emitter B is optically aligned with the light receiver B,
The light projector A and the light projector B rotate relative to each other by a light projector offset angle, and the light receiver A and the light receiver B rotate relative to each other by a light receiver offset angle,
Apparatus according to any one of claims 14 to 18, wherein the emitter offset angle and the receiver offset angle range from 5° to 175°. At least one of the defect detectors is located in series with the tensioning assembly, or the finishing applicator, or the godet roll assembly, or the take-up assembly, or at least one roller, or any combination thereof. 20. The device according to any one of claims 14 to 19, wherein: Apparatus according to any one of claims 14 to 20, further comprising a velocimeter configured to measure the linear velocity of the fiber-containing structure.

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