US2438469A - Method and apparatus for converting bulk filament into staples - Google Patents

Description

5 Sheets-Sheet 1 March 23, 1948. R C, wlLKlE METHOD AND APPARATUS FOR CONVERTING BULK FILAMENT INT0 STAPLES Filed March 1, 1943 March 23, 1948. R. c. wlLKlE METHOD AND APPARATUS FOR CONVERTING BULK FILAMENT INTO STAPLES Filed March 1 1943 5 ASheets-Sheet 2 -l Il mom.

JYVIIII'III m/ fi Rom Cum@ R. C. VVILKIE March 23, 1948.

METHOD AND APPARATUS FOR CONVERTING BULK FILAMENT INTO STAPLES s-Sheet 3 Filed March l, 1943 March 23, 1948. R. c. wlLKlE 2,438,469

METHOD AND APPARATUS FOR CONVERTING BULK FILAMENT INTO STAPLES Filed March 1, 1943 5 Sheets-Sheet 4 vom Q Q3 msm. Sm .f @uw l i am vh .0 .mm fmf om man www Mov msw F March 23, 1948. R. c, wlLKlE METHOD AND APPARATUS Fon coNvERTlNG BULK FILAMEN'T INT0 STAPLES Filed March l, 1945 5 Sheets-Sheet 5 @bm Qumlu @WW GWW en@ nm I aveza'o'af.-

Patented Mar. 23., 1948 OFFICE METHOD AND APPARATUS FOR CONVERT- ING BULK FILAMENT INTO STAPLES Robert C. Wilkie, Andover, Mass., assigner to Pacific Mills, Lawrence, Mass., a corporation of Massachusetts Application March 1, 1943, Serial No. 477,608 In Canada November 23, 1941 30 Claims. (Cl. 19-150) This invention relates to a process and machine for converting bulk filament, such as rayon, of continuous lengths into a sliver of drafted and separated staples ready to be drawn and spun into yarn either alone or after mixing with other bers suchI as wool. Its object is to produce an even, self-sustaining sliver without the necessity for picking, carding, gillng, combing or the like.

In the drawings:

Fig. 1 is a plan view of the right-hand, inlet end of a machine made in accordance with the preferred embodiment of my invention;

Fig. 2 is a side elevation view of the portion of the machine shown in Fig. 1;

Fig. 3 is a plan view of the left-hand, delivery end of the machine showing some parts in common with Fig. 1 to indicate how the two views combine to show the entire machine;

Fig. 4 is a side elevation view of the portion of the machine shown in Fig. 3;

Fig. 5 is an enlarged plan view of the upper fracturing roll showing its effect on the web of continuous filaments;

Fig. 6 is an enlarged vertical section of the debonding apparatus;

Fig. 7 is an enlarged side elevation view, partly in section on the line 'l-l of Fig. 3, showing the collecting cylinder;

Fig. 8 is a diagrammatic vertical section showing the shearing action;

Fig. 9 is a diagrammatic side elevation view of the driving mechanism.

Fig. 10 is a side elevation view of a modification; and

Fig. 11 is a side elevation view of a further modification.

I will first describe my preferred process for converting continuous filaments into a continuous sliver of non-conterminous separated and drafted staples. By staples I mean the individual pieces into which the filaments are severed in my process and machine.

The rst step is to collect the continuous filaments and spread them into a at web. To accomplish this, they are drawn from spools i30 (Fig. 1) and led through apertures E38 in a guide frame M to feed rolls |44, H46 and S48, about which they pass to emerge as a dat web 8.

The next step is to cut or fracture the web into oblique strips I6 (Fig. 5) extending at an angle to the line of feed, preferably of about 10. This is accomplished by one, or more, blunt helical steel threads i4 on the periphery of roll i0 which are pressed strongly against the web supported by the plain metal surface of roll I 2. The lengths of the staples between the cuts or fractures may be varied by presenting the web to the threads at dierent angles by moving the frame |40 sidewise, as will be fully described. Staples, thus produced, of varying lengths simulate the variations in staple length in a wool, worsted or cotton sliver, as is greatly desired.

The forward feeding of the web and strips is assisted by rubbery material |60 between the threads i4 on roll I0. This material also prevents the web from being fed sidewise by the threads.

The next step is to separate the ends of staples which are stuck together by portions of the filaments which were crushed and spread by the blunt threads I4 and to break off those portions. This is accomplished by rolls 24, 26 (Fig. 6), having iiutes 32 and 34 respectively, in cooperation with rolls 20, 22 of slower peripheral speed than that of the surfaces of the uted rolls and with roll 28 and apron 36 of faster surface speed. The iiutes are spaced apart so that they can move relatively to the web. They work and bend the filaments up and down and wipe the leading ends of those staples whose trailing ends are held by the nip of the slower moving rolls 20, 22 and they also wipe the trailing ends of those staples which are pulled between them by the faster moving roll 2B and apron 36, so that any crushed portions ad hering the ends together are removed.

Another step is to advance the staples lying on top of the web with respect to those below, an operation which I call shearing This is acm complished by rolls 28, 44 and 46, which bear on the top staples and have a greater peripheral speed than the surface of an apron 36, on which the bottom staples rest. Further shearing is ac-L complished in the same way by the rolls 62, 6tand 66 and apron 60.

Another step is to draft the staples by the greater surface speed of the rolls or aprons by which they are successively engaged.

By this shearing and drafting, adjacent staples are rendered non-conterminous and caused te overlap one another lengthwise both vertically and laterally. All staples are merged into a prac tically continuous and comparatively thin web 8a (Figs. 3 and 4) composed of such non-conterminous staples.

The final step is to roll this web helically into a sliver 2 disposed diagonally across the line of travel of the web and deliver it lengthwise into a receiving trumpet 408. To accomplish this, the web of staples is delivered by rolls 80, 82 to moving apron 86 and is picked up and wound on itself by a cylinder |00, which is diagonally inclined to the feed of the web oppositely to the diagonal inclination of the strips formed by the rolls I and I2 and rotates in such direction that its lower surface moves in the opposite direction to the travel of the web. Static electricity in the web is reduced by the metallic rollers 92 and 94 electrically connected to the frame and by moistening the apron 86 with water from a tank 2|0 applied by rolls 2I2 and 2|4.

The sliver, drawn through the trumpet |08 by rolls ||0 and I|2, is in condition for further processing, well known in the art, by which it may be formed into thread.

'I'he sliver thus formed is very even in density so that it may be drawn and spun into yarn just as a sliver of wool or cotton is drawn and spun. Its staple bers are evenly distributed with none lying conterminously. If varying length staples have been made at the fracturing rolls, every sample of the sliver will show a good graduation of length. If a wool-rayon mix yarn is desired, the sliver can be made with a graduation of staple length approximating that in the wool top with which it is to be blended and the sliver and top, when blended, will produce a wool-rayon top that can be drawn and spun into yarn in accordance with the conventional worsted system. Similarly a cotton rayon mix can `be obtained.

The specic details of the machine by which I have achieved this result can be Varied considerably, but I have shown in the drawings apparatus which I have used effectively to convert many thousands of pounds of rayon iilament into slivers of staple.

The packages |30 of continuous rayon filaments are supported on spindles |32 of creel 6,

from which the filaments are drawn by rolls |44,

|46 and |48 over a iiXed horizontal rod |34 and through holes I 38 in frame |40. The friction of the filaments 4 as they pass around the stationary rod |34 and against the beveled edges of the holes |38 checks slugs and prevents any twist in the filaments, as they unwind from the packages, from being carried tothe fracturing rolls I0, I2.

The filaments are thus collected and spread into a web on the roll |46 before delivery to the fracturing rolls.

The rolls |44, |46 and |48 are positively driven by mechanism to be described at a peripheral speed which is slightly less than that at which rolls I0 and I2 are driven, so that the filaments between the two sets of rolls are under tension and are, therefore, straightened and parallelized as they reach the fracturing roll I0, I2. vThis tension also reduces crimp where crimped iilaments are employed. The nip of rolls |46, |48

is slightly below the nip of rolls I0, I2, so that the filaments, which enter the nip of the latter rolls, are pressed against the surface of the lower roll I2 and do not work themselves in between the side walls of the threads I4 and the rubbery composition between the threads.

The helical threads I4 on the upper fracturing roll I0 are preferably not sharpened but have fiat or slightly rounded 'edges which crush the web of filaments supported by the lower roll I2. I have found that a breadthat the edge of $654 of an inch gives satisfactory results.

The threads on the roll l0 may be iiush with the surface of the rubbery composition |60, which iills the spaces between the threads, but are preferably slightly countersunk in the composition. The pressure betweenthe rolls forces the composition back, exposing the edges of the threads for fracturing the iilaments. The pressure of the composition against the filaments enables the rolls I0 and I2 to feed the web and also prevents any objectionable movement of the :filaments axially of the rolls. v

The roll I0 is cleaned of pieces of staple by the brush |84 rotated counter to the roll I0. The brush |84 is stripped by the card clothing on roll |86. The staple accumulates in the clothing where it is compacted by brush |88 'and from which clothing it is periodically removed.

The lower roll I2 is made of hardened tough steel alloy and presents a smooth, hard surface which supports the web 8 under the pressure of the upper roll I0.

'I'he roll l0 is mounted in spring-pressed bearings I 62 which apply a heavy pressure, of the order of several tons, to press the roll I0 down on the roll I2 to sever or fracture the filaments. The rolls I0 and I2 are rotated by mechanism to be described and are geared together for equal surface speeds by intermeshing gears 322 and 324 (Fig. 9) at both ends of the rolls. To avoid undue wear of the surface of the lower roll by the edges of the threads, one of the rolls is slightly larger than the other and one of the gears in each pair may have one tooth more than the other gear.

The threads on the upper roll I0 cut or fracture the web of filaments 8 into steeply oblique strips extending at an inclination determined by the angle of the threads with relation to the axis of the cutting roll. For best results, this angle should be about 80 but it may, of course, be varied and should not be less than 60. I have obtained goodresults with an angle as great as 88.

The acutely inclined cut leaves the ends of lat- Verally adjacent staples successively behind one another. This causes the ends of the relatively advanced staples to be gripped and further advanced, relatively to those behind them, by the rolls and aprons to which they are thereafter delivered along the line X of Fig. 5 and the length y of the cut staple is the distance a, perpendicular to the axis of the roll I0, between successive cuts I5 made by the threads. When the frame is moved to the left the web of filaments is deliveredA at a slight angle, as shown at Y, Fig. 5, to this perpendicular. And when the frame is to the right the lament web is delivered at the angle shown by Z. When the web is delivered at the angle Y the staple lengths are longer and when it is delivered at the angle Z they are shorter. By slowly reciprocating the frame the lengths of the staples may be varied from their longest to their shortest and vice versa. This gives a graduated staple length which simulates the graduated lengths of woolen, worsted or cotton fibers and provides a sliver, with such graduations, which may therefore be treated by the conventional worsted or cotton systems to form Thus. I have employed a roll I0' that is 51/2 inches in diameter, has four starts o! the fracturing helix I4 with a half-inch pitch and set at an angle of about 80. With the frame |40 idle and with the -web advancing in the direction X normal to theline of bite of the fracturing rolls, a staple length a approximating 41/2 inches is produced. The distance of the lower aperture |38 from the point of tandency of the filament with roll |44 is '7l/2 inches and employing 5 oscillations per minute of the frame |40 with an amplitude of l/2 inch each side of the center line, I have obtained a uniform graduation in staple length of from approximately 3 inches to 6 inches in all filament guided through said lower aperture |38. These values, as well as others herein, are, of course, merely for illustrative purposes and my invention is in no way limited thereto. y

'I'he oblique strips of fractured staples are delivered to rolls 20, 22 which are power driven to rotate at the same surface speed, which is preferably the same as that of rolls and I2, or slightly greater. The ratch between rolls 20, 22 and rolls 24, 26 and the ratch between rolls 24, 26 and the entering nip of roll 28 and apron 36 are both shorter than the length of the shortest staple cut by roll I0. The rolls 20, 22 nip the staples and restrain the trailing ends of those staples whose leading ends are being worked and .wiped by the flutes 32, 34 on rolls 24, 26. The rolls 20, 22, being small, may be placed very close to the rolls 24, 26 and thereby restrain very short lengths of staples whose leading ends are between rolls 24, 26.

The uted rolls 24 and 26 are geared together by gears 336 and 338 (Fig. 9) to rotate at a surface speed greater than that of rolls 20 and 22. The fiutes of these rolls do not mesh together but merely enter to a limited extent the spaces between the flutes on the opposite roll and this spacing is effected by employinga large enough diameter for these gears. The spacing laterally between the adjacent sides of opposite flutes is suicient so that the web and flutes can be moved relative to each other and this spacing can be adjusted by using the same number of flutes on both rolls and driving gears on'both rolls having one tooth more than the number of flutes, so that the relative positions of opposite flutes can be varied by selecting different meshing positions of the driving gears.

The web of staples is then delivered to apron 36, running over rolls 30, 38, 40 and 42 and returning around roll 43. Between successive rolls 30, 38 and 40 and 42 are upper rolls 28,-44 and 46 against which the apron 36 presses. Rolls 28, 44 and 46 are scratch iluted for better frictional engagement with the staples pressed against them by the belt. The amount of this pressure can be adjusted by mounting roll 43 in vertically adjustable bearings.

As the surface speeds both of apron 36 and rolls 28, 44, and 46 are greater than that of rolls 20, 22, the web of staples is drafted. The staples in each strip i6 approach the roll 28 and apron 36 with their leading ends on the fracture line l oblique to the entering nip between roll 26 and .apron 36, so that the staples in each strip are generally presented successively rather than simultaneously to the rolls and belt.

'Ihe surface speed of rolls 28, 44 and 46 is greater than the surface speed of the apron 36 on which the web of staples lies, so that the rolls advancev the upper staples of the web with respect to the staples lying beneath them, as indicated diagrammatically ln Fig. 8. 'I'here is thus effected a separation and relative movement of the staples of the web vertically with respect to each other, which I call a "shearing action. As a result of this shearing action, the staples which were vertically aligned depthwise of the fracture line now flare out of vertical alignment with some ends protruding more than others. Thereby, depthwise through the web, upper staples are advanced with relation to those beneath them.

The staples are next presented to a further set of drafting rolls 50, 52, the lower of which is scratch fluted, of the same peripheral speed, which is greater than that of rolls 28, 44 and 46. The rolls 58, 52 positively nip the sta). es and draw them out from between the apron 36 and the upper rolls 28, 44 and 46 which press against the staples with less firmness than the nip of rolls 50, 52.

I have found that the extended surface contact between the apron 36 and the upper rolls 28, 44 and 46, as the result of the supporting positions of the lower rolls 30, 38, 46 and 42, has several advantages. It enables the machine to obtain the desired shearing action with as little as 25% difference ln speeds between the apron and the upper rolls. The need for a predetermined ratch between rolls 20, 22 and the entering line of engagement between roll 28 and apron 36, where the first drafting occurs, is obviated because of the extended nip between the roll 28 and the apron. Such elimination of specic :catches relative to staple lengths assists in properly drafting staples of varying lengths, such as are obtained either by a traverse reciprocation of the guide frame I 40 or by substituting a fracturing roll with adiiferent inclination and spacing of the fracturing thread convolutions. Finally, the trailing ends of those staples whose leading ends are in the nip of drafting rolls 50, 52 cannot cause curling of the staples which have not yet reached rolls 50, 52 and which are frictionally engaged by such advancing trailing ends because the staples so frictionally engaged are kept at between upper rolls and the supporting belt.

I prefer to repeat the shearing action. The web of staples passes from the nip of rolls 50, 52 to the apron 60, which passes over rolls 68, l0, 'l2 and 14 and under adjustably mounted tension roll 16. The rolls 62, 64 and 66, which are scratch uted, bear down on the staple web between the rolls 68, 10, 'l2 and '14 and are run at a peripheral speed faster than the surface speed of the apron, whereby a further shearing action is effected. The ratch between rolls 50, 52 and the entering line of engagement between roll 62 and apron 68 may be considerably less than the staple length because, although rolls 50, 52 positively nip the staples, the rolls 62, 64 and 66 press less firmly against them and will slip over staples held back by rolls 5|), 52.

A final pair of positive nip draft rolls and 82 rotates faster perlpherally th'anrolls 62, 64 and 66 to effect a further drafting. The roll 80 is stripped of loose staples by the stripper 202 provided With felt.

After the staple web has thus been sheared and drafted it is delivered to apron 86, which runs around roll 82 and between it and roll 80 (Fig. 3) and returns around roll 9D. The staple web delivered to the apron 86 is made up of non-conterminous staples having leading and trailing ends disposed haphazard throughout the web, and the web is thin compared with the web of filament 8 which was delivered to the fracturing rolls.

In order to avoid the troubles occasioned by the presence of static electricity in the staple web, I provide means for minimizing it. Rolls 92 and 94, having metallic surfaces electrically connected to the frame of the machine, are eective to conduct away static electricity. Both rolls idle ron the web carried by apron-86. Roll 92 is of small diameter and is placed close to roll 80 so as to strip it of any adhering staples. Similarly, roll 94 strips roll 92 and carries the stripped pieces to the web.

I preferably also humidify the room in which my machine is operated so that the air has a relative humidity of about 60 to 65%.

For many types of rayon, such as viscose, the use of rolls 92, 84 where theatmosphere around the machine is humidiiied eliminates entirely any static, so that I can employ bulk rayon filament which has not been provided with the usual anti-static oil finish which, I have found, is apt to cause the staple to adhere together during treatment.

For other types of rayon, such as cellulose acetate, which present a more severe static problem, I also apply a limited amount of moisture to the apron 86. The bottom of the apron, as it is moved rearward, picks up water taken from a tank 2|0 by rolls 2|2 and 2|4. The roll 2|2 is felt covered and the roll 2|4 is scratch uted. The roll 2|4 is power rotated in the same direction as that of the surface of the apron which it contacts and at a slower adjustable surface speed, so that the apron wipes the roll 2|4 and takes moisture from it. The quantity of moisture deposited is determined in part by the depth and spacing of the scratch flutes on the roll 2I4 and may be varied by changing the relative speeds of roll 2|4 and the apron.

The final step is to wind the staple web into a helical sliver. 'I`he cylinder |00 has ribs |02 protruding from and winding spirally around its periphery and is rotated to advance its portion nearest the apron in the opposite direction from the advance of the apron and at a speed at least as great as that of the apron. The ribs b arely touch the apron. As the cylinder rotates it winds up the thin web of staple fibers into a helical roll of sliver 2 which is drawn off through rotating trumpet |08 by the rolls |I0, ||2. The axis of cylinder extends obliquely to the direction of advance of the web and its inclination is opposite to the inclination of the lines of fracture |5. Although the,cut lines have been obliterated by the shearing action and the drafting, yet the web on apron 86 is extremely thin, any gaps in which extend in directions that have the same general inclination as that of the lines of fracture. The Obliquity of the cylinder |00 is effective, not only to roll up the staple fibers and enable them to be drawn oi the apron in helical form, but it also abruptly opposes any approaching gaps so that the staples are collected in a sliver that has no thin places. The inclination of the ribs |02 should be in the direction shown so that their apparent travel when the cylinder rotates is in the direction of advance of the sliver 2.

The cylinder |00 may be kept free of stray fibers by the use of an air jet 220 (Fig. 7) over it and having apertures 222` through which streams of air are directed downwardly against the cylinder.

A stationary guide shield 226 having an e larged lip 228 guides the sliver as it is delivered to the rotating trumpet |08. 'I'he trumpet may be provided with a sliver-receiving throat 240, triangular in cross section, so that its rotation in the direction indicated imparts a similar rotation to the sliver and aids in winding it up into helical form. Rolls H0, I|2 are power'driven to draw the sliver from cylinder |00 and through the trumpet and deliver the sliver to a crimping box 223 having the conventional weighted crimping blade 225 which operates in a known manner toc 'legliver the sliver in crimped form, as shown a The machine is preferably equipped with a stop motion finger which lightly rests on the sliver between the stationary and rotating trumpets and stops the machine automatically if the sliver should break.

After the sliver hasv been formed and conducted away from the apron 86 it may be provided with an anti-static oil finish of conventional sort for inhibiting the generation of static in subsequent processing operations.

Any suitable type of drive, of which the one shown in Fig. 9 is typical, may be employed to obtain the proper relative speeds of rolls and aprons.

The shafts for the several rolls are indicated in Fig. 9-'by the primes of the numbers used to designate the rolls in Fig. 2 and in Fig. 9 no attempt has, of course, been made to show the relative sizes of the elements with accuracy. 300 is the main power shaft rotated counterclockwise as by the motor diagrammatically shown at 302. A sprocket 304 fixed to shaft 300 carries a chain 306 which rotates a sprocket 308 fixed to the shaft i2 to rotate the fracturing roll |2 counterclockwise at a predetermined speed. A sprocket 3|0, also fixed toy shaft I2', is connected by chain 3|2 to sprocket 3|4 on shaft |46' to rotate roll |46 counterclockwise at a surface speed which is the same as or, for tension of the sliver, slightly less than the surface speed of roll l2. Gear 3|6 on shaft |46 meshes both with gear 3|8 on shaft |44 and with gear 320 on shaft |48' to drive the rolls |44 and |48 at the same surface speed as that of roll I 46.

The lower fracturing roll I2 drives the upper roll |0 by gear 322 fixed to shaft l2 meshing with gear 324 xed to shaft I0.

Roll 20 is driven from shaft I0' at the same surface speed as roll I0 or slightly faster by chain 326 running over sprocket 328 fixed to shaft I0 and sprocket 330 on shaft 20. Lower roll 22 is driven by gear 332 fixed to shaft 22 and meshing with gear 334 fixed to shaft 20. The debonding rolls 24 and 26 are geared together by gears 336 on shaft 24 and 338 on shaft 26'. To drive both rolls at a surface speed faster than that of rolls 20, 22, chain 340, extending around sprocket 342, is driven by a sprocket 344 fixed to power shaft 300.

Rolls 28, 44 and 46 are driven at surface speeds greater than that of rolls 24, 26 by chain 346 extending around sprocket 348 on shaft 24 and around smaller sprocket 350 on shaft 28. Roll 44 is driven from roll 28 at the same surface speed by chain 352 passing around sprockets 354 and 356 on shafts 28 and 44.respectively. Roll 46 is driven from roll 44 at the same surface speed by chain 358 passing around sprockets 360 and 362 fixed to shafts 44' and 46' respectively.

Apron 36 is advanced at a surface speed less than that of rolls 28, 44 and 46 but greater than that of rolls 24, 26 by suitably power driving the two end apron supporting rolls 30 and 42. Chain 366 passes around sprockets 388 and 318 fixed to shafts 30 and 42 respectively and around sprocket 368 fixed to jack shaft 310 which is f 9 driven from-shaft 300 by chain 312 passing around sprockets 314 and 316, fixed to shafts 310 and 300 respectively.

Rolls 50, 52 are geared together by gear 400 on shaft 50 and gear 402 on shaft 52. The lower of these rolls is driven at the relative speed above described by chain 404 passing aroundv sprocket 406 on shaft 52 and sprocket 408 on shaft d2.

The drives for the next set of rolls and belts may operate on the same principle as that of the drives just described and therefore their detailed description is believed unnecessary. Rolls 62, 64 and 66 are connected by chains and sprockets and the power is derived from shaft 50' through chain 4 |'0 extending around sprocket 4 I2 on shaft 50 and sprocket 4|4 on shaft 62.

The shafts of the end rolls 68 and 14 supporting belt 60 carry sprockets driven by a chain 4|6 extending around sprocket 420 on shaft 422 which is driven from shaft 310 by chain 424 passing around sprocket 426 on shaft 422 and around sprocket 428 on shaft 310.

Rolls 00, 82 are geared together by gear 430 on shaft 80' and gear 432 on shaft 82'. Conveniently, the shaft 80' may be driven from shaft 66' employing sprocket 434 on the latter driving chain 1336 extending around sprocket 438 fixed to the former.

Cylinder is rotated by belt 462 passing around pulley 460 on the cylinder and pulley 464 on shaft 466 rotated from shaft 422 by bevel gears 468. Trumpetl may conveniently be driven by ring gear 5|0 mounted on the trumpet and meshing with gear 5| 2 on the shaft of cylinder |00. Rolls H0 and i2 are geared together by gears 5|4 and 5|@ and one of these rolls is connected to a going part of the machine, as indicated diagrammatically by bevel gear 5|0 on the shaft of the lower roll meshing with bevel gear 520 xed on the shaft of cylinder |00.

My invention is not limited to the specific embodiment above described except as the appended claims require. As examples of modications which I have found useful in practice, I may substitute for the aprons 36 and 60, shown in Fig. 1, lower sets of rolls which, with the upper rolls, are so arranged as to effect the drafting and depthwlse shear of the staples. Thus, Fig. 10, the iiuted rolls 24 and 26 may be followed by upper and lower rolls 236 and 232 which positively nip the staples and rotate faster peripherally than the rolls 20, 22 to effect drafting and the removal of mashed fragments of laments as the staples are advanced through the rolls 24, 26. An apron 234 is interposed between the rolls 230 and 232 to avoid damage to the staples. The web 8 is delivered by these rolls to a set of rolls numbered consecutively from 240 to 25|. The

-rolls 240, 24| are carrier rolls to support the web extending from rolls 230, 232 to rolls 242, 243. Rolls 242, 243 are spaced from rolls 230, 232 by a ratch approximating the staple length, or the maximum staple length if there is a variation. Roll 243 rotates faster than roll 232, and roll 242 rotates faster than roll 243. The speed difference between rolls 242 and 243 is preferably as much as 50%, although curling of the staples by excess speed of the top roll should, of course, be avoided.

Rolls 242, 243 are spaced a very slight distance from each other, for example, .002 inch for a web of about le inch average thickness, to advance the staples frictionally and slip draft them. At least one of the' rolls 242, 243 is preferably covered with 10 l rubber or other resilient material to -avoid damage to the staples and, because of this resiliency, the spacing of .002 inch may be varied considerably with good results. n

The intermediate carrier rolls 240 and 24| are spaced from each .other a more substantial amount, which may be greater than the web thickness at this point. They are geared together by gears 256 and 258 to rotate at ,the same peripheral speed, which is preferably between the speed of roll 243 and that of roll 232. Because of the comparatively wide separation of the carriers 240 and 24| from each other, they need not be rubber covered but can be -of metal and preferably are scratch uted. Their surfaces should closely approach Without touching the rolls on both sides of them, so that they strip those rolls of adhered staples. The scratch fiutings of the carrier aid their effectiveness for this purpose.

A further lengthwise draft and depthwlse shear is effected by the rolls 246, 241 with intervening rolls 244, 245 acting as carriers. The final pair of carriers 248, 240 conveys the staple to the apron 86, from which it is collected in sliver form.

As a still further modification, the apparatus in Fig. 11 may be employed, having a plurality of upper rolls cooperating with a single lower roll. The lower roll 243a corresponds, for example, with the roll 243 in the embodiment of Fig. 10. In place of the upper roll 242 of Fig. 10, I employ two small rolls 242a and 242b, both preferably made of steel, scratch uted and rotating at the same speed, which is preferably considerably faster than the speed of the roll 243a from which they are slightly spaced, all as explained with reference to Fig. 10. The carrier rolls 240, 24| are shown on the right and 244, 245 are shown on the left. I have found that the use of a plurality of small rolls cooperating with a single larger roll gives a better surface contact with the web and effects a better depthwise shear than ka pair of opposite rolls.

My machine may be used on types of extruded filaments other than rayon. I have found that with some types of filament a depthwlse shear may be obtained through the use of upper rolls which are not power driven but rotate idly by surface contact with the web. Friction causes the upper rolls to drag behind the lower belt or rolls so that the upper surface of the web moves slower than its bottom surface.

The utility of my invention is not limited to its use on rayon or even on other extruded filaments. Thus, where a continuous sliver of long fibers of any sort, whether animal, vegetable or artificial, is processed in my machine the individual lengths of the fibers may be shortened and a sliver of drafted staples made from it just as herein described with relation to the conversion of continuous filaments.

In the specification and claims, where I refer to staples as being fractured I mean that they are either fully severed or partly severed because they may be cut completely through by the threads or they may be crushed, without complete severance, and later broken apart.

This application is a continuation in part of my prior application Serial No. 343,819, led July 3, 1940, now abandoned, for Conversion of bull: filament into staple form.

I claim:

1. Apparatus for producing a sliver of drafted staples from a web of filaments, which includes means for fracturing theweb along lines running l 1 across the web dividing the web into strips, each strip being composed of staples having fractured leading ends aligned with each other along the forward fracture line of the strip, a plurality of sets of staple-separating elements engaging the web along predetermined lines across its opposite surfaces and through which the staples pass, at

least one of the elements of at least one of the sets advancing faster than an opposite element in the same set to urge one layer of the staples to i the staples along a predetermined line, the fracturing mechanism and the staple-separating mechanism being so disposed relative to each other that said lines of fracture and of element engagement form a predetermined angle relative to each other such that the aligned leading ends p of staples in a given laver are engaged and advanced successively rather than simultaneously by opposed moving elements and said collecting cylinder being so disposed with relation to the said fracturing means that the said line of collection has an inclination diagonally opposite to the lines of fracture whereby the drafted staples are collected into a self-sustaining sliver.

2. Apparatus for producing a sliver of drafted staples from a web of filaments. which comprises a pair of filament fracturing rolls, means to drive said rolls. one of said rolls having a hard unyielding surface and thev other of said rolls having on its surface a blunt hard-surfaced helical thread. the anale of inclination of the helix to the axis of the roll being between 60 and 88 to fracture the web into oblique strips inclined to the direction of travel of the web from 2 to 30. each strip being composed of staples having their leading ends ou an oblique line extending across the web. a plurality of opposed web-engaging elements so mounted that the line of their entween 60 and 88 with said oblique line, means to drive said web-engaging elements at surface i speeds greater than the surface speed of the fracturing rolls, said elements gripping and pulling the staples of said strip in succession as the forgagement with the web makes an angle of beward ends of said staples successively enter the l line of engagement of said elements to advance a with relation to the staples adjacent to the other surface of said web. an apron adapted to receive the cut and drafted staples, means to drive said apron at a speed at least as great as the peripheral speed of a web-engagingr element immediately preceding it. and a cylinder in proximity to the apron having its axis oblique to the direction of travel of said staples at an inclination which l is in the same direction as the inclination of said helix and diagonally opposite to the inclination of said oblique strips. means to drive said cylinder at a peripheral speed at least as great as the speed of said apron with the surface of said cylinder in proximity to the apron advancing in the direction opposite to the direction of travel of said apron, said cylinder being `adapted to contact with said staples on said apron and to form iiid staples into a helical roll of sliver and to guide said sliver roll to advance in the direction of its axis.

3. Apparatus for producing a sliver oi drafted staples of different lengths from a web of filaments, which comprises a pair of filament fracturing rolls, means to drive said rolls, one of said rolls having a hard unyielding surface and the other of said rolls having on its surface a blunt hard-surfaced helical thread, the angle of inclination of the helix to the axis of the roll being between 60 and 88, means for guiding the web to said fracturing rolls at different inclinations relative to said inclination of the helix to fracture the web into oblique strips of staples of different lengths, each strip being composed of staples having their leading ends on an oblique lineextending across the web, a plurality of opposed web-engaging elements so mounted that the line of their engagement with the web makes an angle of between 60 and 88 with said oblique line, means to-drive said web-engaging elements at surface speeds greater than the surface speed of the fracturing rolls, said elements gripping and pulling the staples of said strip in succession as the forward ends of said staples successively enter the line of engagement of said elements to advance a staple earlier gripped with relation to a staple later gripped, said driving means being also adapted to drive one element at a greater surface speed than that of an opposite element to advance the staples adjacent to one surface of said web with relation to the staples adjacent to the other surface of said web, an apron adapted to receive the' fractured and drafted staples, means to drive said apron at a speed at least as great as the peripheral speed of c. web-engaging element immediately preceding it, and a cylinder in proximity to the apron having its axis oblique to the direction of travel of said staples at an inclination which is in the same direction as the inclination of said helix and diagonally opposite to the inclination of said oblique strips, means to drive said cylinder at a peripheral speed at least as great as the speed of said apron with the surface of said cylinder in proximity to the apron advancing in the direction opposite to the direction of travel of said apron, said cylinder being adapted to contact with said staples on said apron and to form said staples into a helical roll of sliver and to guide said sliver roll to advance in the direction of its axis.

4. The method of converting aweb of filaments into a sliver of fractured and drafted staples which includes fracturing said web into strips disposed obliquely at an inclination of less than 30 to the longitudinal axis of the web to produce fractured staples having leading ends in each strip substantially aligned at such an inclination to the longitudinal axis of the web, drafting the web to effect a longitudinal separation of said aligned fractured'ends in each strip by advancing said aligned ends in succession so that said fractured ends are no longer aligned at such inclination, and rolling up the fractured and drafted staples into a helical roll of sliver having its axis oblique to said longitudinal axis of the web at an inclination which is in the opposite direction to the inclination of said fracture.

5. Apparatus for producing staples from a web of filaments which includes in combination means for fracturing the web of filaments into staples, and means for removing from adjacent fractured ends of the staples mashed fragments of filament bcnding them together comprising three sucat a peripheral speed greater than that of the first set so that the leading ends of staples grasped by the first set of rolls are wiped by said fiutings to remove fragments therefrom, and means for rotating the third set of rolls at a 4peripheral speed greater than that of the second set so that the trailing ends of staples advanced by the third set of rolls are caused to pursue said serpentine path to remove further fragments therefrom.

6. Apparatus for producing staples from a web of filaments which includes in combination means for fracturing the web of filaments into staples, and means for debonding adjacent fractured ends of the staples comprising three successive sets of rolls throughwhich the staples pass, the first and last sets of which rolls positively grasp and advance the staples and the intermediate set ofwhich rolls presents opposed flutings which intermesh with each other but are so spaced apart as to present an open serpentine path through which the staples are advanced by said first and last sets of rolls so that fragments of mashed filament bonding together the fractured ends of staples are removed.

7. Apparatus for producing a sliver of staples from a web of filaments which includes means for fracturing the web into staples, means for drafting and shearing the said staples, and means for rolling the staples into a sliver, comprising' a traveling conveyor for supporting and advancing the staple web, a longitudinally ribbed cylinder disposed at an inclination to the path of advance of the conveyor and in proximity thereto, and means for rotating the cylinder in a direction opposite to the advance of the conveyor to roll the web of staples into a sliver.

8. Apparatus as defined in claim 7 which also includes a member contacting the staples adapted to conduct away static electricity therefrom and means for applying moisture to the staples and to the apron in a predetermined controlled amount sufiicient to remove further static electricity from the staples but insuflicient to cause the staples to adhere to said conveyor.

9. Apparatus for producing a sliver of staples from a web of filaments which includes means for fracturing the web along lines inclined obliquely thereof to fracture the filamentl into staples, means for drafting the staples, an apron adapted to receive the fractured and drafted staples, a cylinder in proximity to the apron having its axis oblique to the direction of travel of said staples at an inclination which is in the opposite direction to the inclination of said fractures, means to drive said cylinder at a peripheral speed at least as great as the speed of said apron with the cylinder rotated oppositely to the direction of travel of said apron, said cylinder being adapted to contact with said staples on said apron and to form said staples into a helical roll of sliver, and means for withdrawing said said sliver roll in the direction of its axis.

10. In the use of an apparatus for producing a web of staples from a web of filaments the process which includes the steps of fracturing the filaments of the web into staples, separating the staples in said web depthwise by advancing the web in the direction of their length While frictionally engaging the upper and lower faces of said web and positively driving one of said faces at a lower speed than the other of said faces.

11. In the use Vof an apparatus for producing a web of staples from a Web'of filaments the process which includes the steps of fracturing the web of laments into staples and separating the staples in said web depthwise by advancing the web in the direction of their length while frictionally engaging the upper and lower faces of said web and driving one of said faces at a speed at least 25% faster than the other of said faces.

12. In a method of converting a web of filaments into a sliver of drafted staples the steps of fracturing said web into strips disposed obliquely at an angle of less than 30 to the longitudinal axis of the web to produce fractured staples. separating the staples in different horizontal planes in said web depthwise by-advancing the web in the direction of their length while frictionally engaging the upper and lower faces of said web and positively driving one of said faces at a lower speed than the other of said faces and thereafter drafting the staples in said web to effect a longitudinal separation of said staples.

13. `The method of converting a web of filaments into a sliver of drafted staples which includes fracturing said web into strips disposed obliquely at an angle of less than 30 to the longitudinal axis of the web to produce fractured staples, separating the staples in different horizontal planes in said web depthwise by advancing the web in the direction of their length while frictionally engaging the upper and lower faces of said web and positively driving one of said faces at a lower speed than the other of said faces, pressing together said upper and lower faces with a pressure light enough to permit the staples in planes between said faces to be drafted longitudinally, drafting said staples to effect a longitudinal separation of said staples and forming said staples into a sliver.

14. The method of converting a web of filaments into a sliver of drafted staples of different lengths in a continuous movement, which method consists in feeding said web to fracturing means, fracturing said web along steeply oblique lines, varying the angle in the plane of said web at which said web is fed to said fracturing means to produce obliquely extending strips of staples of varying lengths, drafting said staples in said strips to produce a thin web of drafted staples of a variety of lengths and forming said thin web into a sliver.

15. In a method of converting a web of filaments into a web of drafted staples of different lengths, the steps which consist in feeding said web to fracturing means, fracturing said web along steeply oblique lines and varying the angle in the plans of said web at which said web is fed to said fracturing means to produce obliquely extending strips of staples of different lengths.

16. The method of converting a web of filaments into a sliver of drafted staples of different lengths in a continuous movement, which method consists in feeding said web to fracturing means, fracturing said web along steeply oblique lines, varying the angle in the plane of said web at which said web is fed to said fracturing means to produce obliquely extending strips of staples of different lengths, drafting said staples in said strips to ,f from a web of filaments having a main driving shaft, means driven from said shaft for fracturing the web of filaments into staples, mechanism for advancing the web of fractured staples in the direction of their length to separate them depthwise, said mechanism including an upper means having a movable surface frictionally engaging the upper face of the fractured webvand a lower means having a movable surface frictionally en- 1 gaging the lower face of the fractured web, and driving means driven from said shaft for driving each of said means and including devices to drive one of said means at a surface speed slower 'than the surface speed of the other.

18. Apparatus for producing a web of staples from a web of filaments having a main driving shaft, means driven from said shaft for fracturing the web of filaments into staples, mechanism for advancing the web of fractured staples in the direction of their length to separate them depthi wise, said mechanism including an upper means having a movable surface frictionally engaging the upper face of the fractured web and a lower means having a movable surface frictionally engaging the lower face of the fractured web and driving means driven from said shaft for driving each of said means and including devices to drive one of said means at a surface speed at least 25% faster than the surface speed of the other.

19. Apparatus for producing a sliver from a web of filaments which includes in combination a pair of fracturing rolls comprising a smooth hard-surfaced roll and a roll having thereon blunt threads adapted to fracture the filaments supported on the smooth roll by pressure thereagainst, said threads being inclined at a steeply oblique angle to the axis of the roll, means for varying the angle in the plane of said web at which said web is fed to said fracturing rolls to vary the lengths of the staples fractured by said threads, means for debonding said fractured staples, means following said debonding means to separate said staples in horizontal planes,

means to draft said staples and means to roll the drafted staples into a roll of sliver.

20. Apparatus for producing staples from a web of filaments which includes in combination i a pair of fracturing rolls comprising a smooth hard-surfaced roll and a roll having thereon blunt l threads adapted to fracture the filaments supported on the smooth roll by pressure thereagainst, said threads being inclined at a steeply oblique angle to the axis of the roll, and means for varying the angle in the plane of said web at which said web is fed to said fracturing rolls to vary the lengths of the staples fractured by said threads.

21. The method oi' converting filaments of textile fibers into a sliver of cut lengths which comprises forming a plurality of laments into a fiat web, fracturing said web into steeply oblique strips of fractured fibers, the ends of laterally adjacent fibers in a strip lying in an acute oblique line `diagonal to said web, drafting the bers to form a web of cut drafted fibers, rolling 170 said web into a sliver having its axis diagonally disposed to the direction of the feed of the web and oppositely disposed to the diagonal `line on which said strips have been fractured and advancing said sliver axially over said web.

22. Apparatus, for producing a sliver of cut lengths from a web of ber filaments which comprises means for fracturing the fibers of said web, means for drafting said fractured fibers, and means for rolling the fractured'drafted fibers into a sliver comprising a traveling conveyor for supporting and advancing the web of fractured fibers, a ribbed cylinder disposed diagonally to the direction of advance of the conveyor and in proximity thereto and means for rotating the cylinder in a direction opposite to the advance of the conveyor to roll the web of fractured drafted fibers into a sliver.

23. Apparatus for producing cut lengths from a web of fiber laments which comprises in combination rollers for fracturing the web of filaments, one of said rollers having helical threads of one of said rollers from contacting the utes of the other roller, means to drive said fiuted rollers at an equal surfacev speed greater than the surface speed of said fracturing rollers, web feeding means to which the web is delivered from said fluted rollers and means to drive said web feeding means at a surface speed greater than the surface speed of said fiuted rollers, whereby the fractured laments are separated from one another and are formed into separate lengths of fibers.

24. The method for producing cut lengths from a web of fiber filaments which comprises fracturing and crushing the web of filaments on diagonal lines, bending the web of fractured filaments repeatedly up and down while advancing said web at a speed greater than its speed during said fracturing, thereafter advancing said web at a speed greater than its speed when bending the web, whereby the fractured filaments are separated and formed into separate lengths of fibers.

25. Apparatus for producing separate cut lengths from a web of ber filaments which comprises in combination fracturing rollers for fracturing said filaments, one of said rollers having helical threads having cutting edges, a pair of luted rollers, each roller having flutes on its surface which project into the interflute spaces of the other roller, said flutes being adapted to engage the opposite surfaces of the fractured web and to cause said webto undulate, means to maintain said fluted rollers apart a sufficient distance to prevent the flutes of one of said rollers from contacting theflutes of the other roller, means to drive said fluted rollers at an equal surface speed greater than the surface speed of said fracturing rollers, web feeding means to which the web is delivered from said fluted rollers and means to drive said web feeding means at a surface speed greater than the surface speed of said f-luted rollers, whereby the fractured filaments are separated from one another and are formed into separate lengths of fibers.

26. The method for producing separate cut lengths from a web of fiber filaments in a continuous movement which comprises feeding the web of laments to fracturng means, fracturing said moving web, bending said web repeatedly transversely to its plane while advancing said web at a speed greater than the speed of its movement during said fracturing and thereafter advancing said web at a speed greater than the speed of its movement during said bending, whereby the fractured filaments are separated from one another and are formed into separate cut lengths.

lengths from a web of ber filaments in a continuous movement comprising means to press helical threads having cutting edges against said web to fracture said web, means to cause the fractured web to undulate comprising a pair of fluted rollers, means to advance said web between said fluted rollersat a speed greater than its speed during the fracturing and succeeding means to advance said web at a speed greater than its speed when passing between said iluted rollers to separate the lengths of fibers from one another.

28. The method for producing separated cut lengths of fibers from a web of filaments in a continuous movement which comprises feeding the web of filaments to fracturing means, fracturing said moving web, repeatedly flexing said web to cause a differential in linear speed between the bers with relation to one another while advancing the web of fibers at a speed greater than the speed of the filaments through the fracturing means, and thereafter advancing said fibers at a speed greater than the speed of their movement during said ilexlng, whereby the fibers are separated from one another.

29. Apparatus for producing separate cut lengths from aweb of -flber filaments which comprises in combination fracturing rollers for fracturing said maments, one of said rollers having helical threads having cutting edges. agpsir of uted rollers, each roller having flutes' on its surface which project into the interflute spaces of the other roller, said flutes being adapted Ito engage the opposite surfaces of the fractured web and to cause said web to undulatc, means to maintain said fluted rollers apart a sumctent dfstance to prevent the flutes of one of said rollers from contacting the flutes of the other roller. means to. drive said fluted rollers at m m81 surfacespeedgreater-thanthesurfacespeedofl said fracturlng rollers, web mechanism following said nuted rollers for advancing the webof fractured staples in the direction of 18 their length to separate them depthwise, said mechanism including an upper means having a movable surface frictionally engaging the upper face of the fractured .web and lower means 10 27. Apparatus for producing separated cut having a movable surface frictionally engaging the lower face of the fractured web, devices to drive both of said means at surface speeds greater than thesurface speed of said uted rollers and to drive one of said means at a surface speed slower than the surface speed of the other, whereby the fractured filaments are separated from one vanother and are formed into separate lengths of fibers.

30. The method of converting lfilaments of textile fibers into a sliver of cut lengths, which comprises forming a plurality of filaments into a flat web of cut and drafted bers, advancing the web and rolling said fibers as they advance into helices to form a sliver having its axis diagonally disposed to the direction of the advance of said web and advancing said sliver axially over said web.

ROBERT C. WILmE.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date Re. 11,524 Cupers Feb. 25, 1896 802,492 Birch oct. 24, 1905 1,577,620 Gammeter Mar. 23, 1926 1,693,589 Bo.ton Dec. 4. 1928 1,768,221 'Ihoma June 24, 1930 1,786,180 Von Trumbach Dec. 23, 1930 I 1,827,385 Cornibert Oct. 13, 1931 2,031,647 Hale Feb. 25. 1936 2,076,951 Kono Apr. 13, 1937 2,137,908 Gies Nov. 22. 1938 2,221,716 Morton Nov. 12, 1940 2,234,105 Ashton et al. Mar. 4, 1941 2,249,083 Kern July 15, 1941 2,260,383 Killers Oct. 28, 1941 2,272,247 Paulus Feb. 10, 1942 2,284,635 Campbell June 2, 1942 2,294,771 Campbell Sept. 1, 1942 2,323,300 Abbott July 6, 1943 FOREIGN PATENTS Number Country Date 457,557 Great Britain Dec. 1. 1936 Germany Oct. 30, 1939

Images