US3741489A

US3741489A - Bobbin winder, method and yarn package produced thereby

Info

Publication number: US3741489A
Application number: US00125780A
Authority: US
Inventors: S Kawamura; H Matsuno
Original assignee: Toray Engineering Co Ltd
Current assignee: Toray Engineering Co Ltd
Priority date: 1971-03-18
Filing date: 1971-03-18
Publication date: 1973-06-26
Anticipated expiration: 1990-06-26

Abstract

In an apparatus for winding yarn on a bobbin, the yarn is distributed by a flyer which rotates about an axis that is disposed at an angle to the bobbin axis. The bobbin is rotated in a direction opposite to the direction of rotation of the flyer. The flyer moves axially relatively to the bobbin in a single direction throughout the winding period. The resulting package contains yarn that runs continuously in and out between the inner periphery and the outer periphery of the yarn package enhancing subsequent package dyeing operations.

Description

United States Patent [191 Kawamura et a1.

[ BOBBIN WINDER, METHOD AND YARN PACKAGE PRODUCED THEREBY Inventors: Sadao Kawamura,

Kyoto; Hideo Matsuno, Osaka, both of J apan Toray Engineering Co., Ltd., Osaka, Japan Filed: Mar.'18, 1971 1 Appl. No.2 125,780

Assignee:

US. Cl 242/18, 57/1, 242/2, 242/26.5, 242/159 Int. Cl... B65h 54/04, B65h 55/04, B65h 57/00 Field of Search 57/67, 70, 72, 71, .57/34 R, 75,1'15,l18,156,116, 35; 242/26.1, 26.2, 26.3, 27, 159, 168, 174, 178,

[56] References Cited UNITED STATES PATENTS 3,393,502 7/1968' Reecler 57/75 X 2,451,352 10/1948 Nou-Touron 57/116 1 June 26, 1973 2,301,711 11/1942 Seem et a1. 242/178 3,334,842 8/1967 Pillar et al.

3,342,437 9/1967 Massey 242/178 FOREIGN PATENTS OR APPLICATIONS 211,183 4/1957 Australia 57/75 641,708 5/1962 Canada 57/75 530,700 12/1921 France 57/67 800,555 8/1958 Great Britain 57/75 Primary Examiner-D0nald E. Watkins Attorney-Paul & Paul [57] ABSTRACT 9 Claims, 16 Drawing Figures rmmcnmzsm 3.741.469-

sum 1 or a l 1 g PRIOR ART "1 b ERsinB 3/) E PRIOR ART BY H I DEO MATSUNO ATTORNEYS.

' SADAO KAWAMURA' PMENTEUJUI 2 6 I915 I INVENTORS. SADAO KAWAMURA I HIDEO MATSUNO ATTORNEYS.

GENERAL FIELD OF THE INVENTION This invention relates to an apparatus for winding yarn on a bobbin, to a method for performing such winding, and to a package having a novel arrangement of yarn thereon.

In normal bobbin winding, the yarn is reciprocated relatively back and forth along the axis of the bobbin and the yarn is laid upon the bobbin or upon yarn previously laid upon the bobbin, in successive layers commencing at a relatively small radius along the surface of the bobbin and gradually building up to the final relatively large radius corresponding to the outer periphery of the yarn package. Accordingly, when the yarn is disposed in such successive layers, barriers are created which tend to prevent the flow of dye either radially inwardly or radially outwardly through the yarn in a sub sequent package dyeing process. This, of course, impedes the effectiveness of dyeing and sometimes results in non-uniformity of dye intensity in various portions of yarn on the package. Also, dye flow tends to become channeled with such an arrangement, increasing the problems of non-uniformity of dyeing.

Also, such previous processes involve rather rapid axial reciprocation of yarn with respect to the bobbin in addition to rapid rotation of the bobbin and rapid rotation of the'flyer, with attendant mechanical difficulties. i

The dyeing of yarn in a coiled state, or as a cheese or corn is well known and has merit, since it is not necessary' to form coils in preparing the yarnfor dyeing.

However, package dyeing is subject to the drawback that dyeing of yarn tends to be non-uniform. Also, the step of feeding the dyed yarn directly from the packages to looms or knitting machines is difficult because conventional winding techniques have not been matched with package dyeing.

The necessary conditions with respect to the package for package dyeing are (A) minimum overlapping of yarns, ('B) easy passage of dye through the package, (C) no destruction or spoiling of the package as a .result of its treatment with the pressurized dye, and (D) ease of feeding the dyed yarn directly from the package to looms or-knitting machines.

Basically, two main filament winding methods are known; rotary traverse winding and spindle drive winding. ln'the case of rotary traverse winding, a traversing roll'having a traversing slot on its'surface is used, and the roll contacts the surface of the yarn package. When the thickness of the'wound yarn becomes great, the contact pressure between the roll and package also becomes great. Therefore the winding density of the yarn differs between the inner and outer portions of the package. Further, variations of winding tightness or hardness occur between both end portions and the central portion of the package.

When a package formed by the conventional rotary traverse winding is used for package dyeing, the dye tends not to penetrate uniformly throughout the yarn on the package; uneven dyeing of the yarn occurs.

In the case of the spindle drive winding, there are no defects similar to those in rotary traverse winding, because in spindle drive winding it is easy to control the rate of overfeed of yarn and the magnitude of tension of the feed yarn. But in this case it is difficult to employ a wide winding angle; accordingly a layer of yarn is formed in which the wound yarns are positioned almost parallel to each other and in a plane which is almost perpendicular to the axis of the bobbin. When such a package. is used for package dyeing, yarn shrinkage tends to destroy the package. Therefore, even if a yarn could be dyed uniformly, the package is not well suited for use directly as a feed yarn package for looms or knitting machines.

OBJECTS OF THE INVENTION It is accordingly an object of this invention to provide a package which is readily adaptable for package dyeing, in which the uniformity of dyeing throughout the package is improved and dyeing is relatively uniform throughout the package, and rewinding is very easy. Another object is to provide an improved apparatus for producing such a package, and to provide an efficient and economical method for obtaining such a package as well.

SUMMARY OF THE INVENTION It has nowbeen found that by providing a flyer in such a manner that it is rotatable about an axis that is inclined with respect to the axis of the bobbin, and providing a relative axial movement of the bobbin to the flyer, that the yarn is so laid .into the package that it travels continuously inwardly and outwardly toward and away from the inner and outer peripheries of the yarn portion of the package in such a manner that a multiplicity of avenues are provided for dye flow inwardly or outwardly through the package. In this way, uniformity of dyeing in the subsequent dyeing operation is greatly enhanced.

It has also been found that, because of the very slow axial movement of the bobbin that is preferably provided in accordance with this'invention, and because of the precision with which this movement may be controlled in connection with the rotation of the angularly arranged flyer, exceedingly accurate positioning of each yarn is attainable, as each turn of the yarn is arrayed in the actual formation of the package.

These and other objects and advantages of the invention will further become apparent hereinafter, and in the drawings.

DETAILED'DE SCRIPTION OF THE DRAWINGS tures of this invention;

FIG. 2 represents a sectional view of a typical bobbin produced in accordance with this invention;

FIG. 3 (i) represents both an end and a side view of a typical bobbin according to the prior art;

FIG. 3 (ii) represents top and side views corresponding to those of FIG. 3 (i) but showing a typical bobbin prepared in accordance with this invention;

FIG. 4 (i) represents a typical end and side view showing the manner in which the yarn is arrayed on the package in accordance with the procedure of the prior art;

FIG. 4 (ii) represents views corresponding to'those of FIG. 4 (i) showing the unique manner in which the yarn is typically laid upon the package in accordance with the process of this invention;

FIG. 5 represents a side view of the apparatus in accordance with this invention, viewed in a manner similar to FIG. 1, but showing the mechanical apparatus for adjusting the inclination of the flyer back and forth;

FIG. 6 represents a front view of the apparatus shown in FIG. 5, showing two winding positions and showing the adjusting slots just referred to;

FIG. 7 represents a side view similar to FIG. 5, showing the manner in which the thread line is changed by changing the inclination of the flyer axis;

FIG. 8 is a plan view of the apparatus appearing in FIG. 7;

FIG. 9 is a front view of a typical apparatus utilizing features of this invention, showing the drive mechanisms for moving the bobbin axially during the winding procedure, and for returning the bobbin to its initial position quickly after the winding procedure has been completed;

FIG. 10 represents a view, partially in section, showing a partially wound bobbin and the thread paths followed in the course of such winding;

FIG. 11 represents a partial sectional view, taken along the lay line of typical yarns within the bobbin, showing the manner in which they are arrayed in the package;

FIG. 12 represents a view, partly in section, showing an adjustable flyer;

FIG. 13 represents an end view showing another form of adjustable flyer; and

FIG. 14 represents a front view of the adjustable flyer appearing in FIG. 13.

Turning now to the specific forms of the invention selected for illustration in the drawings, it will be appreciated that these drawings and the description of them which follows are not intended to define the scope of the invention, which is defined instead in the claims, but are intended to illustrate preferred ways of carrying the invention into effect.

In FIG. 1 a generally vertical shaft 1 supports and drives a rotating platform for the bobbin 3 which is intended to have the yarn Y wrapped thereon. The number 2 designates a yarn distributing arm, or flyer, which is mounted to rotate about the axis B. The axis of rotation of the flyer 2 is at an angle to the axis of rotation of the bobbin, 0 preferably being an angle within the range from about 2.5 to about 18". As will be observed from the dot-dash line position of the flyer 2, means are provided (not shown in FIG. 1) for shifting the flyer along the axis of the bobbin during the winding operation. Either the flyer or the bobbin, or both, may obviously be moved in order to effect relative movement between them, in a direction generally along the axis of the bobbin.

The

numbers

4, 4 designate bearings supporting rotation of the flyer and the number designates a pulley for driving the flyer, such pulley being connected to a belt and motor of conventional type, not shown.

Preferably, according to this invention, the flyer rotates in the direction of the arrow B about its axis, while the bobbin rotates in the direction of the arrow A about its axis; thus the flyer and the bobbin counter-rotate.

The yarn Y is fed through the center 6 of the sleeve 7 upon which the bearings 4, 4' are mounted and passes through the yarn guides 8 and 9 onto the package. The radius of the flyer is designated by the letter 1, and the line a-b indicates the diameter of the circular arc described by the yarn as it moves with the flyer. As is indicated in the drawing, the distance between point a and point b on the axis of the bobbin is (2) (I) 0 when 0 is the angle of inclination of the flyer axis to the bobbin axis.

The shape of the yarn package appears in detail in FIG. 2 of the drawings; it is substantially rectangular in cross-section with inclined ends.

FIG. 3 (i) shows a typical yarn package which is wound up in successive layers in accordance with the prior art. In contrast, FIG. 3 (ii) shows a package prepared in accordance with this invention.

As will appear in FIG. 4 (i) the yarn in the prior art process referred to is wound in a relatively cylindrical manner; the yarn travels at a substantially constant diameter during each passage of 360 around the axis of the bobbin and the yarn is laid thereby in a helical path back and forth, always at substantially the same diameter. By way of contrast, as is apparent in FIG. 5 (ii) assuming the yarn begins at point 40 at the outer periphery of the package, it moves not only generally helically around the package but also inwardly toward the inner periphery of the yarn portion of the package, traveling between outer diameter D and inner diameter d passing successively through the

points

41, 42 and 43. Then the yarn immediately begins to move along a line of increasing diameter as indicated by the line running from points 43 to 44 and then on to

points

45 and 46, at which time the maximum diameter has again been attained. This procedure continues with great frequency throughout the entire package winding operation and is instrumental in attaining the important advantages heretofore referred to. Since the yarn travels continuously back and forth between the innermost diameter and the outermost diameter, greatly improved package dyeability is achieved.

FIGS. 5 and 6 show a specific means for inclining the flyer with respect to the bobbin and for maintaining the flyer in an adjusted inclined position. In the drawing, the number 3 designates the bobbin and the number I designates the rotating platform on which it is mounted; 2 designates the flyer as heretofore discussed. It will be appreciated that means are provided for rotating the shaft 11 in such a manner that the bobbin supporting plate 10 is very slowly moved along the bobbin axis in a constant direction. The number 12 designates a supporting block for a slotted block 13 having a curved upper surface as appears in FIG. 5. A plate 17 fits on top of the slot 14, and a bolt 15 is provided with an adjusting nut travels within the slot 14. A supporting head 16 for the flyers is mounted on top of the plate 17 and, as will be apparent, can be maintained in any desired adjusted inclined position by adjusting and tightening the screws 15 as will be apparent particularly from FIG. 5.

FIG. 7 shows the manner in which the thread line is changed by changing the inclination of the flyer axis. It has been found that a gentle change of angle of the thread line gives a much lower tension in the yarn than a sharp angle, and is to be preferred in accordance with this invention. This shows a further advantage of the inclination of the flyer in accordance with this invention. The number 19 designates the supply package for the yarn which is to be wound upon the bobbin 3; it is mounted on a supporting rod 20 held by an arm 21 and clamp 22. The thread line through the guide 18 shows the angle that is obtained by a very small inclination of the flyer with respect to the bobbin axis, while the thread line through the guide 18' shows the relatively gentle angle of change of the yarn path that is achieved by a relatively large angle 6 between the flyer axis and the bobbin axis. This relatively gentle angle, as stated, provides for a much lesser tension and assists in producing a superior package.

FIG. 8 is a plan view of the apparatus and of the angles appearing in FIG. 7 and further illustrates this advantageous relationship.

Referring now to FIG. 9 of the drawings, this is a front view showing two different motors for driving the bobbin; one for the winding operation and one for quickly returning the completed bobbin to its initial position after the winding of the package has been completed. The motor 26 is connected to operate through a clutch 27 and a speed reducer 28 to drive the shaft 11 to raise the base plate 10 very slowly. In accordance with the illustrated embodiment of the invention, the flyer 2 is caused to rotate in a fixed position. Thus, in accordance with this embodiment, the base plate 10 is moved in a constant direction and upon completion of this movement the winding has been completed. FIG. 9 also shows another motor 23 connected through a clutch 24 and high speed driving transmission 25, which is automatically connected, using conventional limit switches and relays, to de-energize the motor 26 and to energize the motor 23 at the conclusion of the winding operation to bring the base plate 10 down very quickly, in preparation for a change of bobbins. Thus, when the limit switch (not shown) senses the fact that the base plate 10 has reached its uppermost position shown in dotted lines in FIG. 9, the clutch 27 is disengaged and the clutch 24 is engaged; also the motor 26 is disengaged and the motor. 23 is engaged. This brings the bobbin down quickly to its initial position and ena bles the operator to make a rapid change, replacing the full bobbin with an empty bobbin sleeve.

FIG. 10 shows the nature of a partially completed package when processed in accordance with the showing of FIG. 9. The dash lines show the next course of yarn as it is to be laid upon the package.

FIG. 11 shows in detail the general manner in which typical portions of yarn extend from outside to inside and from inside to outside. These create excellent passages as indicated by the arrows in FIG. 11, for the complete penetration and permeation of the package with dye, when the package is later used in a package dyeing operation.

FIG. 12 shows an adjustable form of

flyer member

47, 48 and 50 wherein the yarn distributing member 50 can be located at any one of a variety of diameters. As shown, the flyer arm 50 and its corresponding counterbalancing element shown at the right side of the figure are located at the maximum diameter. However they may be located at intermediate diameter positions by simply reinserting them into the holes 49 or other holes provided for the purpose.

FIGS. 13 and 14 show similar arrangements using a head 47 for the flyer member 48', 50 and for its corresponding counterbalancing element, together with the use of

bores

51, 52 and set screws 53 for securing these members in any desired adjusted position. millimeter The following examples are illustrative of the invention:

EXAMPLE 1 110 denier, 36 filament nylon yarn was wound, using a winder of this invention under the following conditions:

Inclination between spindle rotational axis and flycr rotational axis 6 Spindle RPM 600 RPM Flyer RPM (in opposite direction to spindle) 250 RPM Bobbin axial movement 4 mm/min Outer diameter of bobbin mm Height of bobbin 180 mm Winding tension 15 g *millimeter The wound package was dyed using a dye liquid containing 2.0 percent of Nylomlne Red 2 BS, 2.0 percent of Lyogen-P and 1.5 percent of acetic acid (concentra tion 99 percent), and under such conditions that the temperature of the dye liquid is controlled at first at normal temperature, and raised to 100 C and maintained at 100 C for 60 minutes, then cooled.

A perforated bobbin was used and the dye was fed from the inside of the bobbin toward the outside.

No deformation of the package was observed and uniform dyeing was obtained. It was easily possible to feed the yarn to a loom or knitting machine at 400 m/min. meter) EXAMPLE 2 A 40-denier two-ply spun polyester yarn was wound on a winder of this invention under the following conditions:

Inclination between spindle rotational axis and flyer The resulting package was dyed with dye liquid containing 2.0 percent Resoline Blue FBL and 1.0 percent Sun Solt No. 1200, under such conditions that the temperature of the dye liquid was at first controlled at 60 C and then raised to C and maintained at 120 C for 60 minutes, and after that cooled.

A perforated bobbin was used and the ,dye was fed reciprocally for 4 minutes from the inside toward the outside, and then for 6 minutes from outside to inside.

After dyeing, the package was treated by reduction for 20 minutes, at 30 C with a liquid containing 1 g/l of caustic alkali, 1 g/l of an alkali metal salt of hydrosulfite and 2 g/l of amylazine.

No deformation of the package was observed, and dyeing was uniform. Feeding the yarn to a machine at 400 m/min was easily accomplished.

EXAMPLE 3 75 denier, 36 filament polyester yarn, bulked up by false twisting, was wound on a winder of this invention under the following conditions:

Inclination between spindle rotational axis and flyer The package was steamed at 85 C for 20 minutes and dyed with a liquid containing 1.5 percent of Resoline Red PB, and 1.0 percent of Sun Solt No. 1200; the temperature of the dye liquid was controlled at first at 60 C, and raised to 125 C and maintained at 125 C for 60 minutes and after that cooled.

A perforated bobbin was used and the dye was fed from inside the bobbin to the outside.

No deformation of the package was observed and uniform dyeing was obtained. Further, the yarn was easily fed at 250 m/min.

EXAMPLE 4 A bulked two-ply 48 denier spun acrylic yarn was wound on a winder of this invention under the following conditions:

Inclination between spindle rotational axis and flyer The package was steamed at 100 C for 30 minutes at -600 mm Hg in an autoclave and dyed with a dye liquid containing 2.0 percent of Catilon Blue NBLH, 1.5 percent of Sumiacryl Yellow 36, 1.0 percent of Catiogen L, acetic acid (concentration 99 percent) and sodium acetate. The temperature of the dye liquid is controlled at first at 60 C, and raised to 100 C and maintained at 100 C for 60 minutes, and after that cooled to 60 C in 40 minutes.

No deformation of package was observed and uniform dyeing was obtained. Further, feeding of the yarn at 250 m/min was accomplished.

The following is claimed:

1. A yarn winding apparatus for producing an annular package of filamentary yarn, said apparatus comprising:

a. a spindle mounted for rotary motion about its axis;

b. yarn guide means mounted adjacent the spindle for circular rotating motion in a plane inclined from about 2.5 to about 18 from a plane perpendicular to the rotational axis of the spindle;

c. means for effecting relative bodily movement between the inclined plane of the yarn guide and the spindle in the longitudinal direction of the spindle axis at a rate of movement which is slow relative to the rotational speeds of said spindle and yarn guide means;

d. said yarn guide means including a flyer mounted on a rotational shaft the axis of which is inclined from about 2.5 to about 18 from the rotational axis of said spindle; and

e. means for effecting rotation of the flyer and rotation of the spindle in opposite directions.

2. Apparatus as defined in claim 1, further comprising means for adjusting the angle between the rotational axis of the flyer and the rotational axis of the spindle.

3. Apparatus as defined in claim 1, further comprising means effective upon completing the winding of a package for quickly returning the spindle bodily to its initial position.

4. Apparatus as defined in claim 1, further comprising means for adjusting the rotational radius of the flyer.

5. Apparatus according to claim 1 wherein said means for effecting rotation of the flyer and rotation of the spindle in opposite directions includes means for effecting rotation of the flyer and rotation of the spindle in opposite directions at different rotational speeds.

6. Apparatus according to claim 5 wherein the means for effecting rotation of the flyer and spindle in opposite directions at different speeds includes means for driving the spindle at a rotational speed substantially higher than that of the flyer.

7. An annular package of continuous filamentary yarn wound on a bobbin, said winding being characterized by:

a. a succession of helical turns of substantially 360 each;

b. each turn traverses a predetermined short length in the axial direction of the bobbin, said length being much shorter than the total axial length of the bobbin;

c. the yarn in each turn is displaced from the center axis of the bobbin by a plurality of radial dimensions.

8. In a method of winding yarn upon a bobbin sleeve,

the steps which comprise:

a. moving the yarn angularly about the bobbin sleeve in a plane inclined from between 2.5 and 18 relative to a plane normal to the axis of the bobbin sleeve to create a turn of yarn at a given location about the sleeve, said turn occupying a short axial distance relative to the total axial length of the sleeve;

b. rotating said sleeve about its axis at a speed higher than that at which said yarn is moved angularly about the bobbin sleeve;

c. repeating the steps of (a) and (b) while slowly displacing the rotating bobbin in its axial direction, whereby individual yarn turns are displaced by different radial distances from the axis of the sleeve.

9. The method of claim 8 characterized by rotating said sleeve in a direction of rotation which is opposite to the direction of movement of the yarn.

l t I. i

Claims

1. A yarn winding apparatus for producing an annular package of filamentary yarn, said apparatus comprising: a. a spindle mounted for rotary motion about its axis; b. yarn guide means mounted adjacent the spindle for circular rotating motion in a plane inclined from about 2.5* to about 18* from a plane perpendicular to the rotational axis of the spindle; c. means for effecting relative bodily movement between the inclined plane of the yarn guide and the spindle in the longitudinal direction of the spindle axis at a rate of movement which is slow relative to the rotational speeds of said spindle and yarn guide means; d. said yarn guide means including a flyer mounted on a rotational shaft the axis of which is incliNed from about 2.5* to about 18* from the rotational axis of said spindle; and e. means for effecting rotation of the flyer and rotation of the spindle in opposite directions.

7. An annular package of continuous filamentary yarn wound on a bobbin, said winding being characterized by: a. a succession of helical turns of substantially 360* each; b. each turn traverses a predetermined short length in the axial direction of the bobbin, said length being much shorter than the total axial length of the bobbin; c. the yarn in each turn is displaced from the center axis of the bobbin by a plurality of radial dimensions.

8. In a method of winding yarn upon a bobbin sleeve, the steps which comprise: a. moving the yarn angularly about the bobbin sleeve in a plane inclined from between 2.5* and 18* relative to a plane normal to the axis of the bobbin sleeve to create a turn of yarn at a given location about the sleeve, said turn occupying a short axial distance relative to the total axial length of the sleeve; b. rotating said sleeve about its axis at a speed higher than that at which said yarn is moved angularly about the bobbin sleeve; c. repeating the steps of (a) and (b) while slowly displacing the rotating bobbin in its axial direction, whereby individual yarn turns are displaced by different radial distances from the axis of the sleeve.