WO2022087193A1

WO2022087193A1 - Defect detection in moving fiber-containing structures

Info

Publication number: WO2022087193A1
Application number: PCT/US2021/055938
Authority: WO
Inventors: Patrick Coffey; Michael IWANSKI
Original assignee: Kuraray America, Inc.
Priority date: 2020-10-21
Filing date: 2021-10-21
Publication date: 2022-04-28
Also published as: EP4232802A1; CA3189645A1; KR20230091888A; CN116761767A; JP2023546917A

Abstract

Disclosed herein are methods and apparatuses (100) for detecting defects in fiber-containing structures (110) using at least one defect detector including a projector (115) and an optical receiver (130) capable of measuring the cross-sectional diameter of the fiber- containing structures while in linear motion. Said cross-sectional diameter is calculated based on a reduction in an amount of light 135 detected by the optical receiver relative to the total amount of light (140) transmitted by the projector. Also disclosed herein are fiber-containing structures that have been subjected to the defect detection methods.

Description

DEFECT DETECTION IN MOVING FIBER-CONTAINING STRUCTURES

TECHNICAL FIELD

[0001] This application relates to materials technology in general and more specifically to the preparation, processing and detection of fiber-containing structures such as threadlines, braidlines and wirelay structures. More particularly, this application discloses methods and apparatuses for real-time detection and characterization of defects in fibercontaining structures that are in linear motion.

BACKGROUND OF THE INVENTION

[0002] When producing or processing fiber-containing structures, such as threadlines (e.g., multi-filament threads), braidlines (e.g., braided yarns, braided core-sheath structures, etc.) and wirelay structures (e.g., wire lay ropes), defects can occur due to, for example, the presence of broken filaments and impurities.

[0003] Broken filaments, for example, can occur due to tensioning, bending or twisting of a fiber-containing structure. When broken filaments are present on the surface of a fiber-containing structure undergoing in-line processing, such broken filaments can weaken the fiber-containing structure and can also become detached and then reattach at different locations along the fiber-containing structure leading to additional defects. Broken fibers, whether attached or detached from their original filaments, can change in shape and grow in size during subsequent in-line processing.

[0004] Although the terminology of defects relating to fiber-containing structures can vary widely in the relevant art, the defects resulting from broken filaments and impurities generally fall within two categories. The first category relates to broken filaments (either single filaments or groups of filaments) that extend outward from the surface of the fibercontaining structure as branch-like structures— which are often termed as “fluff” or “peel” defects. The second category relates to broken (detached) fibers, or other impurities, that become attached to the surface of the fiber-containing structure and tend to grow into mound-like structures— which are often termed as “pill” or “slub” defects— during in-line processing. [0005] Because the defects described above can adversely affect the strength and utility of fiber-containing structures, commercially-available products are generally inspected and often rated based on the quantity or concentration of defects. Although the process of rating fiber-containing structures is often performed by human inspectors using magnification devices such as microscopes, manual inspection can be a tedious process that is not well suited to large-scale production. Furthermore, due to the limitations associated with human inspection, real-time corrective intervention to reduce or eliminate the formation of defects is rarely carried out using human inspection during high-speed production or processing of fiber-containing structures.

SUMMARY OF THE DISCLOSURE

[0006] The present inventors have recognized that a need exists to discover methods and apparatuses for reliably detecting defects in fiber-containing structures while in linear motion during production or processing. A need also exists for such methods and apparatuses to enable the differentiation and characterization of the defects, and to either modify or terminate the production or processing of fiber-containing structures in order to reduce the occurrence of defects.

[0007] The following disclosure describes methods and apparatuses for real-time detection of defects in fiber-containing structures that are in linear motion, as well as fibercontaining structures obtained using these methods and apparatuses.

[0008] Embodiments of the present disclosure, described herein such that one of ordinary skill in this art can make and use them, include the following:

(1 ) One aspect relates to methods for detecting defects in fiber-containing structures by linearly passing a fiber-containing structure through at least one defect detector, measuring at least one cross-sectional diameter of the fiber-containing structure with the defect detector to obtain at least one diameter signal of diameter versus length of the fiber-containing structure, 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 combinations thereof, against 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, wherein (a) the defect detector measures the cross-sectional diameter of the fiber-containing structure by transmitting light onto the fiber-containing structure with a projector, detecting a silhouette image of the fibercontaining structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector, and (b) at least one of the defect detector is situated in series with an extrusion apparatus configured to form the fibercontaining structure, 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 stretch the fiber-containing structure, a winding assembly configured to wind the fiber-containing structure onto a bobbin, or combinations thereof;

(2) Another aspect relates to defect-detected fiber-containing structures obtained by performing the methods (1 ) described above; and

(3) Another aspect relates to apparatuses for detecting defects in fibercontaining structures, the apparatuses comprising (A) an extrusion apparatus configured to form a fiber-containing structure, a braiding machine configured to form the fibercontaining structure, a tensioning assembly configured to apply tension to the fibercontaining structure, a finish applicator configured to apply a coating to the fibercontaining structure, a godet roll assembly configured to stretch the fiber-containing structure, a winding assembly configured to wind the fiber-containing structure onto a bobbin, or combinations thereof, (B) a defect detector configured to measure at least one cross-sectional diameter of the fiber-containing structure by transmitting light onto the fiber-containing structure with a projector, detecting a silhouette image of the fibercontaining structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector; and (C) a processor configured to compare at least one diameter signal obtained from the defect detector, optionally at least one signal-processed diameter signal, or combinations thereof, against at least one reference signal to obtain at least one surface defect signal of a surface defect output versus length of the fiber-containing structure, wherein the defect detector measures the at least one cross-sectional diameter while the fiber-containing structure is linearly passing through the defect detector.

[0009] Additional objects, advantages and other features of the present disclosure will be set forth in part in the description that follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present disclosure. The present disclosure encompasses other and different embodiments from those specifically described below, and the details herein are capable of modifications in various respects without departing from the present disclosure. In this regard, the description herein is to be understood as illustrative in nature, and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Embodiments of this disclosure are explained in the following description in view of figures that show:

[0011] FIG. 1A illustrates a non-twisted, non-braided threadline formed of a plurality of filaments or filament-containing strands;

[0012] FIG. 1 B illustrates a braided fiber-containing structure that is formed of a plurality of filaments or filament-containing strands that are braided together;

[0013] FIG. 1C illustrates a core-sheath fiber-containing structure containing 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;

[0014] FIG. 1 D illustrates a wirelay fiber-containing structure containing a core of filaments or filament-containing strands surrounded by a wire-laid cover formed of a plurality of filaments or filament-containing strands that are wire-laid together in the same direction;

[0015] FIG. 2A illustrates a fiber-containing structure with a defect in the form of a “fluff” or “peel” caused by a broken filament; [0016] FIG. 2B illustrates a fiber-containing structure with a defect in the form of a small “pill” or “slub” caused by an impurity attached to the surface of the fiber-containing structure;

[0017] FIG. 2C illustrates a fiber-containing structure with a defect in the form of an elongated “pill” or “slub” caused by built-up of impurities attached to the surface of the fiber-containing structure;

[0018] FIG. 3 illustrates a defect detector configured to detect and measure the cross- sectional diameter of a fiber-containing structure;

[0019] FIG. 4A illustrates a light projecting slit of a defect detector with belt-shaped parallel light passing through the light projecting slit;

[0020] FIG. 4B illustrates a light receiving slit of a defect detector with partially-blocked parallel light passing through the light receiver slit;

[0021] FIG. 5A illustrates a light receiving slit of a defect detector with parallel light partially blocked by a defect-free portion of a fiber-containing structure that is linearly passing through the defect detector;

[0022] FIG. 5B illustrates a light receiving slit of a defect detector with parallel light partially blocked by a defect-containing portion of a fiber-containing structure that is linearly passing through the defect detector;

[0023] FIG. 6A illustrates a moving fiber-containing structure with a peel defect caused by a broken filament, and shows the location of cross-sectional measurements of the fiber-containing structure occurring at regular intervals;

[0024] FIG. 6B illustrates a moving fiber-containing structure with a small slub defect caused by an attached impurity, and shows the location of cross-sectional measurements of the fiber-containing structure occurring at regular intervals;

[0025] FIG. 6C illustrates a moving fiber-containing structure with an elongated slub defect caused by built-up impurities, and shows the location of cross-sectional measurements of the fiber-containing structure occurring at regular intervals;

[0026] FIG. 7 illustrates an apparatus for producing or processing a fiber-containing structure;

[0027] FIG. 8 illustrates an apparatus for braiding and detecting a fiber-containing structure; and

[0028] FIG. 9 illustrates a defect detector array including two biaxial defect detectors arranged in series relative to a fiber-containing structure moving linearly through the defect detector array.

DETAILED DESCRIPTION

[0029] Embodiments of this disclosure include various methods for detecting defects in moving fiber-containing structures, apparatuses for carrying out the defect-detection methods, and defect-detected fiber-containing structures obtained by performing the defect-detection methods described herein. Certain non-limiting applications for the defect-detection methods of the present disclosure are also described herein.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by persons of ordinary skill in the relevant art. In case of conflict, the present specification, including definitions, will control.

[0031] Unless stated otherwise, all percentages, parts, ratios, etc., are by weight.

[0032] When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present disclosure is to be limited to the specific values recited when defining a range.

[0033] The use of “a” or “an” to describe the various elements and components herein is merely for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is clear that it is otherwise intended.

[0034] Unless expressly stated to the contrary, “or” and “and/or” refers to an inclusive and not to an exclusive. For example, a condition A or B, or A and/or B, is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0035] The terms “about” and “approximately” as used herein refer to being nearly the same as a referenced amount or value, and should be understood to encompass ± 5% of the specified amount or value.

[0036] The term “substantially” as used herein, unless otherwise defined, means all or almost all or the vast majority, as would be understood by the person of ordinary skill in the context used. It is intended to take into account some reasonable variance from 100% that would ordinarily occur in industrial-scale or commercial-scale situations.

[0037] Throughout the present description, unless otherwise defined and described, technical terms and methods employed to determine associated measurement values are in accordance with the description of ASTM D855 / D885M - 10A (2014), Standard Test Methods for Tire Cords, Tire Cord Fabrics, and Industrial Filament Yarns Made From Man-made Organic-base Fibers, published October2014.

[0038] For convenience, many elements of the various embodiments disclosed herein are discussed separately. Although lists of options may be provided and numerical values may be in ranges, the present disclosure should not be considered as being limited to the separately described lists and ranges. Unless stated otherwise, each and every combination possible within the present disclosure should be considered as explicitly disclosed for all purposes.

[0039] The materials, methods, and examples herein are illustrative only and, except as specifically stated, are not intended to be limiting. Methods and materials similar or equivalent to those described herein may also be used in the practice of the present disclosure.

Methods for Detecting Defects in Moving Fiber-Containing Structures [0040] Disclosed herein are methods for detecting defects in fiber-containing structures that are in linear motion. The term “fiber-containing structure” includes any cord-like structure formed of fibers and/or filaments, such as threadlines, braidlines, wirelays and core-sheath structures.

[0041] FIGs. 1A thru 1D illustrate examples of fiber-containing structures that may be used in methods of the present disclosure.

[0042] FIG. 1A illustrates an example of a threadline cord 5 comprising a plurality of filaments (or filament-containing strands) 10 arranged as a non-twisted, non-braided bundle. FIG. 1 B illustrates an example of a braidline cord 15 comprising a plurality of filaments (or filament-containing strands) 20 arranged as a braided bundle with no central core. FIG. 1C illustrates an example of a braided cord 25 having a core-sheath structure comprising 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). FIG. 1 D illustrates a wirelay fiber-containing structure 40 having a core-sheath structure comprising a wirelay 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).

[0043] As explained above, certain defects can occur when producing or processing fiber-containing structures due to, for example, damaged filaments or impurities that can become attached to the fiber-containing structures.

[0044] FIG. 2A illustrates a generic fiber-containing structure 60 with a defect 65 in the form of a “fluff” or “peel” caused by a broken filament. Broken filaments can occur, for example, due to tensioning, bending or twisting of a fiber-containing structure. Typically, broken filaments extend outward at an acute angle 70 relative to the direction of travel 75 of the fiber-containing structure 60 in linear motion during processing. However, in some instances the broken filaments may extend outward at an obtuse angle relative to the direction of travel of the fiber-containing structure. In some situations, the broken filaments may include two branch-like structures including a leading-edge branch 67 extending outward at an obtuse angle (shown in FIGs. 5A and 5B) and a trailing-edge branch 65 extending outward at an acute angle (shown in FIG. 2A) relative to the direction of travel.

[0045] FIG. 2B illustrates a generic fiber-containing structure 80 with a defect 85 in the form of a “pill” or “slub” caused by an impurity attached to the surface of the fibercontaining structure 80. The example of FIG. 2B illustrates a small (recently-introduced) impurity in which the point of attachment 87 of the “pill” or “slub” occupies a relatively small area compared to the overall size of the “pill” or “slub”.

[0046] FIG. 2C illustrates a generic fiber-containing structure 90 with a defect 95 in the form of an elongated or enlarged “pill” or “slub” caused by the built-up or shaping of impurities attached to the surface of the fiber-containing structure 90. The example of FIG. 2C illustrates an elongated or enlarged impurity in which the point of attachment 97 of the “pill” or “slub” occupies a relatively large area compared to the overall size of the “pill” or “slub”.

[0047] Defect detection methods of the present disclosure employ defect detectors configured to measure at least one cross-sectional diameter of moving fiber-containing structures.

[0048] Such methods may include the steps of (1 ) linearly passing a fiber-containing structure through at least one defect detector; (2) measuring at least one cross-sectional diameter of the fiber-containing structure with the defect detector to obtain at least one diameter signal of diameter versus length of the fiber-containing structure; (3) optionally signal processing the diameter signal to obtain at least one signal-processed diameter signal; and (4) comparing the diameter signal, the signal-processed diameter signal, or combinations thereof, against 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.

[0049] In some embodiments the defect detector measures the cross-sectional diameter of the fiber-containing structure by transmitting light onto the fiber-containing structure with a projector, detecting a silhouette image of the fiber-containing structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector.

[0050] FIG. 3 illustrates one example 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. In this embodiment the defect detector 100 includes a projector 115 containing a light source 120 and a lens 125, as well as an optical receiver 130 for detecting the silhouette image 105. The cross-sectional diameter of the fiber-containing structure 110 is calculated based on a reduction in an amount of light 135 detected by the optical receiver relative to the total amount of light 140 transmitted by the projector. The optical receiver 130 produces a diameter signal 145 that is sent to a processor 150 configured to (i) optionally perform signal processing of the diameter signal 145 to obtain a signal-processed diameter signal, and to (ii) compare the diameter signal 145, the optional signal-processed diameter signal, or combinations thereof, against at least one reference signal 155 to general at least one surface defect signal 160 of surface defect output versus the length of the fiber-containing structure 110. In the embodiment of FIG. 3, the optical receiver 130 includes an active-pixel sensor 165.

[0051] Various projectors and optical detectors known in the relevant art may be used in defect detectors of the present disclosure. For example, the projector may include laser diodes and/or light-emitting diodes, and the optical receiver may include an active-pixel sensor. Active-pixel sensors that are used in optical detectors of the present disclosure may include photodiode image sensors, charge-coupled device (CCD) image sensors, complementary metal-oxide-sem iconductor (CMOS) image sensors, or combinations thereof.

[0052] Methods of the present disclosure may employ commercially-available devices capable of detecting the silhouette image of a fiber-containing structure in linear motion. For example, transmissive dimension measuring devices described in US 2010/0271638 by Torii et al. may be used as defect detectors in methods and apparatuses of the present disclosure.

[0053] Methods of the present disclosure may also employ different types of detectors known in the relevant art that are capable of imaging the surface of a fiber-containing structure in linear motion. For example, the detection method may also include a step of imaging a surface of the fiber-containing structure with at least one imaging detector capable of imaging the surface by illuminating the fiber-containing structure with an imaging light and receiving a reflected image of the surface with an imaging receiver. Alternatively, detection methods of the present disclosure may not include imaging a surface of the fiber-containing structure with an imaging detector that receives a reflected image of the surface.

[0054] FIGs. 4A and 4B illustrate how defect detectors of the present disclosure can measure a cross-sectional diameter of a fiber-containing structure.

[0055] As explained and illustrated above, the defect detector 100 measures the cross- sectional diameter of the fiber-containing structure 110 by transmitting light 140 onto the fiber-containing structure 110 with a projector 115, and then detecting a silhouette image 105 of the fiber-containing structure 110 with an optical receiver 130, see FIG. 3.

[0056] FIG. 4A illustrates an embodiment wherein the projector 115 includes a lightprojecting slit 170 through which light transmitted from the light source 120 passes and is shaped into a belt-shaped, parallel light beam 175. FIG. 4B illustrates an embodiment wherein the corresponding optical receiver 130 includes a light-receiving slit 185 through which the partially-blocked parallel light beam 135 passes prior to being detected by, for example, the active-pixel sensor 165.

[0057] In the illustrations of FIGs. 4A and 4B, the presence of a defect-free portion 190 of the fiber-containing structure 110 (being linearly passed through the defect detector 100 at a linear rate v) causes a portion of the parallel light beam 175 to be blocked— such that an amount A^D of the partially-blocked parallel light beam 135 detected by the optical receiver 130 is less than an amount A^T of the parallel light beam 175 transmitted by the projector 115. The blocked portion of the parallel light beam 135 corresponds to the silhouette image 105 of the fiber-containing structure 110. In this manner the cross-sectional diameter D of the fiber-containing structure 110 may be calculated based on 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—/.©., D ~ (A^T - A^D).

[0058] FIGs. 5A and 5B illustrate how the silhouette image 105 of the fiber-containing structure changes when the defect detector 100 detects a defect.

[0059] FIG. 5A illustrates the light-receiving slit 185 of the defect detector 100 at a time when the parallel light beam 175 is partially blocked by the defect-free portion 190 of the fiber-containing structure 110 (being linearly passed through the defect detector 100 at a linear rate v). As explained above, the blocked portion of the parallel light beam 135 corresponds to a silhouette image 105' of the fiber-containing structure 110. In this manner the cross-sectional diameter Di of the defect-free portion 190 at the time ti may be calculated based on the difference between the amount A^T of the transmitted parallel light beam 175 and the amount A^Di of the partially-blocked parallel light beam 135 — /.e., DI ~ (A^T -A^DI).

[0060] FIG. 5B illustrates the light-receiving slit 185 of the defect detector 100 at a time fcwhen the parallel light beam 175 is partially blocked by a defect-containing portion 195 of the fiber-containing structure 110 (being linearly passed through the defect detector 100 at a linear rate v). At time (2, the blocked portion of the parallel light beam 200 corresponds to a silhouette image 105" of the fiber-containing structure 110. In this manner the cross-sectional diameter D20f the defect-containing portion 195 at the time (2 may be calculated based on the difference between the amount A^T of the transmitted parallel light beam 175 and the amount A^D2 of the partially-blocked parallel light beam

[0061] Because the defect-containing portion 195 illustrated in FIG. 5B includes the defect 67 in the form of a “fluff” or “peel” caused by a broken filament, more of the parallel light beam 175 is blocked at the time compared to the time ti. Consequently, in this illustration, the calculated cross-sectional diameter D2 of the defect-containing portion 195 in FIG. 5B is greater than the calculated cross-sectional diameter Di of the defect-free portion 190 in FIG. 5A. In other embodiments, the cross-sectional diameter D2 of the defect-containing portion may be less than the cross-sectional diameter Di of the defect- free portion of the fiber-containing structure 110. For example, when a portion of a broken filament breaks off from the fiber-containing structure, then the resulting defectcontaining portion may have a smaller cross-sectional diameter compared to the corresponding cross-sectional diameter of the defect-free portions of the fibercontaining structure.

[0062] As explained below in greater detail, the measuring of at least one cross- sectional diameter of the fiber-containing structure with at least one defect detector occurs at regular (time / distance) intervals as the fiber-containing structure is linearly passed through the defect detector at a linear rate v. In doing so, the measuring of the at least one cross-sectional diameter may 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 detector is adjusted such that the measuring occurs at constant intervals along the length of the fiber-containing structure. Constant intervals over which the measurements occur may range from about 10 nm to about 1 cm.

[0063] Following the steps 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, methods of the present disclosure may include the step of comparing the diameter signal and/or the signal-processed diameter signal against 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. As explained below, the at least one surface defect signal may relate to the magnitude, slope and/or curvature of the diameter signal.

[0064] The surface defect signal may include a magnitude surface defect count signal of a magnitude surface defect count versus the length of the fiber-containing structure. The magnitude surface defect count signal is generated by comparing the diameter signal against a reference signal of a maximum cross-sectional diameter versus the length of the fiber-containing structure. A magnitude surface defect count of zero occurs when a 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 of greater than zero 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, such that the magnitude surface defect count of greater than zero may be a positive integer corresponding to a percentage of the magnitude of the diameter signal above the maximum cross-sectional diameter relative.

[0065] The surface defect signal may include a slope surface defect count signal of a slope surface defect count versus the length of the fiber-containing structure. The slope surface defect count signal is generated by comparing the signal-processed diameter signal against a reference signal of a maximum first derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a first derivative of the diameter signal. A slope surface defect count of zero occurs when an 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 fibercontaining structure. A slope surface defect count of 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 the particular point along the length of the fibercontaining structure, such that the slope surface defect count of greater than zero may be a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal above the maximum first derivative of the diameter signal.

[0066] The surface defect signal may include a curvature surface defect count signal of a curvature surface defect count versus the length of the fiber-containing structure. The curvature surface defect count signal is generated by comparing the signal- processed diameter signal against a reference signal of a maximum second derivative of the diameter signal versus the length of the fiber-containing structure, where the signal- processed diameter signal is obtained by signal processing the diameter signal to obtain a second derivative of the diameter signal. A curvature surface defect count of zero occurs when an 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 count of 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 the particular point along the length of the fiber-containing structure, such that the curvature surface defect count of greater than zero may be a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal above the maximum second derivative of the diametersignal.

[0067] Detection methods of the present disclosure may also include a step of differentiating and/or categorizing defects contained in a fiber-containing structure based, at least in part, on the magnitude, slope and/or curvature of the diameter signal. Detection methods of the present disclosure may also include a step of generating a surface defect rating of the fiber-containing structure based on the magnitude, slope and/or curvature of the diameter signal.

[0068] FIGs. 6A thru 6C illustrate how changes in the cross-sectional diameters of defect-containing portions of fiber-containing structures can be used to count, differentiate and categorize different defects.

[0069] FIG. 6A illustrates the location of cross-sectional measurements taken of a fibercontaining structure 110 at regular intervals occurring at times ti through ts. The fibercontaining structure 110 (being linearly passed through the defect detector 100 at a linear rate v) includes a defect-containing portion 195 having a defect 65 in the form of a “fluff or a “peel” caused by a broken filament. In this illustration, the calculated cross- sectional diameters at times ts, ts, t4 and ts indicate the presence of the “fluff” or “peel” defect 65 caused by the broken filament.

[0070] Focusing on the magnitude of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6A illustrates wherein (i) the magnitude slightly increases at the time ts relative to the time ts (magnitude surface defect count of slightly greater than zero occurs at the time ts), (ii) the magnitude increases more dramatically at time t4 relative to time ts (magnitude surface defect count of significantly greater than zero occurs at time t4), and then (iii) the magnitude abruptly decreases at the time ts relative to the time t4 (magnitude surface defect count of zero occurs at time ts . This pattern of the slight increase in the magnitude surface defect count at the time ts, in conjunction with the abrupt decrease in the magnitude surface defect count at the time tsback to zero, indicates the presence of a “fluff” or “peel” defect caused by a broken filament having only a single branch (/.e., a trailing-edge branch extending outward at an acute angle relative to the direction of travel - see FIG. 2A).

[0071] Focusing on the slope of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6A illustrates wherein (i) the slope increases at the time fj relative to the time t2 (slope surface defect count of slightly greater than zero occurs at the time ts), (ii) the slope remains constant or slightly increases at time t4 relative to time t3 (slope surface defect count of greater than zero occurs at time t4), and then (iii) the slope abruptly decreases at the time ts relative to the time t4 (slope surface defect count of zero occurs at time ts). This pattern of the increase in the slope surface defect count at the time ts, in conjunction with the abrupt decrease in the slope surface defect count at the time ts back to zero, indicates the presence of a “fluff” or “peel” defect caused by a broken filament having only a single branch (/.e. , a trailing-edge branch extending outward at an acute angle relative to the direction of travel - see FIG. 2A).

[0072] FIG. 6B illustrates the location of cross-sectional measurements taken of a fibercontaining structure 110 at regular intervals occurring at times ti through ts. The fibercontaining structure 110 (being linearly passed through the defect detector 100 at a linear rate v) includes a defect-containing portion 195 having a defect 85 in the form of a small “pill’ or a “slub” caused by an impurity attached to the surface of the fiber-containing structure 110. In this illustration, the calculated cross-sectional diameters at times t2, ts, t4 and ts indicate the presence of the “pill” or “slub” defect 85 caused by the impurity.

[0073] Focusing on the magnitude of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6B illustrates wherein (i) the magnitude abruptly increases at the time ts relative to the time t2 (magnitude surface defect count of significantly greater than zero occurs at the time ts), (ii) the magnitude increases only slightly at time t4 relative to time ts (magnitude surface defect count increases slightly at time t4 relative to the time ts , and then (iii) the magnitude abruptly decreases at the time ts relative to the time t4 (magnitude surface defect count of zero occurs at time ts . This pattern of the abrupt and significant increase in the magnitude surface defect count at the time ts, in conjunction with the abrupt decrease in the magnitude surface defect count at the time fa back to zero, indicates the presence of a small “pill” or “slub” defect caused by a recently-introduced impurity.

[0074] Focusing on the slope of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6B illustrates wherein (i) the slope increases at the time fa relative to the time t2 (slope surface defect count of greater than zero occurs at the time fa), (ii) the slope reduces to nearly zero at the time t4 relative to the time fa (slope surface defect count of around zero occurs at time t4), and then (iii) the slope returns to zero at the time ts relative to the time t4 (slope surface defect count of zero occurs at time ts). This pattern of the increase in the slope surface defect count at the time fa, in conjunction with the abrupt decrease in the slope surface defect count at the time f4 and the decrease in the slope surface defect count back to zero at the time ts, indicates the presence of a “pill” or “slub” defect caused by a recently- introduced impurity.

[0075] Focusing on the curvature of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6B illustrates wherein (i) the curvature increases at the time fa relative to the time fa (curvature surface defect count of greater than zero occurs at the time fa), (ii) the curvature reduces to nearly zero at the time t4 relative to the time fa (curvature surface defect count of near zero occurs at time f4), and then (iii) the curvature remains at zero at the time ts relative to the time t4 (curvature surface defect count of zero occurs at time fa). This pattern of the increase in the curvature surface defect count at the time fa, in conjunction with the reduction in curvature surface defect count to zero at the times t4 and ts, indicates the presence of a “pill” or “slub” defect caused by a recently-introduced impurity.

[0076] FIG. 6C illustrates the location of cross-sectional measurements taken of a fibercontaining structure 110 at regular intervals occurring at times ti through ts. The fibercontaining structure 110 (being linearly passed through the defect detector 100 at a linear rate v) includes a defect-containing portion 195 having a defect 95 in the form of an elongated or enlarged “pill’ or a “slub” caused by the built-up or shaping of impurities attached to the surface of the fiber-containing structure 110. In this illustration, the calculated cross-sectional diameters at times t2, ts, f4and ts indicate the presence of the “pill” or “slub” defect 95 caused by the impurity. [0077] Focusing on the magnitude of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6C illustrates wherein (i) the magnitude increases slightly at the time ts relative to the time t2 (magnitude surface defect count of slightly greater than zero occurs at the time fa), (ii) the magnitude increases more dramatically at time relative to time fa (magnitude surface defect count increases dramatically at time t4 relative to the time fa), and then (iii) the magnitude decreases at the time ts relative to the time t4 (magnitude surface defect count of slightly greater than zero occurs at time ts). This pattern of the slight increase in the magnitude surface defect count at the time fa, in conjunction with the increase in the magnitude surface defect count at the time t4 and then the decrease in the magnitude surface defect count at the time ts, indicates the presence of an elongated or enlarged “pill’ or a “slub” caused by the built- up or shaping of impurities.

[0078] Focusing on the slope of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6C illustrates wherein (i) the slope increases at the time fa relative to the time fa (slope surface defect count of greater than zero occurs at the time fa), (ii) the slope reduces to nearly zero at the time t4 relative to the time fa (slope surface defect count of around zero occurs at time f^), and then (iii) the slope increases again at the time ts relative to the time t4 (slope surface defect count of greater than zero occurs at time fs). This pattern of the increase in the slope surface defect count at the time fa, in conjunction with the abrupt decrease in the slope surface defect count to around zero at the time t4 and the increase in the slope surface defect count at the time ts, indicates the presence of an elongated or enlarged “pill’ or a “slub” caused by the built-up or shaping of impurities.

[0079] Focusing on the curvature of cross-sectional diameter of the fiber-containing structure 110 within the defect-containing portion 195, FIG. 6C illustrates wherein (i) the curvature increases at the time fa relative to the time fa (curvature surface defect count of greater than zero occurs at the time fa), (ii) the curvature reduces to nearly zero at the time t4 relative to the time fa (curvature surface defect count of around zero occurs at time f4), and then (iii) the curvature increases again at the time ts relative to the time t4 (curvature surface defect count of greater than zero occurs at time ts). This pattern of the increase in the curvature surface defect count at the time fa, in conjunction with the abrupt decrease in the curvature surface defect count to around zero at the time t4 and the increase in the curvature surface defect count at the time ts, indicates the presence of an elongated or enlarged “pill’ or a “slub” caused by the built-up or shaping of impurities.

[0080] In general, the ability to differentiate and categorize different defects contained in a fiber-containing structure, being linearly passed through at least one defect detector, can be improved by increasing the sampling rate of the measuring. Thus, for example, if the number of the measurement intervals in FIGs. 6A thru 6C were doubled— such that 16 measurements are taken over the same length of the fiber-containing structure 110— then the ability to differentiate and categorize the different defects could be improved, because the patterns described above could be detected with greaterresolution.

[0081] In some embodiments the defect detection method may include an additional step of changing a linear rate of the fiber-containing structure, based on the surface defect signal. For example, the linear rate of the fiber-containing structure may be reduced in order to increase the number of measurement intervals— thereby increasing the sensitivity and improving the ability to differentiate and categorize the different defects. In this regard, defect detection methods of the present disclosure may employ at least one speedometer to measure the linear rate of the fiber-containing structure. In some embodiments the fiber-containing structure may be linearly passed through the at least one defect detector at a linear rate of at least 300 meters per minute, while in other embodiments the linear rate may be less than 10 centimeters per minute. In some embodiments, for example where the fiber-containing structure is a braided fibercontaining structure or a wire-laid fiber-containing structure having textured surfaces, the fiber-containing structure may be linearly passed through the at least one detector at a linear rate of from less than 10 centimeters per minute to at least 1 meter per minute.

[0082] In some embodiments the defect detection method may include an additional step of changing the sampling rate of measuring the at least one cross-sectional diameter, based on the surface defect signal. For example, the sampling rate may be increased in order to increase the number of measurement intervals— thereby increasing the sensitivity and improving the ability to differentiate and categorize the different defects.

[0083] Regarding the reference signals used to generate the various surface defect signals (e.g., based on the magnitude, slope and/or curvature of the cross-sectional diameter), the reference signals may be constant reference signals that are constant along the length of the fiber-containing structure, the reference signals may be variable reference signals that change at one or more points along the length of the fibercontaining structure, or combinations thereof.

[0084] At least one of the defect detector may be situated in series with at least one roller, at least one extrusion apparatus configured to form the fiber-containing structure, at least one braiding machine configured to form the fiber-containing structure, at least one tensioning assembly configured to apply tension to the fiber-containing structure, at least one finish applicator configured to apply a coating to the fiber-containing structure, at least one godet roll assembly configured to stretch the fiber-containing structure, at least one winding assembly configured to wind the fiber-containing structure onto a bobbin, or combinations thereof. Other apparatuses commonly used to handle, process and/or measure fiber-containing structure may also be situated in series with defect detectors of the present disclosure.

[0085] FIG. 7 illustrates an apparatus for producing or processing a fiber-containing structure, in which a plurality of defect detectors 205, 206, 207, 208, 209 and 210 (or the defect detector arrays described below) are situated with a tensioning assembly 215, a finish applicator 220, a godet roll assembly 225, and a winding assembly 230. In this example, the fiber-containing structure 110 is linearly passed from a bobbin or upstream process 235 thru the tensioning assembly 215, which is situated in series with the surrounding defect detectors 205 and 206, then over a first roller 240 and thru the finish applicator 220, which is situated in series with the surrounding defect detectors 207 and 208, then over a second roller 245 and thru the godet roll assembly 225, which is situated in series with the defect detector 209, then over a third roller 250 and into the winding assembly 230 which includes a dancer arm 255, a traverse guide assembly 260 and a finish bobbin 265. Upstream processes 235 may include, for example, an extrusion, winding or braiding process for producing the fiber-containing structure 110.

[0086] Detection methods of the present disclosure may include a step of forming the fiber-containing structure by an extrusion process, wherein at least one of the defect detector is situated in series with the extrusion apparatus. Detection methods of the present disclosure may also include a step of forming the fiber-containing structure by a braiding process, wherein at least one of the defect detector is situated in series with the braiding machine. Defect detectors may also be situated within a braiding apparatus, for example, between at least one carrier bobbin (or carrier guide) and the winding shaft.

[0087] Detection methods of the present disclosure may also include a step of modifying an operation of the extrusion apparatus, the braiding machine, the tensioning assembly, the finish applicator, the godet roll assembly, the winding assembly, the linear rate, or combinations thereof, based on the surface defect signal. For example, if the method detects an increase in the surface defect output beginning immediately downstream of the finish applicator 220, then the operation of the finish applicator could be modified by reducing the linear rate v of the fiber-containing structure, or by altering the operational parameters of the finish applicator 220 to reduce the surface defect output.

[0088] Defect detector arrays comprising at least two defect detector situated in series may also be employed in methods of the present disclosure. FIG. 8 illustrates an embodiment wherein a defect detector array 270 is situated downstream of a braiding machine 275 and upstream of a downstream process 280 such as the tensioning assembly 215, the finish applicator 220, the godet roll assembly 225, and/or the winding assembly 230 described above. In the example of FIG 8, the defect detector array 270 includes two defect detectors 285 and 290 situated in series. In some embodiments the defect detectors of a defect detector array may be rotated relative to one another by a detector offset angle, such that different silhouette images of the fiber-containing structure are detected by the at least two detect detectors. The detector offset angle may range from 1 ° to less than 360°.

[0089] Defect detectors of the present disclosure may include multi-axis defect detectors capable of simultaneously measuring a plurality of cross-sectional diameters of a fiber-containing structure from different directions.

[0090] In one embodiment a biaxial defect detector includes two projectors for transmitting the light onto the fiber-containing structure, and two optical receivers for detecting the silhouette image of the fiber-containing structure. The two projectors may include a projector A for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B for transmitting a light B onto a surface B of the fibercontaining structure. The two optical receivers may include an optical receiver A for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B for detecting a silhouette image B of the fiber-containing structure. In this scenario, the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B. The projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle. In some embodiments the projector offset angle and the optical receiver offset angle may independently range from 5° to 175°.

[0091] FIG. 9 illustrates a defect detector array 295 including two biaxial defect detectors a 300 and [3 305 mounted in series relative to a fiber-containing structure 110 moving linearly through the defect detector array 295 at a linear rate v. Each of the two biaxial defect detectors a 300 and [3 305 include the projector A 310 and the projector B 315, as well as the optical receiver A 320 and the optical receiver B 325. The projector A 310 is optically aligned with the optical receiver A 320, and the projector B 315 is optically aligned with the optical receiver B 325. In the biaxial defect detector a 300, the projector A 310 and the projector B 315 are rotated relative to one another by a projector offset angle AO_a, where AO_a = ¹ _a - <t>²a. In the biaxial defect detector |3 305, the projector A 310 and the projector B 315 are rotated relative to one another by a projector offset angle AOp, where AOp = 0¹p -

[0092] In the embodiment of FIG. 9 the biaxial defect detectors a 300 and [3 305 are also offset relative to one another by a detector offset angle of approximately 90°, and set apart by a linear separation distance d 330. In some embodiments the detector offset angle may range from 1⁰ to less than 360°. In some embodiments the separation distance d may range from about 1 mm to about 100 mm. Other embodiments of the present disclosure may employ defect detector arrays having at least three of the defect detectors arranged in series. Fiber-Containing Structures

[0093] The present disclosure also relates to fiber-containing structures obtained by the defect detection methods disclosed herein. As explained above, fiber-containing structures may include is threadlines, braidlines or core-sheath structures having a braided or laid sheath. Threadlines may have twist levels of less than 10 turns per meter, or even less than 1 turn per meter.

[0094] The term “core-sheath structure” as used herein describes cord-like structures having an outer sheath (jacket) of braided strands at least partially surrounding a central core. FIGs. 1C and 1D illustrate core-sheath structures having braided and wire-laid sheaths respectively.

[0095] Fiber-containing structures of this disclosure may include core-sheath structures having shape-controlled (flattened) jackets of low thickness than can more tightly conform to the outer surface of the core in order to control the texturing and surface roughness of the outside surface of the core-sheath structures. Such shaped-controlled core-sheath structures include those described in U.S. Provisional Application No. 63/044,418, which was filed on June 26, 2020, the entire contents of which are incorporated herein by reference.

[0096] Fiber-containing structures of this disclosure may also include braided cords with changing cross-sectional areas. Such braided cords with changing cross-sectional area include those described in U.S. Provisional Application No. 63/069,182, which was filed on August 24, 2020, the entire contents of which are incorporated herein by reference.

[0097] In some embodiments the surface coverage of the braided sheath over the core is at least 85%. In other embodiments the 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 with one another. In some embodiments the surface coverage may range from about 25% to about 150%. For example, the surface coverage may range from about 50% to about 125%, or from about 75% to about 110%, or from about 85% to about 105%, or from about 90% to about 100%.

[0098] In some core-sheath structures, the surface coverage may fall significantly below 100% (due to the deliberate presence of gaps) or significantly above 100% (due to strands of the jacket (sheath) being overlapped). Such embodiments can be advantages, for example, when it is beneficial to obtain a jacket (sheath) of higher surface roughness (due to the presence of gaps and/or protrusions) or when addition protection for the core (due to the presence of overlapping strands) is desired.

[0099] The pick count of a braided sheath in a relaxed state (i.e. , a natural resting state where no tension is applied to the core-sheath structure) may range from 30 to 3000 filament unit crossovers per meter. In other embodiments the pick count of the braided sheath may range from about 30 to 3000 crossovers per meter, or from about 50 to about 2000 crossovers per meter, or from about 50 to 1000 crossovers per meter, in the relaxed state.

[0100] The strand (end) count of a braided sheath depends upon the requirements of the core-sheath structure and the capabilities of the braiding device. Strand (end) counts ranging from 3 to more than 200 may be employed depending upon the particular application. In some embodiments the strand (end) count of the braided sheath may range from 4 to 96 ends, and in other applications a strand (end) count limited to about 24 ends may be appropriate. For example, the strand (end) count of core-sheath structures of the present disclosure may range from 4 to 24 ends, or from 4 to 16 ends, or from 4 to 12 ends, or from 4 to 8 ends, or from 4 to 6 ends. In medical applications, core-sheaths structures of the present disclosure often range from 4 to 24 ends.

[0101] The braid angle of a braided sheath in a relaxed state generally ranges from about 5° to about 85°. In other embodiments the braid angle of the S- and Z-strands of the braided sheath in the relaxed state may range from about 5° to about 60°, or from about 10° to about 75°, or from about 15° to about 60°, or from about 20° to about 45°, or from about 5° to 45°.

[0102] Braid angle selection can have a profound effect on the properties of coresheath structures used as fiber-containing structures of the present disclosure. For example, reducing the braid angle tends to increase the modulus and/or the 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. Braid angle selection can also be used to control load sharing between core and the jacket (sheath). In some embodiments a balance of load sharing between the core and the jacket (sheath) is important for obtaining core-sheath structures having optimal tensile strength and durability properties.

[0103] Fiber-containing structure of the present disclosure may include core-sheath structures comprising a core and a braided sheath of strands surrounding the core, wherein the braided sheath comprising strands having a braid angle of 5° or more in a relaxed state, and the strands having the braid angle of 5° or more in the relaxed state include at least one shaped strand of filaments. Such core-sheath structures may be produced such that the shaped strand of filaments is an untwisted strand having a twist level of less than 1 turn per meter, a cross-sectional aspect ratio of the shaped strand of filaments is at least 3:1 as measured in the braided sheath, a thickness of at least a portion of the braided sheath ranges from about 20 to about 200 pm, and/or the braided sheath contains a synthetic fiber having a tensile strength of greater than 12 cN/dtex.

[0104] Core-sheath structures of the present disclosure include embodiments wherein the braided sheath contains at least one untwisted shaped strand of filaments having a twist level of less than 0.75 turn per meter, or less than 0.5 turn per meter, or less than 0.25 turn per meter.

[0105] In some embodiments the cross-sectional aspect ratio of the shaped strand filaments ranges from 3: 1 to 50: 1 , or ranges from 3: 1 to 20: 1 , or ranges from 4: 1 to 15: 1 , or ranges from 5:1 to 10:1. In other instances the cross-sectional aspect ratio of the shaped strand of filaments may range from about 3:1 to about 50:1 (ovality about 68- 98%), or from about 4.1 :1 to about 50:1 (ovality about 75.5-98%), or from about 5.6:1 to about 50:1 (ovality about 82-98%), or from about 8:1 to about 22.2:1 (ovality about 87.5- 95.5%).

[0106] The thickness of at least a portion of the braided sheath may range from about 16 pm to about 250 pm, or from about 40 pm to about 200 pm, or from about 50 pm to about 175 pm, or from about 60 pm to about 150 pm, or from about 50 pm to about 125 pm. [0107] Fiber-containing structures of the present disclosure may contain a synthetic fiber having a tensile strength of greater than 12 cN/dtex. The synthetic fiber 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 fiber contained in the braided sheath may have a tensile strength ranging from 13 cN/dtex to 50 cN/dtex, or from 15 cN/dtex to 45 cN/dtex.

[0108] In addition to the synthetic fiber having a tensile strength of greater than 12 cN/dtex, fiber-containing structures of the present disclosure may include other synthetic and non-synthetic fibers and filaments having tensile strengths ranging from about 1 cN/dtex to about 30 cN/dtex. For example, some fiber-containing structure may include at least one synthetic fiber having the tensile strength of greater than 12 cN/dtex and at least one synthetic or non-synthetic fiber having a tensile strength of less than 12 cN/dtex.

[0109] Fiber-containing structures of the present disclosure may also have a maximum (outer) diameter ranging from about 15 pm to about 20 mm. In other embodiments the outer diameter may range from about 20 pm to about 8 mm, or from about 30 pm to about 5 mm, or from about 50 pm to about 3 mm, or from about 50 pm to about 1 mm.

[0110] A wide variety of core sizes may also be used in core-sheath structures of the present disclosure. For example, a maximum diameter of the core may range from about 10 pm to about 20 mm. In other embodiments the maximum diameter of the core may range from about 15 pm to about 10 mm, or from about 25 pm to about 5 mm, or from about 50 pm to about 1 mm, or from about 50 pm to about 500 pm.

[0111] Core-sheath structures of the present disclosure may employ twisted or nontwisted cores, as well as mono-filament cores. In some embodiments the core comprises at least two core strands twisted together at a twist level of from greater than 0 to 1600 turns per meter. The number of core strands included in the twisted or untwisted core may range from 1 to 500, and the twist level of the core or the core strands used to produce a multi-strand core may range from 1 to 1600 turns per meter. Combinations of twisted, non-twisted, and/or braided filaments may also be used to produce cores in the core-sheath structures of the present disclosure.

[0112] Embodiments of the present disclosure include core-sheath structures comprising a round core with a circular cross section and a braided sheath consisting of shaped strands, wherein the flattening factor of the shaped strands ranges from about 0.05 to about 0.45. 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.

[0113] In some embodiments the core in the core-sheath structures is a surface treated core. For example, the core component surface may be corona or plasma treated prior to application of the braided sheath. Such treatment may create surface imperfections or modifications that enhance contact (surface interaction) between the core and an inner surface of the braided sheath, further enhancing the interaction between the core and the braided sheath.

[0114] 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 step are shaped strands, whereas in other embodiments only a fraction of the strands used in the braiding step are shaped strands. For example, in some embodiments all of the S-strands braided in the left-hand direction are shaped strands, whereas all of the Z-strands braided in the right-hand direction are non-shaped strands that are not subjected to the shaping step that occurs before the braiding step, or vice versa. In still other embodiments only a fraction of one or both of the S- and Z- strands may be shaped strands. Embodiments of the present disclosure include coresheath structures including only one shaped strand in the braided sheath, or including all (100%) shaped strands in the braided sheath, or including any combination between one shaped strand and 100% of shaped strands in the braided sheath.

[0115] Fiber-containing structures of the present disclosure also include core-sheath structures in which the braided sheath is a hybrid jacket including at least one of the shaped strand of filaments having a cross-sectional aspect ratio of at least 3:1 and at least one non-shaped strand of filaments having a cross-sectional aspect ratio of less than 2:1. For example, in some embodiments the braided sheath is a hybrid jacket including at least one shaped strand of filaments having a cross-sectional aspect ratio of at least 3:1 and at least one twisted (non-shaped) strand of filaments having a twist level of greater than 0 to 1600 turns per meter. As explained above, a twisted filament bundle (i.e., twisted strand) is more rigid and less prone to shaping compared to an untwisted filament bundle.

[0116] Core-sheath structures used as the fiber-containing structure of the present disclosure may also include triaxial braided sheaths comprising, in addition to S-strands braided in the left-hand direction and Z-strands braided in the right-hand direction, longitudinal strands having a braid angle of less than 5° in a relaxed state. In some embodiments the triaxial braided sheath may include at least one shaped longitudinal strand formed by shaping at least one of the longitudinal strands prior to the braiding of the plurality of strands. For example, a triaxial braided sheath of the present disclosure may include, in addition to the S- and Z-strands, one shaped longitudinal strand, all shaped longitudinal strands, or any combination in between.

[0117] Fiber-containing structures of the present disclosure may also contain additional components such as a lubricant, a fiber, a surface-coated filament, or combinations thereof. Lubricants used in fiber-containing structures of the present disclosure may include at least one of a lubricating filament and a lubricating fiber. Surface-coated filaments may include cross-linked or non-cross-linked silicone polymers as the surface coating.

[0118] Fiber-containing structures of the present disclosure may 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 may range 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.

[0119] Fiber-containing structures of the present disclosure may include organic fibers. The chemical composition of fibers contained in fiber-containing structures of the present disclosure may be of any high performance polymer known to provide a combination of high tensile strength, high tenacity and low creep and may be selected from but is not restricted to liquid crystalline polyester filaments, aramid filaments, copolymer aramid filaments, polyether ether ketone filaments, poly(p-phenylene benzobisoxazole) (PBO) filaments, ultra-high molecular weight polyethylene filaments, high modulus polyethylene filaments, polypropylene filaments, polyethylene terephthalate filaments, polyamide filaments, high-strength polyvinyl alcohol filaments, polyhydroquinone diimidazopyridine (PIPD) filaments, and combinations thereof, just to name a few.

[0120] Polyhydroquinone diimidazopyridine (PIPD) filament fibers are based on polymers of the following repeating unit:

[0121] Fiber-containing structures of the present disclosure may include at least one selected from a liquid crystalline polyester filament, an aramid filament, co-polymer aramid filament, a polyether ether ketone filament, a poly(p-phenylene benzobisoxazole) filament, an ultra-high molecular weight polyethylene filament, a high modulus polyethylene filament, a polypropylene filament, a polyethylene terephthalate filament, a polyamide filament, a polyhydroquinone diimidazopyridine filament, and a high-strength polyvinyl alcohol filament. In other embodiments at least two of these materials may be included in the fiber-containing structures.

[0122] In some embodiments the fiber-containing structures may contain at least one fiber selected from a liquid crystalline polyester fiber, an aramid fiber, a PBO fiber, an ultra-high molecular weight polyethylene fiber, and a high strength polyvinyl alcohol fiber. In other embodiments the shaped and/or non-shaped strands of the braided sheath may be selected from a liquid crystalline polyester fiber and an aramid fiber, and particularly a liquid crystalline polyesterfiber.

[0123] Core-sheath structures of the present disclosure may, in some embodiments, include a core comprising at least one selected from the group consisting of a liquid crystalline polyester filament, an aramid filament, co-polymer aramid filament, a polyether ether ketone filament, a poly(phenylene benzobisoxazole) filament, an ultra-high molecular weight polyethylene filament, a polypropylene filament, a high modulus polyethylene filament, a polyethylene terephthalate filament, a polyamide filament, and a high-strength polyvinyl alcohol filament.

[0124] Polymerized units may include those illustrated shown in Table 1.

Table 1

(in which m = 0 to 2, and Y = a substituent selected from a hydrogen atom, a halogen atom, an alkyl group, an aryl group, art aralkyl group, an alkoxy group, an aryloxy group, and an aralkyloxy group)

[0125] Regarding the polymerized units illustrated in Table 1 above, the number of Y substituent groups is equal to the maximum number of substitutable positions in the ring structure, and each Y independently represents a hydrogen atom, a halogen atom (for example, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, etc.), an alkyl group (for example, an alkyl group having 1 to 4 carbon atoms such as a methyl group, an ethyl group, an isopropyl group, or a t-butyl group), an alkoxy group (for example, a methoxy group, an ethoxy group, an isopropoxy group, an n-butoxy group, etc.), an aryl group (for example, a phenyl group, a naphthyl group, etc.), an aralkyl group [a benzyl group (a phenylmethyl group), a phenethyl group (a phenylethyl group), etc.], an aryloxy group (for example, a phenoxy group, etc.), an aralkyloxy group (for example, a benzyloxy group, etc.), or mixtures thereof. [0126] Liquid crystalline polyester fibers may be obtained by melt spinning of a liquid crystalline polyester resin. The spun fiber may be further heat treated to enhance mechanical properties. The liquid crystalline polyester may be composed of a repeating polymerized unit, for example, derived from an aromatic diol, an aromatic dicarboxylic acid, or an aromatic hydroxycarboxylic acid. The liquid crystalline polyester may optionally further comprise a polymerized unit derived from an aromatic diamine, an aromatic hydroxyamine, and/or an aromatic aminocarboxylic acid.

[0127] More specific polymerized units are illustrated in the following structures shown in Tables 2-4 below.

[0128] When the polymerized unit in the formulas is a unit which can represent plural structures, two or more units may be used in combination as polymerized units constituting a polymer.

[0129] In the polymerized units of Tables 2, 3, and 4, n is an integer of 1 or 2, and the respective units n = 1 , n = 2 may exist alone or in combination; and Yi and Y2 each independently may be a hydrogen atom, a halogen atom (for example, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, etc.), an alkyl group (for example, an alkyl group having 1 to 4 carbon atoms such as a methyl group, an ethyl group, an isopropyl group, or a t-butyl group), an alkoxy group (for example, a methoxy group, an ethoxy group, an isopropoxy group, an n-butoxy group, etc.), an aryl group (for example, a phenyl group, a naphthyl group, etc.), an aralkyl group (a benzyl group (a phenylmethyl group), a phenethyl group (a phenylethyl group), etc.), an aryloxy group (for example, a phenoxy group, etc.), an aralkyloxy group (for example, a benzyloxy group, etc.), or mixtures thereof. Among these groups, Y is preferably a hydrogen atom, a chlorine atom, a bromine atom, or a methyl group. Table 2

Table 3

Table 4

[0130] Z in (14) of Table 3 may comprise divalent groups represented by the formulae below.

[0131] In some embodiments a liquid crystalline polyester may be a combination comprising a naphthalene skeleton as a polymerized unit. Particularly, it may include both a polymerized unit (A) derived from hydroxybenzoic acid and a polymerized unit (B) derived from hydroxynaphthoic acid. For example, the unit (A) may be of formula (A) and the unit (B) may be of formula (B). From the viewpoint of improving melt moldability, a ratio of the units (A) to the units (B) may be in a range of from 9/1 to 1/1 , preferably 7/1 to 1/1 , and more preferably 5/1 to 1/1 .

[0133] The melting point as used herein is a main absorption peak temperature which is measured and observed by a differential scanning calorimeter (DSC) (e.g., “TA3000” manufactured by METTLER Co.) in accordance with the JIS K7121 test method. Specifically, 10 to 20 mg of a sample is used in the above-mentioned DSC apparatus and, after the sample is encapsulated in an aluminum pan, nitrogen is allowed to flow as a carrier gas at a flow rate of 100 cc/m inute and an endothermic peak upon heating at a rate of 20°C/m inute is measured. When a well-defined peak does not appear at the first run in the DSC measurement depending on the type of the polymer, the temperature is raised to a temperature which is 50°C higher than an expected flow temperature at a temperature rise rate (or heating rate) of 50°C/minute, followed by complete melting at the same temperature for 3 minutes and further cooling to 50°C at a temperature drop rate (or cooling rate) of -80°C/minute. Thereafter, the endothermic peak may be measured at a temperature rise rate of 20°C/minute.

[0134] Commercially available LCPs contained in braided sheaths of the present disclosure may include VECTRAN® HT BLACK manufactured by KURARAY CO., LTD., VECTRAN® HT manufactured by KURARAY CO., LTD., SIVERAS® manufactured by Toray Industries, Inc., monofilament manufactured by ZEUS and ZXION® manufactured by KB SEIREN, LTD.

[0135] Liquid crystalline polyesters may be used alone or in combination in core-sheath structures of the present disclosure.

[0136] According to the present invention, “aramid fiber” means a polyamide fiber with high heat resistance and high strength comprising a molecular skeleton composed of an aromatic (benzene) ring. Aramid fibers may be classified into a para-aramid fiber and a meta-aramid fiber according to a chemical structure thereof, with para-aramid fibers being preferably included in some braided sheaths of the present disclosure.

[0137] Examples of commercially available aramid and co-polymer aramid fibers include para-aramid fibers, for example, KEVLAR® manufactured by E.l. du Pont de Nemours and Company, HE RAC RON® from Kolon Industries Inc. and TWARON® and TECHNORA® manufactured by Teijin Limited; and meta-aramid fibers, for example, NOMEX® manufactured by E.l. du Pont de Nemours and Company and CONEX® manufactured by Teijin Limited.

[0138] When contained in fiber-containing structures of the present disclosure, aramid fibers may be used alone or in combination. In some embodiments the filaments contained in fiber-containing structures may contain a co-polymer aramid filament. For example, in some embodiments the fiber-containing structures comprise a copolyparaphenylene / 3,4’-oxydiphenylene terephthalamide filament.

[0139] This material is conventionally referred to as TECHNORA® and is available from Teijin.

[0140] Polyparaphenylenebenzobisoxazole (poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers are commercially available as ZYLON®AS and ZYLON® HM manufactured by TOYOBO CO., LTD.

[0141] Fiber-containing structures of the present disclosure may also be formed of polyether ether ketone (PEEK) materials such as VICTREX™ PEEK polymers. In some embodiments the use of high-dpf PEEK polymers as components of the fiber-containing structures can impart the fiber-containing structures with improved tensile properties.

[0142] Ultra-high molecular weight polyethylene fibers used in some fiber-containing structures of the present disclosure may have an intrinsic viscosity in a range of from about 5.0, or from about 7.0, or from about 10, to about 30, or to about 28, or to about 24 dL/g. When the intrinsic viscosity of the “ultra-high molecular weight polyethylene fiber” is in a range of from about 5.0 to about 30 dL/g, fibers having good dimensional stability are obtained.

[0143] A weight average molecular weight of the “ultra-high molecular weight polyethylene fiber” may be from about 700,000, or from about 800,000, or from about 900,000, to about 8,000,000, or to about 7,000,000, or to about 6,000,000. When the weight average molecular weight of the “ultra-high molecular weight polyethylene fiber” is in the range of from about 700,000 to about 8,000,000, high tensile strength and elastic modulus may be obtained.

[0144] Due to difficulties in determining the weight average molecular weight of “ultra- high molecular weight polyethylene fibers” using GPC methods, it is possible to determine the weight average molecular weight based on a value of the above-mentioned intrinsic viscosity according to the equation below mentioned in “Polymer Handbook Fourth Edition, Chapter 4 (John Wiley, published 1999)”.

Weight average molecular weight = 5.365 x 10⁴ x (intrinsic viscosity)^{1 37}

[0145] In some embodiments it may be preferable for the repeating units of a “ultra- high molecular weight polyethylene fiber” to contain substantially ethylene. However, it may be possible to use, in addition to a homopolymer of ethylene, a copolymer of ethylene with a small amount of another monomer, for example, a-olefin, acrylic acid and derivatives thereof, methacrylic acid and derivatives thereof, and vinylsilane and derivatives thereof. The polyethylene fiber may have a partial crosslinked structure. The polyethylene fiber may also be a blend of a high-density polyethylene with an ultra-high molecular weight polyethylene, a blend of a low-density polyethylene with an ultra-high molecular weight polyethylene, or a blend of a high-density polyethylene, a low-density polyethylene with an ultra-high molecular weight polyethylene. The polyethylene fiber may be a combination of two or more ultra-high molecular weight polyethylenes having different weight average molecular weights, or two or more polyethylenes having different molecular weight distributions.

[0146] Commercially available “ultra-high molecular weight polyethylene fibers” include DYNEEMA® SK60, DYNEEMA® SK, IZANAS ® SK60 and IZANAS ® SK71 manufactured by TOYOBO CO., LTD.; and SPECTRA FIBER 900® and SPECTRA FIBER 1000 manufactured by Honeywell, Ltd.

[0147] These “ultra-high molecular weight polyethylene fibers” can be used alone or in combination.

[0148] Performance and characteristics of fiber-containing structures of the present disclosure may be modified and managed by applying finish compositions to the core and/or the braided sheath. For example, the fiber-containing structures may contain a filament, fiber or strand having a coating of a cross-linked silicone polymer, or a noncross-linked silicone polymer or a long chain fatty acid. Suitable long chain fatty acids may include stearic acid.

[0149] Application of cross-linking silicone polymers may provide advantageous performance enhancement to the tensile strength of fiber-containing structures of the present invention.

[0150] Generally, there are three crosslinking reaction methods available to prepare silicone resins: 1 ) peroxide cure wherein heat activation of polymerization occurs under the formation of peroxide free radicals; 2) condensation in the presence of a tin salt or titanium alkoxide catalyst under the influence of heat or moisture; and 3) addition reaction chemistry catalyzed by a platinum or rhodium complex which may be temperature- or photo-initiated.

[0151] A cross-linked silicone coating may enhance moisture resistance of coated strands and may also enhance the lubricity of the strands such that, when the core-sheath structure is under longitudinal stress, the braid responds more efficiently in comparison to a non-coated structure where frictional interaction may need to be overcome.

[0152] Coating compositions of the present disclosure may be applied via surface application techniques which are known to those skilled in the art. These surface application techniques may include simple pumping finish solutions through a finish guide where the fiber comes into contact with the finish and is wicked into the fiber bundle via capillary action. Alternatively, other techniques may include spraying, rolling, or submersion application techniques such as dip coating. Subsequent treatment of the fiber with finish solution applied may include contact with roller or rollers for the purpose of setting the finish and/or influencing the degree of cross linking in a finish formulation. The roller(s) may or may not be heated. The coating composition may then be cured to cause cross-linking of the cross-linkable silicone polymer. When thermal curing is used the temperature may be from about 20°C, or from about 50°C, or from about 120°C, to about 200°C, or to about 170°C, or to about 150°C. The curing temperature may be determined by the thermal stability properties of the filament, fiber or strand and the actual cross-linking system beingemployed.

[0153] The degree of the cross-linking obtained may be controlled to provide differing degrees of flexibility or other surface characteristics to the filament, fiber or strand. The degree of crosslinking may be determined by the method described in US 8,881 ,496 B2 where the coating is extracted with a solvent which dissolves monomer, but not the crosslinked polymer. The degree of cross-linking may be determined by the difference in weight before and after the extraction.

[0154] The degree of cross-linking 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 cross-linking may be about 100%. The weight of the cross-linked coating may be from about 1 wt% to about 20 wt%, or to about 10 wt%, or to about 5 wt%, based on the total weight of the filament, fiber or strand.

[0155] In some embodiments a maximum cross-sectional diameter of the fibercontaining structures may range from about 15 pm to about 20 mm. In other embodiments the maximum diameter may range from about 20 pm to about 5 mm, or from about 30 pm to about 4 mm, or from about 40 pm to about 3.5 mm, or from about 50 pm to about 3 mm, or from about 50 pm to about 2 mm. An average cross-sectional diameter of the fiber-containing structure may range from about 20 pm to about 10 mm. [0156] Fiber-containing structures of the present disclosure may be designed to satisfy various properties including break tenacity. In some embodiments a break tenacity is at least 15 cN/dtex. In other embodiments the break tenacity 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.

[0157] Fiber-containing structures of the present disclosure include tension members that are useful in various applications including medical cords. For example, fibercontaining 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, just to name a few.

[0158] Fiber-containing structures of the present disclosure may include cords having linear mass densities ranging from about 30 denier to about 10,000 denier. In other embodiments the linear mass density may range 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.

Apparatuses for Detecting Defects in Moving Fiber-Containing Structures

[0159] The present disclosure also relates to apparatuses for detecting defects in moving fiber-containing structures. Such apparatus may include (A) the extrusion apparatus configured to form a fiber-containing structure, the braiding machine configured to form the fiber-containing structure, the tensioning assembly configured to apply tension to the fiber-containing structure, the finish applicator configured to apply a coating to the fiber-containing structure, the godet roll assembly configured to stretch the fibercontaining structure, the winding assembly configured to wind the fiber-containing structure onto a bobbin, the roller, or combinations thereof; (B) a defect detector configured to measure at least one cross-sectional diameter of the fiber-containing structure by transmitting light onto the fiber-containing structure with a projector, detecting a silhouette image of the fiber-containing structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector; and (C) a processor configured to compare at least one diameter signal obtained from the defect detector, optionally at least one signal-processed diameter signal, or combinations thereof, against at least one reference signal to obtain at least one surface defect signal of a surface defect output versus length of the fiber-containing structure, wherein the defect detector measures the at least one cross-sectional diameter while the fiber-containing structure is linearly passing through the defect detector.

[0160] Apparatuses of the present disclosure operate as described in the methods above, and may be modified in accordance with the subject matter described above.

EMBODIMENTS

[0161] Embodiment [1 ] of the present disclosure relates to a method, comprising: linearly passing a fiber-containing structure through at least one defect detector; measuring at least one cross-sectional diameter of the fiber-containing structure with the defect detector to obtain at least one diameter signal of diameter versus length of the fiber-containing structure; 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 combinations thereof, against 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, wherein: the defect detector measures the cross- sectional diameter of the fiber-containing structure by transmitting light onto the fibercontaining structure with a projector, detecting a silhouette image of the fiber-containing structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector; and at least one of the defect detector is situated in series with an extrusion apparatus configured to form 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, a finish 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 the fiber-containing structure onto a bobbin, or combinations thereof.

[0162] Embodiment [2] of the present disclosure relates to the method of Embodiment [1 ], wherein the fiber-containing structure is linearly passed through the at least one defect detector at a linear rate of at least 300 meters per minute.

[0163] Embodiment [3] of the present disclosure relates to the method of Embodiments [1 ] and [2], wherein the fiber-containing structure is a braided fiber- containing structure or a wire-laid fiber-containing structure, and the fiber-containing structure is linearly passed through the at least one detector at a linear rate of at least 1 meter per minute.

[0164] Embodiment [4] of the present disclosure relates to the method of Embodiments [1 ]-[3], wherein the fiber-containing structure is a non-braided fiber- containing structure having a twist level of less than 1 turn per meter, the fiber-containing structure is a braided fiber-containing structure, or the fiber-containing structure is a wire- laid fibercontaining structure.

[0165] Embodiment [5] of the present disclosure relates to the method of Embodiments [1]-[4], wherein the fiber-containing structure is a core-sheath structure comprising a core and a braided sheath of strands surrounding the core.

[0166] Embodiment [6] of the present disclosure relates to the method of Embodiments [1]-[5], wherein the fiber-containing structure is cord having a core-sheath structure comprising a braided sheath surrounding a core, and a braid angle of the braided sheath in a relaxed state ranges from about 5° to about 85°.

[0167] Embodiment [7] of the present disclosure relates to the method of Embodiments [1]-[6], wherein the fiber-containing structure is cord having a core-sheath structure comprising a braided sheath surrounding a core, and a pick count of the braided sheath in a relaxed state is from 6 to 3,000 filament unit crossovers per meter.

[0168] Embodiment [8] of the present disclosure relates to the method of Embodiments [1]-[7], wherein the fiber-containing structure is cord having a core-sheath structure comprising a braided sheath surrounding a core, and a strand (end) count of the braided sheath is from 3 to 24 ends.

[0169] Embodiment [9] of the present disclosure relates to the method of Embodiments [1]-[8], wherein the fiber-containing structure is a cord having a wirelay structure comprising a non-braided sheath surrounding a core.

[0170] Embodiment [10] of the present disclosure relates to the method of

Embodiments [1 ]-[9], wherein the fiber-containing structure comprises an organic fiber.

[0171] Embodiment [11] of the present disclosure relates to the method of

Embodiments [1 ]-[10], wherein the fiber-containing structure comprises a synthetic fiber having a tensile strength of greater than 12 cN/dtex.

[0172] Embodiment [12] of the present disclosure relates to the method of Embodiments [1]-[11], wherein the fiber-containing structure comprises at least one selected from the group consisting of a liquid crystalline polyester filament, an aramid filament, co-polymer aramid filament, a polyether ether ketone filament, a poly(p- phenylene benzobisoxazole) filament, an ultra-high molecular weight polyethylene filament, a high modulus polyethylene filament, a polypropylene filament, a polyethylene terephthalate filament, a polyamide filament, a polyhydroquinone diimidazopyridine filament, and a high-strength polyvinyl alcohol filament.

[0173] Embodiment [13] of the present disclosure relates to the method of Embodiments [1 ]-[12], wherein the fiber-containing structure comprises a synthetic fiber and at least one of a lubricant, a staple fiber and a surface coating.

[0174] 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 from about 30 to about 10,000 denier.

[0175] Embodiment [15] of the present disclosure relates to the method of Embodiments [1]-[14], wherein a maximum cross-sectional diameter of the fibercontaining structure ranges from about 20 pm to about 10 mm.

[0176] Embodiment [16] of the present disclosure relates to the method of Embodiments [1]-[15], wherein an average cross-sectional diameter of the fibercontaining structure ranges from about 20 pm to about 10 mm.

[0177] Embodiment [17] of the present disclosure relates to the method of Embodiments [1]-[16], further comprising forming the fiber-containing structure by an extrusion process, wherein at least one of the defect detector is situated in series with the extrusion apparatus.

[0178] Embodiment [18] of the present disclosure relates to the method of Embodiments [1]-[7], further comprising forming the fiber-containing structure by a braiding process, wherein at least one of the defect detector is situated in series with the braiding machine.

[0179] Embodiment [19] of the present disclosure relates to the method of Embodiments [1 ]-[18], further comprising forming the fiber-containing structure by a braiding process, wherein: a defect detector array is situated in series with the braiding machine, such that the fiber-containing structure linearly passes through the defect detector array; the defect detector array comprises at least two of the defect detector situated in series; the at least two of the defect detector are rotated relative to one another by a detector offset angle, such that different silhouette images of the fiber-containing structure are detected by the at least two of the detect detector; and the detector offset angle ranges from 1⁰ to less than 360°.

[0180] Embodiment [20] of the present disclosure relates to the method of Embodiment [19], wherein the defect detector array comprises at least three of the defect detector situated in series.

[0181] Embodiment [21] of the present disclosure relates to the method of Embodiments [19] and [20], wherein a separation distance between the at least two of the defect detector in the defect detector array ranges from 1 mm to 100 mm.

[0182] Embodiment [22] of the present disclosure relates to the method of Embodiments [19]-[21], wherein: the defect detector comprises two projectors for transmitting the light onto the fiber-containing structure and two optical receivers for detecting the silhouette image of the fiber-containing structure; the two projectors comprise a projector A, for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B, for transmitting a light B onto a surface B of the fibercontaining structure; the two optical receivers comprise an optical receiver A, for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B, for detecting a silhouette image B of the fiber-containing structure; the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B; the projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle; and the projector offset angle and the optical receiver offset angle range from 5° to 175°.

[0183] Embodiment [23] of the present disclosure relates to the method of Embodiments [1 ]-[22], wherein at least one of the defect detector is situated in series with the tensioning assembly.

[0184] Embodiment [24] of the present disclosure relates to the method of Embodiments [1 ]-[23], wherein at least one of the defect detector is situated in series with the finish applicator.

[0185] Embodiment [25] of the present disclosure relates to the method of Embodiments [1 ]-[24] , wherein at least one of the defect detector is situated in series with the godet roll assembly.

[0186] Embodiment [26] of the present disclosure relates to the method of Embodiments [1 ]-[25], wherein at least one of the defect detector is situated in series with the winding assembly.

[0187] Embodiment [27] of the present disclosure relates to the method of Embodiments [1 ]-[26], wherein at least one of the defect detector is situated in series with at least one roller.

[0188] Embodiment [28] of the present disclosure relates to the method of Embodiments [1 ]-[27], wherein: the measuring of the fiber-containing structure includes at least two of the defect detector adjacently situated together in series as a defect detector array; and a detector offset angle between adjacently-situated defect detectors in the defect detector array ranges from 1⁰ to less than 360°.

[0189] Embodiment [29] of the present disclosure relates to the method of Embodiments [1 ]-[28], wherein: the measuring of the fiber-containing structure includes at least three of the defect detector adjacently situated together in series as a defect detector array; and a detector offset angle between adjacently-situated defect detectors in the defect detector array ranges from 1⁰ to less than 360°.

[0190] Embodiment [30] of the present disclosure relates to the method of Embodiments [1]-[29], wherein the defect detector is a multi-axis defect detector configured to measure at least two cross-sectional diameters of the fiber-containing structure, such that an offset angle between the at least two cross-sectional diameters ranges from 5° to 175°.

[0191] Embodiment [31] of the present disclosure relates to the method of Embodiments [1 ]-[30], wherein: the defect detector comprises two projectors for transmitting the light onto the fiber-containing structure and two optical receivers for detecting the silhouette image of the fiber-containing structure; the two projectors comprise a projector A, for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B, for transmitting a light B onto a surface B of the fibercontaining structure; the two optical receivers comprise an optical receiver A, for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B, for detecting a silhouette image B of the fiber-containing structure; the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B; the projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle; the projector offset angle and the optical receiver offset angle range from 5° to 175°.

[0192] Embodiment [32] of the present disclosure relates to the method of Embodiments [1 ]-[31], wherein the projector comprises a laser diode or a light-emitting diode.

[0193] Embodiment [33] of the present disclosure relates to the method of Embodiments [1 ]-[32], wherein the optical receiver is an active-pixel sensor.

[0194] Embodiment [34] of the present disclosure relates to the method of Embodiments [1 ]-[33], wherein the optical receiver is an active-pixel sensor comprising a photodiode image sensor, a charge-coupled device (CCD) image sensor or a complementary metal-oxide-semiconductor (CMOS) image sensor.

[0195] Embodiment [35] of the present disclosure relates to the method of Embodiments [1]-[34], further comprising imaging a surface of the fiber-containing structure with at least one imaging detector, wherein the imaging detector images the surface by illuminating the fiber-containing structure with an imaging light, and receiving a reflected image of the surface with an imaging receiver.

[0196] Embodiment [36] of the present disclosure relates to the method of Embodiments [1]-[35], further comprising imaging a surface of the fiber-containing structure with at least one imaging detector, wherein: the imaging detector images the surface by illuminating the fiber-containing structure with an imaging light, and receiving a reflected image of the surface with an imaging receiver; and at least one of the imaging detector is situated in series with the extrusion apparatus, the braiding machine, the tensioning assembly, the finish applicator, the godet roll assembly, the winding assembly, or the combinations thereof.

[0197] Embodiment [37] of the present disclosure relates to the method of Embodiments [1 ]-[36], wherein the method does not include imaging a surface of the fiber-containing structure with an imaging detector that receives a reflected image of the surface.

[0198] Embodiment [38] of the present disclosure relates to the method of Embodiments [1 ]-[37], wherein the measuring of the at least one cross-sectional diameter occurs at a sampling rate of at least 5,000 samples-per-second.

[0199] Embodiment [39] of the present disclosure relates to the method of Embodiments [1]-[38], wherein: the measuring of the at least one cross-sectional diameter occurs at a sampling rate; the sampling rate of at least one of the defect detector is adjusted such that the measuring occurs at constant intervals along the length of the fiber-containing structure; and the constant intervals range from 10 nm to 1 cm.

[0200] Embodiment [40] of the present disclosure relates to the method of Embodiments [1]-[39], further comprising generating a surface defect rating of the fibercontaining structure based on the surface defect signal.

[0201] Embodiment [41] of the present disclosure relates to the method of Embodiments [1]-[40], wherein the at least one surface defect signal comprises a magnitude surface defect count signal of a magnitude surface defect count versus the length of the fiber-containing structure, in which: the magnitude surface defect count signal is generated by comparing the diameter signal against a reference signal of a maximum cross-sectional diameter versus the length of the fiber-containing structure; a magnitude surface defect count of zero occurs when a 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; and a magnitude surface defect count of greater than zero 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 fibercontaining structure, such that the magnitude surface defect count of greater than zero is a positive integer corresponding to a percentage of the magnitude of the diameter signal above the maximum cross-sectional diameter relative.

[0202] Embodiment [42] of the present disclosure relates to the method of Embodiment [41], further comprising generating a surface defect rating of the fiber- containing structure based, at least in part, on the magnitude surface defect count signal.

[0203] Embodiment [43] of the present disclosure relates to the method of Embodiments [41 ] and [42], further comprising categorizing defects contained in the fibercontaining structure based, at least in part, on the magnitude surface defect count signal.

[0204] Embodiment [44] of the present disclosure relates to the method of Embodiments [1]-[43], wherein the at least one surface defect signal comprises a slope surface defect count signal of a slope surface defect count versus the length of the fibercontaining structure, in which: the slope surface defect count signal is generated by comparing the signal-processed diameter signal against a reference signal of a maximum first derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a first derivative of the diameter signal; a slope surface defect count of zero occurs when an 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; and a slope surface defect count of 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 the particular point along the length of the fiber-containing structure, such that the slope surface defect count of greater than zero is a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal above the maximum first derivative of the diameter signal.

[0205] Embodiment [45] of the present disclosure relates to the method of Embodiment [44], further comprising generating a surface defect rating of the fiber-containing structure based on the slope surface defect count signal.

[0206] Embodiment [46] of the present disclosure relates to the method of Embodiments [44] and [45], further comprising categorizing defects contained in the fibercontaining structure based, at least in part, on the slope surface defect count signal.

[0207] Embodiment [47] of the present disclosure relates to the method of Embodiments [1 ]-[46], wherein the at least one surface defect signal comprises a curvature surface defect count signal of a curvature surface defect count versus the length of the fiber-containing structure, in which: the curvature surface defect count signal is generated by comparing the signal-processed diameter signal against a reference signal of a maximum second derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a second derivative of the diameter signal; a curvature surface defect count of zero occurs when an 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; and a curvature surface defect count of 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 the particular point along the length of the fiber-containing structure, such that the curvature surface defect count of greater than zero is a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal above the maximum second derivative of the diameter signal.

[0208] Embodiment [48] of the present disclosure relates to the method of Embodiments [1]-[47], further comprising generating a surface defect rating of the fibercontaining structure based on the curvature surface defect count signal.

[0209] Embodiment [49] of the present disclosure relates to the method of Embodiments [1]-[48], further comprising categorizing defects contained in the fibercontaining structure based, at least in part, on the curvature surface defect count signal.

[0210] Embodiment [50] of the present disclosure relates to the method of Embodiments [1 ]-[49], wherein the reference signal is a constant reference signal that is constant along the length of the fiber-containing structure.

[0211] Embodiment [51] of the present disclosure relates to the method of Embodiments [1]-[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.

[0212] Embodiment [52] of the present disclosure relates to the method of Embodiments [1]-[51], further comprising: measuring a linear rate of the fiber-containing structure using at least one speedometer.

[0213] Embodiment [53] of the present disclosure relates to the method of Embodiments [1]-[52], further comprising modifying an operation of the extrusion apparatus, the braiding machine, the tensioning assembly, the finish applicator, the godet roll assembly, the winding assembly, or combinations thereof, based on the surface defect signal.

[0214] Embodiment [54] of the present disclosure relates to the method of Embodiments [1 ]-[53], further comprising changing a linear rate of the fiber-containing structure, based on the surface defect signal.

[0215] Embodiment [55] of the present disclosure relates to the method of Embodiments [1 ]-[54], further comprising changing a sampling rate of measuring of the at least one cross-sectional diameter, based on the surface defect signal.

[0216] Embodiment [56] of the present disclosure relates to the method of Embodiments [1]-[55], further comprising categorizing defects contained in the fibercontaining structure, based on the at least one surface defect signal.

[0217] Embodiment [57] of the present disclosure relates to a fiber-containing structure obtained by the method of Embodiments [1 ]-[57],

[0218] Embodiment [58] of the present disclosure relates to fiber-containing structure obtained by the method of Embodiments [1 ]-[56], wherein the fiber-containing structure is a threadline or a braidline.

[0219] Embodiment [59] of the present disclosure relates to a fiber-containing structure obtained by the method of Embodiments [1 ]-[56], wherein the fiber-containing structure is a threadline having a twist level of less than 10 turns permeter.

[0220] Embodiment [60] of the present disclosure relates to a defect-detected fibercontaining structure obtained by the method of Embodiments [1 ]-[56], wherein the defect- detected fiber-containing structure is a core-sheath structure having a braided or laid sheath.

[0221] Embodiment [61 ] of the present disclosure relates to an apparatus, comprising:

(A) an extrusion apparatus configured to form a 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, a finish 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 the fibercontaining structure onto a bobbin, or combinations thereof; (B) a defect detector configured to measure at least one cross-sectional diameter of the fiber-containing structure by transmitting light onto the fiber-containing structure with a projector, detecting a silhouette image of the fiber-containing structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector; and (C) a processor configured to compare at least one diameter signal obtained from the defect detector, optionally at least one signal-processed diameter signal, or combinations thereof, against at least one reference signal to obtain at least one surface defect signal of a surface defect output versus length of the fiber-containing structure, wherein the defect detector measures the at least one cross-sectional diameter while the fiber-containing structure is linearly passing through the defect detector.

[0222] Embodiment [62] of the present disclosure relates to the apparatus of Embodiment [61], wherein the fiber-containing structure is linearly passed through the at least one defect detector at a linear rate of at least 300 meters per minute.

[0223] Embodiment [63] of the present disclosure relates to the apparatus of Embodiments [61]and [62], wherein the fiber-containing structure is a braided fibercontaining structure or a wire-laid fiber-containing structure, and the fiber-containing structure is linearly passed through the at least one detector at a linear rate of at least 1 meter per minute.

[0224] Embodiment [64] of the present disclosure relates to the apparatus of Embodiments [61]-[63], wherein the fiber-containing structure is a non-braided fibercontaining structure having a twist level of less than 1 turn per meter, the fiber-containing structure is a braided fiber-containing structure, or the fiber-containing structure is a wire- laid fiber-containing structure.

[0225] Embodiment [65] of the present disclosure relates to the apparatus of Embodiments [61 ]-[64], wherein the fiber-containing structure is a core-sheath structure comprising a core and a braided sheath of strands surrounding the core.

[0226] Embodiment [66] of the present disclosure relates to the apparatus of Embodiments [61]-[65], wherein the fiber-containing structure is cord having a coresheath structure comprising a braided sheath surrounding a core, and a braid angle of the braided sheath in a relaxed state ranges from about 5° to about 85°.

[0227] Embodiment [67] of the present disclosure relates to the apparatus of

Embodiments [61]-[66], wherein the fiber-containing structure is cord having a core- sheath structure comprising a braided sheath surrounding a core, and a pick count of the braided sheath in a relaxed state is from 6 to 3,000 filament unit crossovers permeter.

[0228] Embodiment [68] of the present disclosure relates to the apparatus of Embodiments [61]-[67], wherein the fiber-containing structure is cord having a coresheath structure comprising a braided sheath surrounding a core, and a strand (end) count of the braided sheath is from 3 to 24 ends.

[0229] Embodiment [69] of the present disclosure relates to the apparatus of Embodiments [61]-[68], wherein the fiber-containing structure is a cord having a wirelay structure comprising a non-braided sheath surrounding a core.

[0230] Embodiment [70] of the present disclosure relates to the apparatus of Embodiments [61 ]-[69], wherein the fiber-containing structure comprises an organic fiber.

[0231] Embodiment [71] of the present disclosure relates to the apparatus of Embodiments [61 ]-[70], wherein the fiber-containing structure comprises a synthetic fiber having a tensile strength of greater than 12 cN/dtex.

[0232] Embodiment [72] of the present disclosure relates to the apparatus of Embodiments [61 ]-[71], wherein the fiber-containing structure comprises at least one selected from the group consisting of a liquid crystalline polyester filament, an aramid filament, co-polymer aramid filament, a polyether ether ketone filament, a poly(p- phenylene benzobisoxazole) filament, an ultra-high molecular weight polyethylene filament, a high modulus polyethylene filament, a polypropylene filament, a polyethylene terephthalate filament, a polyamide filament, a polyhydroquinone diimidazopyridine filament, and a high-strength polyvinyl alcohol filament.

[0233] Embodiment [73] of the present disclosure relates to the apparatus of Embodiments [61 ]-[72], wherein the fiber-containing structure comprises a synthetic fiber and at least one of a lubricant, a staple fiber and a surface coating.

[0234] Embodiment [74] of the present disclosure relates to the apparatus of Embodiments [61]-[73], wherein the fiber-containing structure is a cord having a linear mass density of from about 30 to about 10,000 denier. [0235] Embodiment [75] of the present disclosure relates to the apparatus of Embodiments [61]-[74], wherein a maximum cross-sectional diameter of the fibercontaining structure ranges from about 20 pm to about 10 mm.

[0236] Embodiment [76] of the present disclosure relates to the apparatus of Embodiments [61 ]-[75], wherein an average cross-sectional diameter of the fibercontaining structure ranges from about 20 pm to about 10 mm.

[0237] Embodiment [77] of the present disclosure relates to the apparatus of Embodiments [61 ]-[76], wherein at least one of the defect detector is situated in series with the extrusion apparatus.

[0238] Embodiment [78] of the present disclosure relates to the apparatus of Embodiments [61 ]-[77], wherein at least one of the defect detector is situated in series with the braiding machine.

[0239] Embodiment [79] of the present disclosure relates to the apparatus of Embodiments [61]-[78], comprising a defect detector array situated in series with the braiding machine, such that the fiber-containing structure linearly passes through the defect detector array, wherein: the defect detector array comprises at least two of the defect detector situated in series; the at least two of the defect detector are rotated relative to one another by a detector offset angle, such that different silhouette images of the fibercontaining structure are detected by the at least two of the detect detector; and the detector offset angle ranges from 1⁰ to less than 360°.

[0240] Embodiment [80] of the present disclosure relates to the apparatus of Embodiment [79], wherein the defect detector array comprises at least three of the defect detector situated in series.

[0241] Embodiment [81] of the present disclosure relates to the apparatus of Embodiments [79] and [80], wherein a separation distance between the at least two of the defect detector in the defect detector array ranges from 1 mm to 100 mm.

[0242] Embodiment [82] of the present disclosure relates to the apparatus of Embodiments [79]-[81], wherein: the defect detector comprises two projectors for transmitting the light onto the fiber-containing structure and two optical receivers for detecting the silhouette image of the fiber-containing structure; the two projectors comprise a projector A, for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B, for transmitting a light B onto a surface B of the fibercontaining structure; the two optical receivers comprise an optical receiver A, for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B, for detecting a silhouette image B of the fiber-containing structure; the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B; the projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle; the projector offset angle and the optical receiver offset angle range from 5° to 175°.

[0243] Embodiment [83] of the present disclosure relates to the apparatus of Embodiments [61 ]-[82], wherein at least one of the defect detector is situated in series with the tensioning assembly.

[0244] Embodiment [84] of the present disclosure relates to the apparatus of Embodiments [61 ]-[83], wherein at least one of the defect detector is situated in series with the finish applicator.

[0245] Embodiment [85] of the present disclosure relates to the apparatus of Embodiments [61 ]-[84], wherein at least one of the defect detector is situated in series with the godet roll assembly.

[0246] Embodiment [86] of the present disclosure relates to the apparatus of Embodiments [61 ]-[85], wherein at least one of the defect detector is situated in series with the winding assembly.

[0247] Embodiment [87] of the present disclosure relates to the apparatus of Embodiments [61 ]-[86], wherein at least one of the defect detector is situated in series with at least one roller. [0248] Embodiment [88] of the present disclosure relates to the apparatus of Embodiments [61 ]-[87], wherein at least two of the defect detector are adjacently situated together in series as a defect detector array, and a detector offset angle between adjacently-situated defect detectors in the defect detector array ranges from 1⁰ to less than 360°.

[0249] Embodiment [89] of the present disclosure relates to the apparatus of Embodiments [61]-[88], wherein at least three of the defect detector are adjacently situated together in series as a defect detector array, and a detector offset angle between adjacently-situated defect detectors in the defect detector array ranges from 1⁰ to less than 360°.

[0250] Embodiment [90] of the present disclosure relates to the apparatus of Embodiments [61]-[89], wherein the defect detector is a multi-axis defect detector configured to measure at least two cross-sectional diameters of the fiber-containing structure, such that an offset angle between the at least two cross-sectional diameters ranges from 5° to 175°.

[0251] Embodiment [91] of the present disclosure relates to the apparatus of Embodiments [61]-[90], wherein: the defect detector comprises two projectors for transmitting the light onto the fiber-containing structure and two optical receivers for detecting the silhouette image of the fiber-containing structure; the two projectors comprise a projector A, for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B, for transmitting a light B onto a surface B of the fibercontaining structure; the two optical receivers comprise an optical receiver A, for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B, for detecting a silhouette image B of the fiber-containing structure; the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B; the projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle; the projector offset angle and the optical receiver offset angle range from 5° to 175°.

[0252] Embodiment [92] of the present disclosure relates to the apparatus of Embodiments [61 ]-[91 ], wherein the projector comprises a laser diode or a light-emitting diode.

[0253] Embodiment [93] of the present disclosure relates to the apparatus of Embodiments [61 ]-[92], wherein the optical receiver is an active-pixel sensor.

[0254] Embodiment [94] of the present disclosure relates to the apparatus of Embodiments [61 ]-[93], wherein the optical receiver is an active-pixel sensor comprising a photodiode image sensor, a charge-coupled device (CCD) image sensor or a complementary metal-oxide-semiconductor (CMOS) image sensor.

[0255] Embodiment [95] of the present disclosure relates to the apparatus of Embodiments [61]-[94], further comprising (D) an imaging detector configured to image a surface of the fiber-containing structure, wherein the imaging detector images the surface by illuminating the fiber-containing structure with an imaging light, and receiving a reflected image of the surface with an imaging receiver.

[0256] Embodiment [96] of the present disclosure relates to the apparatus of Embodiments [61]-[95], further comprising (D) an imaging detector configured to image a surface of the fiber-containing structure, wherein: the imaging detector images the surface by illuminating the fiber-containing structure with an imaging light, and receiving a reflected image of the surface with an imaging receiver; and at least one of the imaging detector is situated in series with the extrusion apparatus, the braiding machine, the tensioning assembly, the finish applicator, the godet roll assembly, the winding assembly, or the combinations thereof.

[0257] Embodiment [97] of the present disclosure relates to the apparatus of Embodiments [61]-[96], which does not include imaging a surface of the fiber-containing structure with an imaging detector that receives a reflected image of the surface.

[0258] Embodiment [98] of the present disclosure relates to the apparatus of Embodiments [61]-[97], wherein the defect detector measures the at least one cross- sectional diameter occurs at a sampling rate of at least 5,000 samples-per-second.

[0259] Embodiment [99] of the present disclosure relates to the apparatus of Embodiments [61]-[98], wherein: the defect detector measures the at least one cross- sectional diameter occurs at a sampling rate; the sampling rate of at least one of the defect detector is adjusted such that the measuring occurs at constant intervals along the length of the fiber-containing structure; and the constant intervals range from 10 nm to 1 cm.

[0260] Embodiment [100] of the present disclosure relates to the apparatus of Embodiments [61]-[99], wherein the at least one surface defect signal comprises a magnitude surface defect count signal of a magnitude surface defect count versus the length of the fiber-containing structure, in which: the magnitude surface defect count signal is generated by comparing the diameter signal against a reference signal of a maximum cross-sectional diameter versus the length of the fiber-containing structure; a magnitude surface defect count of zero occurs when a 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; and a magnitude surface defect count of greater than zero 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 fibercontaining structure, such that the magnitude surface defect count of greater than zero is a positive integer corresponding to a percentage of the magnitude of the diameter signal above the maximum cross-sectional diameter relative.

[0261] Embodiment [101] of the present disclosure relates to the apparatus of Embodiments [61 ]-[100], wherein the at least one surface defect signal comprises a slope surface defect count signal of a slope surface defect count versus the length of the fibercontaining structure, in which: the slope surface defect count signal is generated by comparing the signal-processed diameter signal against a reference signal of a maximum first derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a first derivative of the diameter signal; a slope surface defect count of zero occurs when an 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; and a slope surface defect count of 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 the particular point along the length of the fiber-containing structure, such that the slope surface defect count of greater than zero is a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal above the maximum first derivative of the diameter signal.

[0262] Embodiment [102] of the present disclosure relates to the apparatus of Embodiments [61]-[101 ], wherein the at least one surface defect signal comprises a curvature surface defect count signal of a curvature surface defect count versus the length of the fiber-containing structure, in which: the curvature surface defect count signal is generated by comparing the signal-processed diameter signal against a reference signal of a maximum second derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a second derivative of the diameter signal; a curvature surface defect count of zero occurs when an 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; and a curvature surface defect count of 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 the particular point along the length of the fiber-containing structure, such that the curvature surface defect count of greater than zero is a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal above the maximum second derivative of the diameter signal.

[0263] 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.

[0264] Embodiment [104] of the present disclosure relates to the apparatus of Embodiments [61 ]-[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.

[0265] Embodiment [105] of the present disclosure relates to the apparatus of Embodiments [61]-[104], further comprising a speedometer configured to measure a linear rate of the fiber-containing structure.

[0266] The above description is presented to enable a 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 generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, this invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. In this regard, certain embodiments within the disclosure may not show every benefit of the invention, considered broadly.

Claims

CLAIMS What is claimed is:

1. A method, comprising: linearly passing a fiber-containing structure through at least one defect detector; measuring at least one cross-sectional diameter of the fiber- containing structure with the defect detector to obtain at least one diameter signal of diameter versus length of the fiber-containing structure; 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 combinations thereof, against at least one reference signal to generate at least one surface defect signal of a surface defect output versus the length of the fibercontaining structure, wherein: the defect detector measures the cross-sectional diameter of the fibercontaining structure by transmitting light onto the fiber-containing structure with a projector, detecting a silhouette image of the fiber-containing structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector; and at least one of the defect detector is situated in series with an extrusion apparatus configured to form 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, a finish 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 the fiber-containing structure onto a bobbin, or com binations thereof. The method of claim 1 , further comprising: forming the fiber-containing structure by an extrusion process, wherein at least one of the defect detector is situated in series with the extrusion apparatus. The method of claim 1 , further comprising: forming the fiber-containing structure by a braiding process, wherein at least one of the defect detector is situated in series with the braiding machine. The method of claim 3, further comprising: forming the fiber-containing structure by a braiding process, wherein: a defect detector array is situated in series with the braiding machine, such that the fiber-containing structure linearly passes through the defect detector array; the defect detector array comprises at least two of the defect detector situated in series; the at least two of the defect detector are rotated relative to one another by a detector offset angle, such that different silhouette images of the fiber-containing structure are detected by the at least two of the detect detector; and the detector offset angle ranges from 1 ° to less than 360°. The method of claim 4, wherein the defect detector array comprises at least three of the defect detector situated in series. The method of any one of claims 1 -5, wherein: the defect detector comprises two projectors for transmitting the light onto the fiber-containing structure and two optical receivers for detecting the silhouette image of the fiber-containing structure; the two projectors comprise a projector A, for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B, for transmitting a light B onto a surface B of the fiber-containing structure; the two optical receivers comprise an optical receiver A, for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B, for detecting a silhouette image B of the fiber-containing structure; the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B; the projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle; and the projector offset angle and the optical receiver offset angle range from 5° to 175°. The method of any one of claims 1-6, wherein the defect detector is a multi-axis defect detector configured to measure at least two cross-sectional diameters of the fiber- containing structure, such that an offset angle between the at least two cross- sectional diameters ranges from 5° to 175°. The method of any one of claims 1 -7, further comprising: imaging a surface of the fiber-containing structure with at least one imaging detector, wherein: the imaging detector images the surface by illuminating the fiber-containing structure with an imaging light, and receiving a reflected image of the surface with an imaging receiver; and at least one of the imaging detector is situated in series with the extrusion apparatus, the braiding machine, the tensioning assembly, the finish applicator, the godet roll assembly, the winding assembly, or the combinations thereof. The method of any one of claims 1 -8, wherein the at least one surface defect signal comprises a magnitude surface defect count signal of a magnitude surface defect count versus the length of the fiber-containing structure, in which: the magnitude surface defect count signal is generated by comparing the diameter signal against a reference signal of a maximum cross-sectional diameter versus the length of the fiber-containing structure; a magnitude surface defect count of zero occurs when a 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; and a magnitude surface defect count of greater than zero 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, such that the magnitude surface defect count of greater than zero is a positive integer corresponding to a percentage of the magnitude of the diameter signal above the maximum cross-sectional diameter relative. The method of any one of claims 1 -8, wherein the at least one surface defect signal comprises a slope surface defect count signal of a slope surface defect count versus the length of the fiber-containing structure, in which: the slope surface defect count signal is generated by comparing the signal- processed diameter signal against a reference signal of a maximum first derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a first derivative of the diameter signal; a slope surface defect count of zero occurs when an 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 fibercontaining structure; and a slope surface defect count of 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 the particular point along the length of the fibercontaining structure, such that the slope surface defect count of greater than zero is a positive integer corresponding to a percentage of the absolute value of the first derivative of the diameter signal above the maximum first derivative of the diameter signal. The method of any one of claims 1 -8, wherein the at least one surface defect signal comprises a curvature surface defect count signal of a curvature surface defect count versus the length of the fiber-containing structure, in which: the curvature surface defect count signal is generated by comparing the signal-processed diameter signal against a reference signal of a maximum second derivative of the diameter signal versus the length of the fiber-containing structure, where the signal-processed diameter signal is obtained by signal processing the diameter signal to obtain a second derivative of the diameter signal; a curvature surface defect count of zero occurs when an 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; and a curvature surface defect count of 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 the particular point along the length of the fiber-containing structure, such that the curvature surface defect count of greater than zero is a positive integer corresponding to a percentage of the absolute value of the second derivative of the diameter signal above the maximum second derivative of the diameter signal. The method of any one of claims 1 -11 , further comprising: measuring a linear rate of the fiber-containing structure using at least one speedometer. The method of any one of claims 1 -11 , further comprising: modifying an operation of the extrusion apparatus, the braiding machine, the tensioning assembly, the finish applicator, the godet roll assembly, the winding assembly, or combinations thereof, based on the surface defect signal. An apparatus, comprising:

(A) an extrusion apparatus configured to form a 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, a finish 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 the fiber-containing structure onto a bobbin, or combinations thereof;

(B) a defect detector configured to measure at least one cross-sectional diameter of the fiber-containing structure by transmitting light onto the fibercontaining structure with a projector, detecting a silhouette image of the fibercontaining structure with an optical receiver, and calculating the cross-sectional diameter based on a reduction in an amount of the light detected by the optical receiver relative to a total amount of the light transmitted by the projector; and

(C) a processor configured to compare at least one diameter signal obtained from the defect detector, optionally at least one signal-processed diameter signal, or combinations thereof, against at least one reference signal to obtain at least one surface defect signal of a surface defect output versus length of the fiber-containing structure, wherein the defect detector measures the at least one cross-sectional diameter while the fiber-containing structure is linearly passing through the defect detector. The apparatus of claim 14, wherein at least one of the defect detector is situated in series with the extrusion apparatus. The apparatus of claim 14, wherein at least one of the defect detector is situated in series with the braiding machine. The apparatus of claim 16, comprising a defect detector array situated in series with the braiding machine, such that the fiber-containing structure linearly passes through the defect detector array, wherein: the defect detector array comprises at least two of the defect detector situated in series; the at least two of the defect detector are rotated relative to one another by a detector offset angle, such that different silhouette images of the fiber-containing structure are detected by the at least two of the detect detector; and the detector offset angle ranges from 1 ° to less than 360°. The apparatus of any one of claims 14-17, wherein the defect detector array comprises at least three of the defect detector situated in series. The apparatus of any one of claims 14-18, wherein: the defect detector comprises two projectors for transmitting the light onto the fiber-containing structure and two optical receivers for detecting the silhouette image of the fiber-containing structure; the two projectors comprise a projector A, for transmitting a light A onto a surface A of the fiber-containing structure, and a projector B, for transmitting a light B onto a surface B of the fiber-containing structure; the two optical receivers comprise an optical receiver A, for detecting a silhouette image A of the fiber-containing structure, and an optical receiver B, for detecting a silhouette image B of the fiber-containing structure; the projector A is optically aligned with the optical receiver A, and the projector B is optically aligned with the optical receiver B; the projector A and the projector B are rotated relative to one another by a projector offset angle, and the optical receiver A and the optical receiver B are rotated relative to one another by an optical receiver offset angle; the projector offset angle and the optical receiver offset angle range from 5° to 175°. The apparatus of any one of claims 14-19, wherein at least one of the defect detector is situated in series with the tensioning assembly, or the finish applicator, or the godet roll assembly, or the winding assembly, or at least one roller, or any combination thereof. The apparatus of any one of claims 14-20, further comprising: a speedometer configured to measure a linear rate of the fiber-containing structure.