U.S. patent application number 09/782571 was filed with the patent office on 2002-03-07 for method and apparatus for blending textile fibers.
Invention is credited to Beason, Mark Jay, Foster, Raymond Keith.
Application Number | 20020026687 09/782571 |
Document ID | / |
Family ID | 24623615 |
Filed Date | 2002-03-07 |
United States Patent
Application |
20020026687 |
Kind Code |
A1 |
Foster, Raymond Keith ; et
al. |
March 7, 2002 |
Method and apparatus for blending textile fibers
Abstract
Two dispersers tunnels (20, 22) are provided at a disperser
station. Each disperser tunnel (20, 22) houses two dispersers (24,
26 and 28, 30). Each pair of dispersers (24, 26 and 38, 30) are
spaced apart and confront each other, with a mixing zone (42, 54)
being defined between them. A separate conveyor (32, 34, 36, 38) is
provided for feeding textile fiber modules, e.g. cotton boll
modules (18, 18', 18", 18'"), to the dispersers (24, 26, 28, 30).
Each pair of dispersers (24, 26) removes fiber clumps from the
leading ends of the modules (18, 18', 18", 18'") and dispenses them
into the mixing zone (42, 54) in admixture with the fiber clumps
from the other disperser (24, 26, 28, 30) of the pair. The blend or
mixture of fiber clumps is collected in the upper run (50) of a
conveyor (52) that serves to carry the fiber clumps away from the
disperser station. The feed rate of the modules (18, 18', 18",
18'") may be regulated and varied by regulating and varying the
speed rates of the conveyors (32, 34, 36, 38).
Inventors: |
Foster, Raymond Keith;
(Madras, OR) ; Beason, Mark Jay; (Redmond,
OR) |
Correspondence
Address: |
Delbert J. Barnard
Barnard & Pauly, P.S.
P.O. Box 58888
Seattle
WA
98138-1888
US
|
Family ID: |
24623615 |
Appl. No.: |
09/782571 |
Filed: |
February 13, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09782571 |
Feb 13, 2001 |
|
|
|
09654144 |
Sep 1, 2000 |
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Current U.S.
Class: |
19/80R |
Current CPC
Class: |
D01G 7/04 20130101; D01G
13/00 20130101 |
Class at
Publication: |
19/80.00R |
International
Class: |
D01G 007/00 |
Claims
What is claimed is:
1. Apparatus for dispersing textile fiber clumps from a plurality
of textile fiber modules and then mixing the clumps to form a
blend, comprising: a first pair of confronting dispersers, each
having an input side and an output side, said output sides facing
each other on opposite sides of a first mixing zone; a second pair
of confronting dispersers, each having an input side and an output
side, said output sides facing each other on opposite sides of a
second mixing zone; an infeed conveyor for each disperser, each
positioned to feed textile fiber modules into the input side of its
disperser; a separate outfeed conveyor for each pair of dispersers
positioned in the mixing zone of the disperser; a blend conveyor
positioned to receive fiber clumps from the outfeed conveyors,
whereby the infeed conveyors are adapted to move textile fiber
modules to the dispersers, each disperser removes textile fiber
clumps from its module and discharges them into its mixing zone
into admixture with textile fiber clumps from the disperser on the
other side of said mixing zone, and the mixed blends of textile
fiber clumps fall onto the outfeed conveyors and the outfeed
conveyors carry the blends of textile fiber clumps away from the
dispersers to the blend conveyor.
2. The apparatus of claim 1, wherein the infeed conveyors are
reciprocating slat conveyors.
3. The apparatus of claim 1, wherein the outfeed conveyors are
mechanical conveyors.
4. The apparatus of claim 3, wherein the outfeed conveyors are
endless belt conveyors.
5. The apparatus of claim 3, wherein the outfeed conveyors are
helical screw conveyors.
6. The apparatus of claim 1, wherein the blend conveyor comprises a
mechanical conveyor section followed by an airstream conveyor
section, whereby the outfeed conveyors deliver blended textile
fibers clumps from the two dispersers onto the mechanical conveyor
section of the blend conveyor and the mechanical conveyor section
of the blend conveyor delivers the fiber clumps into the airstream
conveyor wherein they are fluidized and further blended as they are
conveyed away from the dispersers.
7. The apparatus of claim 1, wherein the blend conveyor comprises
an airstream conveyor having an inlet portion over the outfeed
conveyors, whereby blends of textile fiber clumps are conveyed by
the outfeed conveyors to the inlet portion of the airstream
conveyor, are picked up by the airstream conveyor, and are
fluidized and further mixed as they are conveyed forwardly by the
airstream conveyor away from the dispersers.
8. Apparatus for dispersing textile fiber clumps from a plurality
of textile fiber modules and then mixing the clumps to form a
blend, comprising: a plurality of dispersers, each having an input
side and an output side, said output sides each facing a fiber
clump receiving zone having a bottom, an infeed conveyor for each
disperser, each positioned to feed textile fiber modules into the
input side of its disperser; an outfeed conveyor in the fiber clump
receiving zone and positioned for receiving fiber clumps; a blend
conveyor positioned to receive fiber clumps from the outfeed
conveyor, whereby the infeed conveyors move textile fiber modules
to the dispersers, each disperser removes textile fiber clumps from
its module and discharges them into the fiber clump receiving zone,
onto the outfeed conveyor and the outfeed conveyor carries the
blends of textile fiber clumps away from the dispersers to the
blend conveyor.
9. The apparatus of claim 8, wherein the blend conveyor comprises
an airstream conveyor section having an inlet portion, whereby
blends of textile fiber clumps are picked up by the airstream
conveyor and are fluidized and further mixed as they are conveyed
forwardly by the airstream conveyor, away from the dispersers.
10. The apparatus of claim 8, wherein the infeed conveyors are
reciprocating slat conveyors.
11. The apparatus of claim 8, wherein the outfeed conveyor is a
mechanical conveyor.
12. The apparatus of claim 11, wherein the outfeed conveyor is an
endless belt conveyor.
13. The apparatus of claim 11, wherein the outfeed conveyor is a
helical screw conveyor.
14. The apparatus of claim 8, wherein the blend conveyor comprises
a mechanical conveyor section followed by the airstream conveyor
section, whereby the outfeed conveyors deliver blended textile
fibers from the two disperser onto the mechanical conveyor section
of the blend conveyor and the mechanical conveyor section of the
blend conveyor delivers the fiber clumps into the airstream
conveyor, wherein they are fluidized and further blended as they
are conveyed away from the dispersers.
15. The apparatus of claim 8, wherein the dispersers are parallel
to each other.
16. The apparatus of claim 8, wherein the outfeed conveyors are
below the level of the infeed conveyors.
17. The apparatus of claim 8, wherein the outfeed conveyors are
above the level of the infeed conveyors.
18. The apparatus of claim 8, comprising two dispersers on opposite
sides of the fiber clump receiving zone, said dispersers having
output sides that face each other on opposite sides of the fiber
clump receiving zone, whereby each disperser removes textile fiber
clumps from its module and discharges them into said fiber clump
receiving zone into admixture with the textile fiber clumps from
the disperser on the other side of said zone, and the mixed blends
of textile fiber clumps fall onto the outfeed conveyor and the
outfeed conveyor carries the blends of textile fiber clumps away
from the disperser toward the blend conveyor.
19. The apparatus of claim 18, wherein the outfeed conveyor is
below the level of the infeed conveyor.
20. The apparatus of claim 18, wherein the outfeed conveyor is
above the level of the infeed conveyor.
21. The apparatus of claim 18, wherein the blend conveyor comprises
an airstream conveyor section having an inlet portion, whereby
blends of textile fiber clumps are picked up by the airstream
conveyor and are fluidized and further mixed as they are conveyed
forwardly by the airstream conveyor, away from the dispersers.
22. A method of dispersing and blending textile fiber clumps from a
plurality of textile fiber modules, comprising: positioning first
and second dispersers at a disperser station; operating the first
and second dispersers while feeding a first textile fiber module
against the first disperser and feeding a second textile fiber
module against the second disperser; operating said first and
second dispersers so that each will disperse fiber clumps from its
module and deliver them into a fiber clump receiving zone;
collecting the fiber clumps in the fiber clump receiving zone and
carrying the fiber clumps onto the inlet of a fluid conveyor
section; and using said fluid conveyor section to convey, fluidize
and blend the textile fiber clumps, while conveying them away from
the dispersers.
23. The method of claim 22, comprising feeding the textile fiber
modules against the dispersers by use of conveyors, and controlling
the feed rate by controlling conveyor speed.
24. The method of claim 22, comprising positioning the first and
second dispersers at the disperser station, in a spaced apart
confronting relationship, so that the fiber clump receiving zone is
between them; and operating the first and second dispersers while
feeding a first textile fiber module against the first disperser
and feeding a second textile fiber module against the second
disperser, so that each will disperse fiber clumps from its module
and deliver them into the fiber clump receiving zone, in admixture
with the fiber clumps from the other disperser.
25. The method of claim 24, comprising positioning third and fourth
dispersers at the disperser station in a spaced apart confronting
relationship, so as to define a second fiber clump receiving zone
between them; operating the third and fourth dispersers while
feeding a third textile fiber module against the third disperser
and feeding a fourth textile fiber module against the fourth
disperser; operating said third and fourth dispersers so that each
will disperse fiber clumps from its module and deliver them into
the second fiber clump receiving zone in admixture with the fiber
clumps from the other disperser of the pair; and collecting the
mixture of fiber clumps from the two fiber clump receiving zones
and carrying it away from the disperser station.
26. The method of claim 25, further comprising using conveyors for
feeding the textile fiber modules against the dispersers, and
controlling the feed rate by controlling conveyor speed.
27. The method of claim 26, comprising using reciprocating slat
conveyors for feeding the textile fiber modules to the
dispersers.
28. The method of claim 22, comprising positioning the first and
second dispersers at the disperser station, in a spaced apart
parallel relationship.
29. The method of claim 28, comprising using a single conveyor that
passes through the fiber clump receiving zones of the first and
second dispersers for delivering fiber clumps to the inlet of the
fluid conveyor section.
30. The method of claim 28, comprising using separate conveyors for
collecting the fiber clumps from the fiber clump receiving zones of
the dispersers and carrying the fiber clumps onto the inlet of the
fluid conveyor section.
Description
[0001] RELATED APPLICATION
[0002] This application is a continuation-in-part of our
application Ser. No. 09/654,144, filed Sep. 1, 2000, and entitled
Method and Apparatus For Mixing Textile Fibers and Particulate
Material.
TECHNICAL FIELD
[0003] This invention relates to a method and apparatus for
dispersing fiber clumps, e.g. cotton boll clumps, from two or more
textile fiber modules, e.g. cotton boll modules, at the same time,
and mixing the clumps to form a blend and then cleaning and ginning
the clumps to form a cotton lint blend.
BACKGROUND OF THE INVENTION
[0004] Below there is a description of the handling of cotton
fibers, starting with the harvesting of cotton bolls. However, the
invention is not limited to the handling of cotton fibers but
rather applies equally as well to the handling of other textile
fibers that have been compressed into large modules that need to be
mechanically dispersed into clumps of fibers so that the fibers can
be separated, cleaned and then further processed, ultimately into
yarns.
[0005] As known to those skilled in the art, cotton plants produce
seedpods, known as cotton bolls, which contain the seeds. Seed
hairs, or fibers, growing from the outer skin of the seeds, become
tightly packed within the boll, which bursts open upon maturity,
revealing soft masses of the fibers. These fibers are white to
yellowish white in color, range from about 0.75 to about 1.5 inches
in length and are composed of about 85-90% cellulose, a
carbohydrate plant substance; five to eight percent water; and four
to six percent natural impurities.
[0006] Cotton is harvested when the bolls open. In the fields, the
cotton bolls are tightly compressed into large modules which are
transported from the fields to processing plants. In the processing
plants, the modules are mechanically dispersed into clumps of bolls
and then the fibers are separated from the seeds and are cleaned
and then are further processed, ultimately into yarns.
[0007] It is known to disperse the cotton boll modules by use of a
stack of rolls that include fingers which rotate into an advancing
end of a cotton module, to tear loose clumps of the bolls from the
module as they rotate. The stack of rolls is termed a disperser and
it is common to use conveyors for delivering the cotton modules to
the disperser. Example disperser systems are disclosed by the
following United States Patents: U.S. Pat No. 4,497,085, granted
Feb. 5, 1985 to Donald W. Van Doorn, James B. Hawkins, Tommy W.
Webb and William A. Harmon, Jr.; U.S. Pat. No. 5,121,841, granted
Jun. 16, 1992, to Keith Harrington and Donald Rogers; U.S. Pat. No.
5,222,675, granted Jun. 29, 1993, to Jimmy R. Stover; U.S. Pat. No.
5,340,264, granted Aug. 23, 1994 to Manfred W. Quaeck and U.S. Pat.
No. 5,469,603, granted Nov. 28, 1995, to Jimmy R. Stover. These
patents show examples of the conveyors which have been used, or
proposed, for delivering the cotton modules to the disperser. The
present invention is not limited to any particular type of
conveyor. However, a reciprocating slat conveyor is preferred.
Example reciprocating slat conveyors that are suitable are
disclosed by U.S. Pat. No. 5,934,445, granted Aug. 10, 1999, to
Raymond Keith Foster, Randall M. Foster and Kenneth A. Stout, and
U.S. Pat. No. RE 35,022, granted Aug. 22, 1995, to Raymond Keith
Foster.
[0008] Cotton fibers, for example, may be roughly classified into
three main groups, based on staple length (average length of the
fibers in a cotton module) and appearance. The first group includes
the fine, lustrous fibers with staple length ranging from about 1
to about 2.5 inches and includes types of the highest quality--such
as Sea Island, Egyptian and Pima cottons. Least plentiful and most
difficult to grow, long-staple cottons are costly and are used
mainly for fine fabrics, yarns and hosiery. The second group
contains the second group contains the standard medium-staple
cotton, such as American Upland, with staple length from about 0.5
to 1.3 inches. The third group includes the short-staple, coarse
cottons, ranging from about 0.375 to 1 inch in length, used to make
carpets and blankets, and to make coarse and inexpensive fabrics
when blended with other fibers. Within each group, the quality of
the fibers can vary depending on such things as where the cotton is
grown. It is desirable to blend the lower quality fibers with
higher quality fibers to produce an acceptable quality blend of
fibers. It is an object of the present invention to provide a
method and apparatus for blending cotton clumps as they are removed
from the cotton modules. The clumps of bolls are mixed together to
form the blend and then the blend is further processed to separate
the fibers from the seeds, etc.
[0009] Another object of the present invention is to provide a
method and apparatus for blending other types of textile fiber
clumps as they are removed from the textile fiber modules. Clumps
from different modules are mixed together to form a blend of the
fibers and then the blend is conveyed on for further
processing.
[0010] It is yet another object of the invention to provide a
method and apparatus for mixing particulate materials, such as
different types and/or grades of wood fiber chips, and wood fiber
chips with other materials, e.g. granule recycled plastic.
BRIEF SUMMARY OF THE INVENTION
[0011] One apparatus of the present invention is basically
characterized by a pair of confronting dispersers, each having an
input side and an output side. The output sides of the two
dispersers face each other on opposite sides of a mixing zone. An
infeed conveyor is provided for each disperser. Each infeed
conveyor is adapted to feed textile fiber modules into the input
side of its disperser. An outfeed conveyor is positioned between
the two dispersers, at the bottom of the mixing zone. The infeed
conveyors are adapted to move the modules in to the dispersers.
Each disperser removes fiber clumps from its module and discharges
them into the mixing zone into admixture with fiber clumps from the
other disperser. The mixed blend of fiber clumps falls on the
outfeed conveyor and the output conveyor carries the blend away
from the mixing zone.
[0012] Each disperser comprises a plurality of power driven rolls,
each of which is supported for rotation about a horizontal axis and
includes a plurality of fingers that move into and then out from
the module as the rollers locate. The fingers are adapted to remove
fiber clumps from the module and project them into the mixing
zone.
[0013] Preferably, the outfeed conveyor extends generally
perpendicular to the infeed conveyors. Preferably also, the infeed
conveyors are reciprocating slat conveyors. The outfeed conveyor
may be an endless belt conveyor or a helical screw conveyor.
[0014] According to an aspect of the invention, the apparatus may
comprise first and second pairs of confronting dispersers of the
type described, each disperser having its own infeed conveyor. The
outfeed conveyor may pick up a blend of fiber clumps from the first
mixing zone and move the blend onto the second mixing zone where a
second blend of fibers and fiber clumps is deposited onto the fiber
clumps already on the outfeed conveyor. Or, each pair is of
dispersers may include its own outfeed conveyor and the two outfeed
conveyors may carry the fiber clamps onto a blend conveyor.
[0015] The method of the present invention is basically
characterized by positioning first and second dispersers at a
disperser station, in a spaced apart confronting relationship, so
as to define a mixing zone between them. The first and second
dispersers are operated while a first module is fed into the first
disperser and a second module is fed into the second disperser. The
first and second dispersers are operated so that each will disperse
fiber clumps from its module and deliver them into the mixing zone
in admixture with fiber clumps from the other disperser. The
mixture of fiber clumps is collected at the bottom of the mixing
zone and is carried away from the disperser station.
[0016] Another aspect of the invention is to feed the modules
against the dispersers by use of conveyors and controlling the feed
rate by controlling the conveyor speed.
[0017] A further aspect of the invention is to provide third and
fourth dispersers at the disperser station, also in a spaced apart
confronting relationship, so as to define a second mixing zone
between them. The third and fourth dispersers are operated while a
third textile fiber module is fed into the third disperser and a
fourth textile fiber module is fed into the fourth disperser. The
third and fourth dispersers are operated so that each will disperse
fiber clumps from its module and deliver them into the second
mixing zone in admixture with the fiber clumps from the other
disperser of the pair. The mixture of fiber clumps is collected at
the bottom of the second mixing zone, on top of the mixture of
fiber clumps from the first mixing zone, and the total mixture is
carried away from the disperser station. Or, each pair of
dispersers may have its own outfeed conveyor and the two outfeed
conveyors may deliver their fiber clumps to a blend conveyor.
[0018] An object of the present invention is to provide a cotton
handling system that includes infeed conveyors for delivering
textile fiber modules to dispersers and outfeed conveyors for
moving textile fiber clumps away from the dispersers. The infeed
conveyors may be reciprocating slat conveyors. The outfeed
conveyors may be mechanical conveyors, including endless belt
conveyors and helical screw conveyors. They can be a system of
conveyors which includes a mechanical conveyor section followed by
an airstream conveyor section.
[0019] It is within the scope of the invention for the outfeed
conveyors to be either below or above the level of the infeed
conveyors or module pads on the input sides of the dispersers.
[0020] An important object of the present invention is that textile
fiber clumps form a plurality of modules are mixed together to form
a textile fiber blend at the dispersers and/or between the
dispersers and the cleaners that receive the textile fiber clumps
from the dispersers. Mixing or blending occurs in airstream
conveyors which move the textile fiber clumps from the disperser
station onto the dryers, cleaners and gins. This mixing or blending
of the textile fiber clumps results in the subsequent operations
handling the mixture or blend. In these operations there is
additional mixing and blending of the textile fiber clumps.
Additional mixing or blending also occurs in the gins as the
textile fiber clumps are being processed by the gins.
[0021] Other objects, advantages and features of the invention will
become apparent from the description of the best mode set forth
below, from the drawings, from the claims and from the principles
that are embodied in the specific structures that are illustrated
and described.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0022] Like reference numerals and letters refer to like parts
throughout the several views of the drawing, and:
[0023] FIG. 1 is a pictorial view of a mature cotton boll, showing
how it appears when harvested;
[0024] FIG. 2 is a pictorial view of a first example apparatus that
incorporates aspects of the present invention which is adapted for
dispersing clumps of cotton bolls from a plurality of cotton
modules and mixing them together for delivery to the next stage of
processing, such view being taken from above and looking towards
the top, one side and one end of the apparatus;
[0025] FIG. 3 is a diagrammatic sectional view through the center
region of the apparatus shown by FIG. 2, showing a mixing zone
formed by and between two dispersers, and an output conveyor below
the mixing zone;
[0026] FIG. 4 is a view similar to FIG. 3, but showing two pairs of
dispersers, a mixing zone between the dispersers of each pair, and
including a schematic diagram of a computer controlled system for
controlling the speed rate of the conveyors that deliver the cotton
modules to the dispersers;
[0027] FIG. 5 is a side elevational view of one of the disperser
rollers;
[0028] FIG. 6 is an enlarged scale fragmentary view of the roller
shown by FIG. 5;
[0029] FIG. 7 is a sectional view taken substantially along line
7--7 of FIG. 6;
[0030] FIG. 8 is a sectional view taken substantially along line
8--8 of FIG. 6;
[0031] FIG. 9 is a fragmentary view looking towards one side of one
of the disperser tunnels, such view showing the two end halves of
the disperser tunnel moved apart and a baffle positioned in the
center of the mixing zone, between the two dispersers, such view
also showing how the disperser rolls and drive motor are mounted on
the frame of the disperser tunnel;
[0032] FIG. 10 is a sectional view taken substantially along line
10-10 of FIG. 9, such view including a drive train diagram showing
how the disperser rolls are connected to the drive motor;
[0033] FIG. 11 is a view like FIG. 3, but showing the outfeed
conveyor above the floor level;
[0034] FIG. 12 is a side elevational diagram showing two outfeed
conveyors positioned to discharge onto the third conveyor;
[0035] FIG. 13 is a top plan view of the conveyor assembly of FIG.
12, showing the third conveyor discharging in to the inlet of a
fluid conveyor;
[0036] FIG. 14 is a view like FIG. 12, but showing the use of
helical screw-type outfeed conveyors;
[0037] FIG. 15 is a view like FIG. 13, but showing helical
screw-type outfeed conveyors;
[0038] FIG. 16 is a view like FIGS. 12 and 14, but showing the two
feed conveyors positioned to convey cotton clumps to an inlet for
an air conveyor;
[0039] FIG. 17 is a view like FIGS. 13 and 15, but of the conveyor
assembly shown by FIG. 16;
[0040] FIG. 18 is a view like FIG. 16, but showing the use of
helical screw-type outfeed conveyors;
[0041] FIG. 19 is a view like FIG. 17, but showing the use of
helical screw-type outfeed conveyors;
[0042] FIG. 20 is a view like FIG. 2, but showing four dispersers
positioned side-by-side and further showing a single module feeding
conveyor for each disperser;
[0043] FIG. 21 is a view like FIG. 3, but with respect to the
dispersers shown by FIG. 20;
[0044] FIG. 22 is a view like FIG. 11, but with respect to the
dispersers shown by FIG. 20;
[0045] FIG. 23 is a view like FIG. 12, with respect to a disperser
shown by FIG. 20;
[0046] FIG. 24 is a view like FIG. 13, but with respect to a
disperser of the type shown by FIG. 20;
[0047] FIG. 25 is a view like FIG. 23, but showing a helical
screw-type outfeed conveyor;
[0048] FIG. 26 is a view like FIG. 24, but showing a helical
screw-type outfeed conveyor; and
[0049] FIG. 27 is a flow diagram of a cotton particle handling
system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIG. 1 is a pictorial view of a single cotton boll
substantially as it appears at harvest time. The boll 10 comprises
a stem 12, a base 14 connected to the stem 12 and a ball of seed
hairs, or fibers, growing from the outer skin of seeds that are
within the boll 10. In a manner that is well known in the art, the
cotton bolls 10 are removed from the cotton plant and are tightly
compressed into large modules 18, 18', 18", 18'" that are removed
from the field and transported to the processing plant.
[0051] FIG. 2 shows a disperser station at a processing plant that
incorporates the present invention. This disperser station
comprises a pair of disperser tunnels 20, 22 each including a pair
of confronting dispersers 24, 26 and 28, 30. Each disperser, 24,
26, 28, 30 is provided with its own infeed conveyor 32, 34, 36, 38.
In the illustrated system, the infeed conveyors 32, 34, 36, 38 are
reciprocating slat conveyors.
[0052] FIG. 3 is a longitudinal sectional view of disperser tunnel
20 and its two dispersers 24, 26. In FIG. 3, the structure is
somewhat schematically shown as the constructional details of the
tunnel 20 is not particularly important to the present invention.
FIG. 3 shows infeed conveyor 32 positioned and arranged to feed the
modules 18, 18', 18", 18'" into the input sides of the dispersers
24, 26, respectively. In this embodiment, the dispersers 24, 26 are
identical and each comprises a plurality of disperser rolls 40. In
each disperser 24, 26, the bank of rolls 40 lean to the rear from
vertical. A lean angle x (FIG. 9) of about thirty degrees
(30.degree.) is illustrated. A mixing zone 42 in the shape of an
inverted trapezoid is defined by and between the two dispersers 24,
26 and below the top of the disperser tunnel 20. Mixing zone 42
includes a lower portion 44 situated below the conveyors 32, 34 and
above the upper run 50 of an outfeed conveyor 52. Mixing zone
portion 44 includes sidewalls 46, 48 that slope downwardly from the
conveyors 32, 34 to the upper run 50 of the conveyor 52.
[0053] FIG. 4 shows a schematic of the disperser tunnel 22 below
the schematic of the disperser tunnel 20. In FIG. 4, a mixing zone
54 is shown between the two dispersers 28, 30 and below the top of
the mixing tunnel 22. Mixing zone 54 is in series with mixing zone
42 and it shares the same outfeed conveyor 52 and the same
sidewalls 46, 48.
[0054] At times, it may be desirable to use a single disperser
(e.g. disperser 24) in a single disperser tunnel (e.g. tunnel 20),
in which case the associated conveyor (e.g. conveyor 32) will be
operated to move modules 18 into the dispersing tunnel and against
the rolls 40 of the disperser 24.
[0055] Preferably, when a single disperser is used, a baffle B is
positioned at the center of the disperser tunnel 20. As shown by
FIGS. 2, 9 and 11, each disperser tunnel 20, 22 may be constructed
in two longitudinal halves. In FIG. 9, the two halves are shown
spaced apart. This is so that a baffle B can be included in the
view. Preferably, the two tunnel parts are connected together and a
slot is provided in the top of the assembly where the two parts
meet. The slot leads into vertical slideways that are positioned to
collect opposite side edge portions of the baffle B. A top plate 31
may extend along the upper edge of the baffle B. One or more
handles H may be secured to the plate 31. In use, when it is
desired to use only a single disperser, e.g. disperser 24, in a
single disperser tunnel, e.g. tunnel 20, a workman need only pick
up the baffle B by use of the handle or handles H. The lower edge
of the baffle B can be dropped into the slot provided at the top of
the tunnel. Then, the baffle B may be allowed to move downwardly
under the influence of gravity until the top plate 31 is on top of
the disperser tunnel, overlying the top and the slot and portions
of the tunnel top that immediately border the slot. Whenever it is
desired to use both dispersers at once, the workman need only grab
the handle or handles H and pull the baffle B up out of the
slideways and set it to one side. Of course, other ways may be used
for providing a baffle B at the center of the mixing zone.
[0056] When the baffle B is in place, the fiber clumps that are
being thrown into the mixing zone by the disperser that is
operating will strike the baffle B and then drop downwardly onto
the outfeed conveyor 52.
[0057] As will hereinafter be described in greater detail, rotation
of the disperser rolls 40 will move fingers into the module 18 that
will dislodge clumps of fibers from the front end of the module 18.
As the fingers move into, then through, and then out from the
module 18, they form the clumps and then throw the clumps into the
chamber 42. The clumps then fall by gravity onto the upper run 50
of the outfeed conveyor 52. The output conveyor 52 then moves the
clumps on to the next station in the processing plant. Herein, the
term "cotton boll clumps" includes a single cotton boll, a portion
of a single cotton boll, a plurality of cotton bolls, and one or
more cotton bolls stuck together by themselves or with any portion
or portions of one or more additional cotton bolls. The term
"textile fiber clumps" means the same thing but also includes other
textile fiber materials. Hereinafter, the apparatus and method will
sometimes be described by referring to cotton bolls and cotton boll
clumps by way of example.
[0058] Referring again to FIG. 3, at times it may be desired to
remove cotton boll clumps from two modules 18, 18' at the same
time, by operating both conveyors 32, 34 at the same time. Conveyor
32 is operated to move a module 18 into the input of disperser 24
while conveyor 34 is operated to move a module 18' into the input
of disperser 26. When this is done, the cotton clumps from the two
modules 18, 18' are mixed together in the mixing zone 42. In FIG.
3, broken lines are used to show the travel paths of the cotton
boll clumps. Mixing occurs as the cotton boll clumps are propelled
into the mixing zone 42 so it can be said that each disperser 24,
26 removes cotton boll clumps from its module 18, 18' and
discharges them into the mixing zone 42 into admixture with the
cotton boll clumps from the other dispenser 24, 26. When both
conveyors 32, 34 and both dispersers 24, 26 are operated, a blend
of cotton boll clumps is formed in the mixing zone 42. This blend
drops onto the upper run 50 of the outfeed conveyor 52.
[0059] As will be appreciated, the two conveyors 32, 34 can be
operated at either substantially the same feed rate or at different
feed rates. When operating them at substantially the same feed
rate, the blend will comprise approximately 50% cotton boll clumps
from module 18 and 50% cotton boll clumps from module 18'. Or, the
feed rate of the conveyors 32, 34 may be different. For example,
conveyor 32 may be operated to cause travel twice as fast as
conveyor 34. In this event, the blend or mixture will comprise two
parts cotton boll clumps from module 18 and one part cotton boll
clumps from module 18'.
[0060] Referring again to FIG. 4, it may be desirable to mix
together cotton boll clumps from three grades or types of module.
For example, conveyors 32, 34 and 36 may be operated at the same
time, each at substantially the same feed rate or at different feed
rates. In this mode of operation, a baffle B will be inserted
between disperser 28, 30. The cotton boll clumps that are dispersed
from disperser 28 strike the baffle B and then fall down and are
deposited onto the blend of cotton boll clumps from dispersers 24,
28 that is on the upper run 50 of the conveyor 52.
[0061] The system also permits the mixing together of cotton boll
clumps from four distinct modules. This is done by utilizing all
four conveyors 32, 34, 36, 38 for simultaneously feeding four
modules 18, 18', 18", 18'", each with a different quality content.
Operation of conveyers 32, 34 and dispersers 24, 26 will admix
cotton boll clumps from modules 18, 18'. They will drop down onto
the upper run 50 of the conveyor 52. Operation of conveyors 36, 38
and dispersers 28, 30 together will admix cotton boll clumps from
modules 18", 18'". This mixture will drop on the mixture of cotton
boll clumps from modules 18, 18' which is already on the upper run
50 of the conveyor 52.
[0062] FIG. 4 shows a schematic diagram of a control system that
includes a programmed computer 56 that is adapted to send control
signals to feed control devices 58, 60, 62, 64 associated with the
conveyors 32, 34, 36, 38. The control system disclosed in the
aforementioned U.S. Pat. No. 5,934,445 includes a programmable
processor or computer and circuit components for varying the feed
rate of the conveyor. It is within the skill of the art for a
programmer to adapt the processor 56 so that it can be used for
controlling the feed rates of the four conveyors 32, 34, 36, 38.
The processor 56 can be programmed to select how many of the
conveyors 32, 34, 36, 38 will be used at a given time, and the feed
rate of each conveyor. It can also be programmed to turn the
dispersers 24, 26, 28, 30 on and off, and also control the speed
rate of the rollers 40.
[0063] Keith Manufacturing Company of 401 N.W. Adler, Madras, Oreg.
97741, makes a conveyor known as the "Running Floor II.RTM."
unloading system or unloader. This system controls the feed rate of
the conveyor by controlling the output of the pump that delivers
hydraulic fluid to the hydraulic cylinders that move the conveyor
slats. The pump output is controlled by controlling revolutions per
minute of the tractor motor that drives the pump. In the system of
FIG. 4, the conveyors 32, 34, 36, 38 can be Running Floor II.RTM.
conveyors. The processor 56 can be programmed to vary the drive
input to the pump or in another suitable way, vary the flow rate of
hydraulic fluid to the hydraulic cylinders that move the conveyor
slats.
[0064] Various ways may be used to determine the feed rate of fiber
clumps into the mixing zones. For example, it can be calculated
from knowing the cross sectional dimensions of the module and the
conveyor speed. Also, sensors may be provided along the path of
travel of each module and used to determine movement of a
particular part of the module over a particular amount of time.
Each module may be provided with a mark on its side or top and the
sensors may be positioned to monitor the position of this mark. The
information received from the sensors can then be fed to the
control system, as a feedback system, and used for changing the
speed rate of the conveyor.
[0065] FIGS. 5-8 show a preferred construction of the disperser
roll 40, also termed the "spike roll". This construction is quite
simple but yet provides a very sturdy, durable roller. In preferred
form, roller 40 includes an elongated tubular core 60 that extends
substantially the full length of the main body of the roll. Core 60
is mounted for rotation by a live shaft 62 having end portions 64,
66 that extend axially outwardly of the opposite ends of the core
60. The core tube 60 may be supported on the member or members that
provide the live shafts 64, 66 in any suitable manner, such as by
use of disks or spiders that project radially outwardly from the
members 64, 66 to the core tube 60. Members 64, 66 may be opposite
end portions of a continuous member that extends all the way
through the core tube 60. Or, they may be shorter members that are
connected to the opposite end portions of the tubular core member
60.
[0066] The roll is divided into a plurality of sections by radial
disks. In the illustrated embodiment, four disks 68, 70, 72, 74 are
used. They divide the roll 40 into three sections that may be of
substantially the same length or their lengths may vary to some
extent. The disks 68, 70, 72, 74 may have a circular outline and
may include a circular center opening through which the core tube
60 extends. The disks 68, 70, 72, 74 may be welded to the core tube
60.
[0067] The live shaft end portions 64, 66 are mounted for rotation
in bearings. Shaft end portion 66 is connected to a suitable drive
device for rotating the shaft portion 66, and hence, the roll 40.
Bearing support systems and drive systems for disperser rolls are
known in the prior art and do not per se form a part of the present
invention.
[0068] According to the present invention, a plurality of elongated
tooth support members 76, 78, 80 are spaced around the tubular
core, as shown by FIGS. 6 and 7. By way of typical and therefore
non-limitive example, there are four members 76, four members 78,
and four members 80. As shown by FIGS. 7 and 8, the two support
members for each section are angularly spaced in position from the
two support members of the adjacent section. In FIG. 7, the two
support members 76 are shown at north, east, south and west
positions. In FIG. 8, the two support members are shown in
northeast, southeast, southwest and northwest positions. The two
support members 80 are in axial alignment with the two support
members 76. In other words, they are also in north, east, south and
west positions and the 76, 78 are in the positions shown by FIGS. 7
and 8.
[0069] In preferred form, each tooth support member 76, 78, 80 is a
length of angle iron. The angle iron members 76, 78, 80 are
positioned such that they present an inner leg that preferably
contacts the core tube 60 and an outer leg. The outer leg is
substantially perpendicular to the inner leg and extends chordwise
of the disks 68, 70, 72, 74. The inner leg is perpendicular to the
outer leg but does not extend radially. The opposite ends of the
two support members 76, 78, 80 are welded or otherwise firmly
connected to the disks 68, 70, 72, 74.
[0070] Each tooth support member 76, 78, 80 supports a plurality of
teeth or "spikes" 82 that are detachably connected to the outer leg
of the tooth support member 76, 78, 80. The teeth or spikes 82 may
be in the form of rods provided with a threaded connection 84 where
they are connected to the tooth support members 76, 78, 80. As will
be apparent, the angular staggering of the tooth support members
76, 78, 80 results in an angular staggering of the teeth 82 in the
center section relative to the teeth 82 in the two end
sections.
[0071] Referring to FIGS. 9 and 10, the disperser roll shafts 64,
66 are mounted onto frame portions of the tunnel structure 20, 22
by bearing assemblies that are shown in FIG. 9. Preferably, the
tunnel structure includes diagonal frame members, one of which is
designated 150 in FIG. 9. It also includes bottom rails, one of
which is designated 152 in FIG. 9. In the illustrated embodiment,
the bearing blocks for the upper five disperser rolls 50 are bolted
to the frame member 150. The bearing block for the lowest disperser
roll 40 is bolted to the bottom of frame member 152. The bearing
block for the disperser roll 40 that is second from the bottom is
bolted to the top of frame member 152. For each disperser 24, 26,
28, 30 a drive motor 154 is mounted on top of the disperser tunnel.
As shown in FIG. 10, a drive belt assembly 156 may connect an
output pulley 158 on motor 154 to a pulley 160 that is connected to
end shaft 64' of the center disperser roll 40. In the illustrated
embodiment, there are seven disperser rolls 40. Thus, there are
three disperser rolls 40 above and three disperser rolls 40 below
the center disperser roll 40. By way of typical and therefore
non-limitive example, the drive belt assembly may comprise five vee
belts. As also shown by FIG. 10, at the opposite ends of the
disperser rolls 40, pulleys are connected to the end shaft 66 of
the disperser rolls 40. Drive belts 162, 164, 166, 168, 170, 172
interconnect adjacent pulleys. The pulley on end shaft 66 for the
center disperser is connected to both the pulley on the end shaft
66 above it and the pulley on the end shaft 66 below it. The
connection pattern of the pulleys 162, 164, 166, 168, 170, 172 is
shown in FIG. 10. Preferably, the belts are cogged belts or are
timing belts. The belt and pulley drive system that is illustrated
operates to rotate the disperser rolls 40 in the same direction and
at substantially the same speed. The direction may be either
clockwise or counterclockwise. The speed may be a variable speed
that is determined by the output of motor 154. That is, a variable
speed motor 154 may be used. Or, the motor may include a variable
speed output transmission.
[0072] FIG. 11 is like FIG. 3 except that the outfeed conveyor 52
is elevated above the conveyors 32, 34 or, above the module support
pads in installations that do not have conveyors under the modules.
In the FIG. 11 embodiment, the mixing zone sidewalls 46, 48 of FIG.
3 are replaced by sidewalls 174, 176 which are shaped to help
direct textile fiber clumps up on to the upper run 50 (not shown)
of the conveyor 52, and to also shield against textile fiber clumps
dropping between the lowermost disperser rolls 40 and the conveyor
52.
[0073] FIG. 12 shows the two disperser tunnels 20, 22 having
separate outfeed conveyors 52 directed to convey towards each
other. The conveyors 52 discharge the cotton boll clumps onto the
upper run 178 of an endless belt conveyor 180. Herein, the term
"blend" conveyor is used to designate a conveyor that extends from
the outfeed conveyors to the first stage operation in the cleaning
and ginning plant. In FIGS. 12 and 13, the conveyor 18 is a first
stage mechanical conveyor that delivers the cotton boll clumps to
an airstream conveyor 182 having an entry portion 184.
[0074] In FIGS. 14 and 15, helical screw type outfeed conveyors 184
are substituted for the endless belt conveyors 52 shown in FIGS. 12
and 13.
[0075] FIGS. 16 and 17 show the outfeed conveyors 52 feeding
directly to the inlet 186 of an airstream conveyor 188. The inlet
structure 188 has branches 190, 192 that are positioned over the
discharge end portions 194 and 196 of the conveyors 180. Fans or
pumps in the ducting 188 sucks up the cotton boll clumps and moves
them on to the cleaning and ginning plant. The air conveyor 182
operates in the same way except the cotton boll clumps are dropped
into its inlet structure 184.
[0076] FIGS. 18 and 19 are like FIGS. 16 and 17 except that the
endless belt-type outfeed conveyors 180 are replaced by the helical
screw-type outfeed conveyors 184. In this installation, the inlet
branches 190, 192 are positioned over the discharge end portions
198, 200 of the conveyors 184. As in the installation described
above in connection with FIGS. 16 and 17, the cotton boll clumps
are sucked into the ducting 190, 192, 188 and are delivered onto
the cleaning and ginning plant.
[0077] FIG. 20 shows a plurality of infeed conveyors 202, 204, 206,
208 delivering cotton boll modules 18 to a plurality of disperser
tunnels 210, 212, 214, 216. In FIG. 20, the infeed conveyors 202,
204, 206, 208 are shown in the form of reciprocating slat conveyors
of the type that has been previously described. FIGS. 20 and 21
show an outfeed conveyor 218 positioned below the level of the tops
of the conveyors 200, 204, 206, 208. Each disperser tunnel 210,
212, 214, 216 includes a disperser of the type that has been
previously described (e.g. disperser 24). The disperser tunnels
210, 212, 214, 216 include closed end walls 220, 222, 224, 226. The
cotton boll clumps are discharged by the disperser rolls 40 into a
cotton boll collecting zone 28. A single outfeed conveyor 218 may
extend through all of the collection zones 228, in series. Or,
disperser tunnels 210, 212 may have a first outfeed conveyor and
disperser tunnels 214, 216 may have a second outfeed conveyor, with
the outfeed conveyors conveying towards each other and to a common
discharge location that is between disperser tunnels 212, 214.
Other arrangements may be used as well.
[0078] FIG. 22 is like FIG. 21 except that the outfeed conveyor 218
is elevated to a position above the top surface of the conveyor
208, or the top surface of a pad on which the module sits in
installations which do not have a conveyor below the modules 18.
The embodiment of FIG. 22 includes a barrier 230 that helps guide
cotton boll clumps up onto the upper run of the conveyor 218' and
to also block against downward movement of cotton boll clumps
between the lowest disperser roller 40 and the conveyor 218'.
[0079] FIGS. 23 and 24 show a single outfeed conveyor 218 that runs
through all four cotton boll clump collection zones and delivers
the cotton boll clumps into the inlet 230 of an airstream conveyor
232. In FIGS. 23 and 24, the outfeed conveyor 218 is broken away so
as to show the entrance 228 for the outfeed conveyor 218 that is
located in the first disperser tunnel 210, and show the airstream
conveyor ducting 230, 230 positioned to receive cotton boll clumps
from the conveyor 218.
[0080] FIGS. 25 and 26 are like FIGS. 23 and 24 but show a helical
screw conveyor 184 substituted for the endless belt conveyor 218.
The conveyor 184 is cut away so as to show the beginning portion of
it that is within the disperser tunnel 210 and to show the
discharge portion of it that is downstream of the disperser tunnel
226, below the inlet structure 230 of the airstream conveyor
232.
[0081] FIG. 27 is a flow diagram of a ginning system that includes
aspects of the invention. D/G identifies a dividing line between
the disperser operation and the ginning operation. As will
hereinafter be described, the ginning operation includes cleaning
procedures in addition to the actual ginning.
[0082] The prior art practice has been to deliver cotton modules to
a disperser located at a disperser station that is at the gin mill.
The disperser or dispersers are used to disperse the cotton boll
modules into cotton boll clumps. These clumps are then delivered
into the ginning system, starting at boundary line G/G. Most
commonly, the modules are dispersed one at a time. The dispersers
are moved relative to stationary modules. Or, the modules are feed
into the dispersers by use of various types of conveyor equipment.
As previously described, U.S. Pat. No. 5,222,675; U.S. Pat. No.
5,469,603 and U.S. Pat. No. 5,934,445 each discloses using a
reciprocating slat conveyor for feeding the modules into the
dispersers.
[0083] As described above, in the practice of the present
invention, the cotton boll clumps are mixed together upstream of
the boundary line D/G so that it is blended cotton boll clumps that
are delivered into the cleaning and ginning system. Referring to
FIG. 27, two dispersers 242 are illustrated. However, it is to be
understood that more than two dispersers can be used. Preferably,
but not necessarily, the dispersers are used in confronting pairs
so that the cotton boll clumps will be admixed as they leave the
dispersers and fly into the mixing zone between the dispersers. In
the confronting-disperser embodiments, the first mixing or blending
of the cotton boll clumps (or other textile fiber clumps) occurs as
a part of the dispersing operation. The clumps are then fed into an
airstream conveyor. When a plurality of dispersers are used in
parallel, the initial mixing or blending of the dispersed fibers
occurs in the airstream conveyor section that leaves the dispersers
242, or mechanical conveyor sections downstream of the dispersers
242. According to an important aspect of the invention, measured
quantities of different qualities of cotton boll clumps or other
textile fiber clumps are mixed or blended to produce a blend of a
quality that is somewhere between the lowest quality fibers
selected and the highest quality fibers selected. Careful
calculations are made so that the fiber clump mix delivered into
the cleaning and ginning operation will produce blended lint of a
desired quantity and quality. As previously mentioned, the feed
rate of the various infeed conveyors can be regulated so as to vary
the quantity of each quality of fiber that is added to the blend or
mix. For example, if only two qualities of textile fiber clumps are
mixed, it might be desirable to mix them fifty-fifty (50/50). In
such case, the infeed conveyors will be operated to deliver the
cotton modules 18 into the dispersers at the same rate of speed.
Or, it might be desirable to mix together two quantities of fiber
clumps from one module with one quantity of fiber clumps from a
second module. This can be easily done by operating the infeed
conveyors for the modules so that the infeed conveyor for the first
quality modules will disperse the fiber clumps at twice the rate of
the fiber clumps that are being dispersed from the other module.
Fiber clumps from three qualities of fiber clump modules can be
blended. And, fiber clumps from four or more qualities of fiber
clump modules can be blended. The quantity and quality of the
resulting blend or mixture can be regulated by regulating the feed
rate of the infeed conveyors and hence the dispersion rate of the
fiber clumps from the various modules.
[0084] As discussed above, the fiber clumps are ultimately picked
up by an airstream conveyor and delivered by such conveyor into the
cleaning and ginning plant, i.e. beyond boundary D/G. The equipment
shown in FIG. 27 downstream of the boundary line D/G is equipment
that already exists in the prior art. This portion of the flow
diagram represents the more sophisticated flow diagram that is
illustrated in a brochure produced by the Lummus Corporation, and
entitled "The Gentle Ginning System." A copy of this brochure has
been supplied to the United States Patent and Trademark Office for
inclusion in the prosecution history of this patent.
[0085] In FIG. 27, a rock and boll separator 246 receives the blend
of cotton boll clumps from the dispersers and removes at least some
of the rocks out through path 248 and delivers the remaining
portion of the mixture through path 250 to a tower dryer 252. The
fiber blend then moves on to a hot air cleaner 254 and from the hot
air cleaner 254 onto a stripper 256 in which sticks and leaves are
removed. The effluent of stripper 256 moves on to another dryer 258
where it is heated and moisture is removed. The effluent from dryer
258 moves on to another hot air cleaner 260. The effluent of the
hot air cleaner 260 moves on to a trash cleaner 262. The effluent
of the trash cleaner 262 moves to a feed 264 which moves the fiber
blend into saw gins 266. The effluent of the saw gins 266 moves on
to a series of lint cleaners 268, 270. The effluent of lint cleaner
270 moves on to a moisture conditioning condenser 272.
[0086] After passing through the moisture conditioner condenser
272, the fiber blend may be balled and the bales may then be moved
into storage or on to a customer. Or, the fiber blend may be
collected in a truck/trailer box, for example, and delivered to a
customer in an unballed condition.
[0087] A part of the present invention is that the fiber clumps
that are moved past boundary D/G into the cleaning and ginning
plant is already blended so that additional blending of the fiber
lint does not have to be done by the customer who receives the
lint.
[0088] The aforementioned application Ser. No. 09/654,144 is hereby
expressly incorporated herein by this specific reference.
Accordingly, aspects of the present invention can be used for
blending particulate material.
[0089] The illustrated embodiments are only examples of the present
invention and, therefore, are non-limitive. It is to be understood
that many changes in the particular structure, materials and
features of the invention may be made without departing from the
spirit and scope of the invention. Therefore, it is my intention
that my patent rights not be limited by the particular embodiments
illustrated and described herein, but rather determined by the
following claims, interpreted according to accepted doctrines of
claim interpretation, including use of the doctrine of equivalents
and reversal of parts.
* * * * *