U.S. patent application number 12/911418 was filed with the patent office on 2011-06-02 for mobile creel.
Invention is credited to John J.M. REES, Kyle SMITH, III.
Application Number | 20110127364 12/911418 |
Document ID | / |
Family ID | 44068108 |
Filed Date | 2011-06-02 |
United States Patent
Application |
20110127364 |
Kind Code |
A1 |
REES; John J.M. ; et
al. |
June 2, 2011 |
MOBILE CREEL
Abstract
A mobile creel for organizing yarn packages and directing yarn
is disclosed. In one aspect, the mobile creel has a plurality of
support frames and an upright creel docking post. The front portion
of the base of each support frame can be configured for engagement
with the lower portion of the upright creel docking post. The creel
docking post can simultaneously engage one, two, three, or four
support frames.
Inventors: |
REES; John J.M.;
(Chattanooga, TN) ; SMITH, III; Kyle; (Calhoun,
GA) |
Family ID: |
44068108 |
Appl. No.: |
12/911418 |
Filed: |
October 25, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61265607 |
Dec 1, 2009 |
|
|
|
Current U.S.
Class: |
242/594 |
Current CPC
Class: |
B65H 49/16 20130101;
B65H 2701/31 20130101; B65H 59/06 20130101 |
Class at
Publication: |
242/594 |
International
Class: |
D02H 1/00 20060101
D02H001/00; B65H 49/16 20060101 B65H049/16 |
Claims
1. A mobile creel for organizing yarn packages and directing yarn,
the mobile creel comprising: an upright creel docking post having a
lower portion and an upper portion; and at least one support frame,
each support frame comprising: a base having a front portion and a
rear portion; a plurality of substantially upright support members
extending upwardly therefrom the rear portion of the base; and a
plurality of spaced creel mounts positioned thereon at least one
support member of the plurality of substantially upright support
members, each creel mount configured to selectively hold a yarn
package, wherein the front portion of the base of each support
frame is configured for engagement with the lower portion of the
upright creel docking post, and wherein each creel mount of the
plurality of spaced creel mounts is oriented toward the upright
creel docking post.
2. The mobile creel of claim 1, wherein the base of each support
frame has a substantially triangular shape.
3. The mobile creel of claim 1, wherein each spaced creel mount of
the plurality of spaced creel mounts comprises a tempered bent-wire
package holder.
4. The mobile creel of claim 1, wherein the plurality of
substantially upright support members comprises two outer support
members and a central support member, and wherein the plurality of
spaced creel mounts are positioned thereon the two outer support
members.
5. The mobile creel of claim 4, wherein each support frame of the
at least one support frame further comprises means for allowing the
support frame to be moved relative to the upright creel docking
post.
6. The mobile creel of claim 4, wherein the means for allowing the
support frame to be moved comprises a plurality of casters coupled
to a bottom surface of the base.
7. The mobile creel of claim 6, wherein the plurality of casters
comprises: at least one lockable caster mounted underneath the rear
portion of the base; and a center pivoting caster mounted
underneath the front portion of the base.
8. The mobile creel of claim 4, wherein the plurality of spaced
creel mounts are substantially evenly spaced along the longitudinal
length of the outer support members to create a plurality of levels
for securing yarn packages, and wherein adjacent creel mounts on
the respective outer support members are substantially
co-planar.
9. The mobile creel of claim 8, wherein each support frame of the
at least one support frame further comprises a plurality of
substantially horizontal creel package separators mounted thereon
the plurality of substantially upright support members to divide
the levels for securing yarn packages.
10. The mobile creel of claim 1, wherein the lower portion of the
upright creel docking post comprises a guide plate having a
plurality of slots configured to receive the front portion of the
base of each support frame.
11. The mobile creel of claim 1, wherein the lower portion of the
upright creel docking post comprises at least one magnet, and
wherein the at least one magnet is configured to maintain the
engagement of the front portion of the base of each support frame
with the lower portion of the upright creel docking post.
12. The mobile creel of claim 1, wherein the upper portion of the
upright creel docking post comprises means for directing at least
one path of yarn therefrom the at least one support frame.
13. The mobile creel of claim 12, wherein the means for directing
at least one path of yarn therefrom the at least one support frame
comprises a series of spaced pre-guide rings positioned along the
upper portion of the upright creel docking post.
14. The mobile creel of claim 13, wherein the means for directing
at least one path of yarn therefrom the at least one support frame
further comprises a series of spaced ball tension controllers
positioned along the upper portion of the upright creel docking
post, and wherein the series of spaced pre-guide rings and the
series of spaced ball tension controllers are positioned in an
interdigitated relationship.
15. The mobile creel of claim 14, wherein the means for directing
at least one path of yarn therefrom the at least one support frame
further comprises a plurality of yarn guides mounted thereto the
upper portion of the upright creel docking post, wherein each yarn
guide of the plurality of yarn guides is configured to guide the at
least one path of yarn into a predetermined yarn formation.
16. The mobile creel of claim 1, wherein the front portion of the
base of each support frame of the at least one support frame is
engaged with the lower portion of the upright creel docking
post.
17. The mobile creel of claim 16, wherein the at least one support
frame comprises a plurality of support frames.
18. The mobile creel of claim 17, wherein the plurality of support
frames is selected from a group consisting of two, three, and four
support frames.
19. The mobile creel of claim 1, wherein each creel mount of the
plurality of spaced creel mounts is operably positioned to
substantially face the upright creel docking post.
20. A support frame for engagement with an upright docking post of
a mobile creel for organizing yarn packages and directing yarn, the
support frame comprising: a substantially triangular base having a
vertex and a rear portion; a plurality of substantially upright
support members extending upwardly therefrom the rear portion of
the substantially triangular base; and a plurality of spaced creel
mounts positioned thereon at least one support member of the
plurality of substantially upright support members, each creel
mount configured to selectively hold a yarn package, wherein the
vertex of the base is configured for engagement with the upright
creel docking post, wherein each creel mount of the plurality of
spaced creel mounts is operably positioned to extend along a mount
axis, wherein the mount axis of each respective spaced creel mount
is oriented toward the vertex of the substantially triangular
base.
21. A method for organizing yarn packages and directing yarn, the
method comprising: providing a mobile creel, the mobile creel
comprising: an upright creel docking post having a lower portion
and an upper portion; and a plurality of support frames, each
support frame comprising: a base having a front portion and a rear
portion; a plurality of substantially upright support members
extending upwardly therefrom the rear portion of the base; and a
plurality of spaced creel mounts positioned thereon at least one
support member of the plurality of substantially upright support
members, each creel mount configured to selectively hold a yarn
package, wherein the front portion of the base of each support
frame is configured for engagement with the lower portion of the
upright creel docking post, wherein each creel mount of the
plurality of spaced creel mounts is oriented toward the upright
creel docking post, and wherein the upper portion of the upright
creel docking post comprises means for directing at least one path
of yarn therefrom the plurality of support frames; securing a yarn
package thereon at least one spaced creel mount of the plurality of
spaced creel mounts; positioning the front portion of the base of
at least one selected support frame of the plurality of support
frames in engagement with the lower portion of the upright creel
docking post; and positioning the yarn of at least one yarn package
secured thereon the at least one selected support frame in
communication with the means for directing at least one path of
yarn therefrom the plurality of support frames.
22. The method of claim 21, wherein the plurality of spaced creel
mounts are substantially evenly spaced along at least two support
members of the plurality of substantially upright support members
to create a plurality of levels for securing yarn packages, wherein
adjacent creel mounts on the respective support members are
substantially co-planar, wherein the step of securing a yarn
package thereon at least one spaced creel mount further comprises
securing at least two yarn packages thereon respective spaced creel
mounts within a selected level of the plurality of levels for
securing yarn packages, and wherein the step of positioning the
yarn of at least one yarn package further comprises serially tying
yarn from a first yarn package secured thereon a first spaced creel
mount within the selected level to yarn from a second yarn package
secured thereon a second spaced creel mount within the selected
level.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S.
Provisional Patent Application Ser. No. 61/265,607, filed on Dec.
1, 2009, the entire disclosure of which is incorporated by
reference herein for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates to a creel for holding yarn packages
in a carpet manufacturing process. More specifically, this
invention relates to a highly mobile creel configured for layered
storage of yarn packages around a creel docking post in a carpet
manufacturing process.
BACKGROUND OF THE INVENTION
[0003] A standard creel has a frame provided with a plurality of
vertical rows of holders each adapted to hold a respective bobbin
comprised of a tubular core and a mass of filament--yarn or
thread--wound on the core. A filament is pulled from each bobbin
and guided through a respective eye, whence it passes to a warp or
weft system of a loom or the like. A standard creel can hold
hundreds and even thousands of bobbins, thus space requirement is a
problem. Additionally, conventional creel design requires that the
tufting machine be placed out of operation during the times an
operator is required to change the bobbins on the creel in order to
change yarns. Further, a significant amount of labor is required to
successfully relocate a standard creel or to load or unload yarn
packages on the creel.
[0004] Thus, there is a need in the pertinent art for an easily
movable creel having a compact design for securely holding yarn
packages. Additionally, there is a need in the pertinent art for a
creel that is configured to allow for efficient loading and
unloading of yarn packages.
SUMMARY
[0005] The invention relates to a mobile creel for organizing yarn
packages and directing yarn to a carpet manufacturing process. A
mobile creel provides flexibility for carpet manufactures in that
operators can pre-load mobile creels with yarn packages and roll
the mobile creels to a desired location, where the mobile creel can
be tied into an existing yarn feed. Due to the mobility of the
mobile creel, heavier and larger creel packages can be used so as
to extend the runtime between creelings throughout the carpet
manufacturing process. Because of these extended runtimes and the
decreased need for loading and unloading of creel packages,
material-handling labor within a textile plant is significantly
reduced.
[0006] In one aspect, the mobile creel has at least one support
frame and an upright creel docking post. Each support frame of the
mobile creel has a base with a front portion and a rear portion.
The base of each support frame can have a substantially triangular
shape. In another aspect, each support frame has a plurality of
substantially upright support members extending upwardly from the
rear portion of the base. In a further aspect, each support frame
can have a plurality of spaced creel mounts positioned on at least
one of the support members. Each creel mount can be configured to
selectively hold a yarn package.
[0007] In another aspect, the upright creel docking post has a
lower portion and an upper portion. The front portion of the base
of each support frame can be configured for engagement with the
lower portion of the upright creel docking post. In a further
aspect, each creel mount can be configured so as to be operably
positioned to substantially face a portion of the upright creel
docking post after engagement of the base by the upright creel
docking post. In one non-limiting example, the creel docking post
can simultaneously engage one, two, three, or four support
frames.
[0008] In an additional aspect, the support frame can have a
plurality of casters to enable the mobile creel to be readily moved
over flooring surfaces within a carpet manufacturing plant. In a
further aspect, the creel mounts can be evenly spaced along the
outer support members to create a plurality of levels for securing
yarn packages. In another aspect, the support frame can have a
plurality of substantially horizontal creel package separators
mounted on the support members.
[0009] In a further aspect, the lower portion of the upright creel
docking post can have a guide plate configured to receive the base
of each support frame. In another aspect, the lower portion of the
docking post has at least one magnet for maintaining the engagement
of the front portion of each base with the lower portion of the
docking post. In still another aspect, the upper portion of the
upright creel docking post can have means for directing at least
one path of yarn from the support frames to a selected process,
including, for example and without limitation, a carpet tufting
machine or a heat setting. For example and without limitation, the
means for directing at least one path of yarn can be, alone or in
combination, a series of spaced pre-guide rings, a series of spaced
ball tension controllers, a plurality of yarn guides, or the
like.
DETAILED DESCRIPTION OF THE FIGURES
[0010] These and other features of the preferred embodiments of the
invention will become more apparent in the detailed description in
which reference is made to the appended drawings wherein:
[0011] FIG. 1 is a perspective view of the support frame of the
mobile creel according to one aspect of the present invention.
[0012] FIG. 2 is a perspective view of the upright creel docking
post of the mobile creel according to one aspect of the present
invention.
[0013] FIG. 3 is a perspective view of the mobile creel according
to one aspect of the present invention, illustrating the docking of
two support frames to the upright creel docking post.
[0014] FIG. 4 is a perspective view of the mobile creel according
to one aspect of the present invention, illustrating the docking of
two support frames to the upright creel docking post in a "magazine
creeling" configuration.
[0015] FIG. 5 is an elevational view of the mobile creel according
to one aspect of the present invention, illustrating the docking of
four support frames to the upright creel docking post such that the
spaced creel mounts of the support frames are operably positioned
to extend along a mount axis.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention can be understood more readily by
reference to the following detailed description, examples, drawing,
and claims, and their previous and following description. However,
before the present devices, systems, and/or methods are disclosed
and described, it is to be understood that this invention is not
limited to the specific devices, systems, and/or methods disclosed
unless otherwise specified, as such can, of course, vary. It is
also to be understood that the terminology used herein is for the
purpose of describing particular aspects only and is not intended
to be limiting.
[0017] The following description of the invention is provided as an
enabling teaching of the invention in its best, currently known
embodiment. To this end, those skilled in the relevant art will
recognize and appreciate that many changes can be made to the
various aspects of the invention described herein, while still
obtaining the beneficial results of the present invention. It will
also be apparent that some of the desired benefits of the present
invention can be obtained by selecting some of the features of the
present invention without utilizing other features. Accordingly,
those who work in the art will recognize that many modifications
and adaptations to the present invention are possible and can even
be desirable in certain circumstances and are a part of the present
invention. Thus, the following description is provided as
illustrative of the principles of the present invention and not in
limitation thereof.
[0018] As used throughout, the singular forms "a," "an" and "the"
include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to "a yarn package" can
include two or more such yarn packages unless the context indicates
otherwise.
[0019] Ranges can be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another aspect includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another aspect. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint, and independently of the other endpoint.
[0020] As used herein, the terms "optional" or "optionally" mean
that the subsequently described event or circumstance may or may
not occur, and that the description includes instances where said
event or circumstance occurs and instances where it does not.
[0021] In one embodiment, the invention relates to a mobile creel
10 for organizing yarn packages 20 and directing yarn to a carpet
manufacturing process. The mobile creel 10 provides flexibility for
carpet manufactures in that operators can pre-load portable creels
with yarn packages 20 for future runs and move them into position
when needed. In one aspect, the mobile creel 10 comprises at least
one support frame 100 and an upright creel docking post 200.
[0022] In one aspect, and referring to FIG. 1, each support frame
100 of the mobile creel comprises a base 110 having a front portion
and a rear portion. In this aspect, the base 110 of each support
frame 100 can have a substantially triangular shape. In another
aspect, each support frame 100 comprises a plurality of
substantially upright support members 130 extending upwardly from
the rear portion of the base 110. In a further aspect, each support
frame 100 comprises a plurality of spaced creel mounts 150
positioned on at least one of the support members 130. As one will
appreciate, each spaced creel mount 150 can be secured to its
respective support member 130 by any means known in the art,
including, for example and without limitation, welding of the creel
mounts 150 to two sides of their respective support members 130. In
this aspect, each creel mount 150 can be configured to selectively
hold a yarn package 20. It is contemplated that, in one aspect, the
creel mount can comprise a conventional creel mount. For example
and without limitation, each creel mount 150 can comprise a
tempered bent-wire package holder.
[0023] In one aspect, and referring to FIG. 2, the upright creel
docking post 200 comprises a lower portion and an upper portion. In
another aspect, and referring to FIGS. 3 and 4, the front portion
of the base 110 can be configured for engagement with the lower
portion of the upright creel docking post 200. In a further aspect,
each creel mount 150 can be configured so as to be oriented toward
a portion of the upright creel docking post 200 after operative
engagement of the base 110 by the upright creel docking post. In
still a further aspect, each creel mount 150 can be configured so
as to be operably positioned to substantially face a portion of the
upright creel docking post 200 after operative engagement of the
base 110 by the upright creel docking post.
[0024] In another aspect, and referring to FIG. 1, the plurality of
substantially upright support members 130 comprises two outer
support members. In this aspect, the plurality of spaced creel
mounts 150 can be mounted on the two outer support members.
Optionally, the upright support members 130 can also comprise a
central support member. In an additional aspect, the support frame
100 comprises a central gusset 140 attached to the central support
member and the base 110.
[0025] In an additional aspect, and referring to FIG. 1, the
support frame 100 comprises a transport means, such as, for example
and without limitation, casters, rollers, skids, or the like, for
allowing movement of the support frame relative to the upright
creel docking post 200. In one aspect, and without limitation, a
plurality of casters 120 can be mounted on a bottom surface of the
base. In this aspect, the plurality of casters can comprise at
least one lockable caster mounted underneath the rear portion of
the base 110, as well as a center pivoting caster mounted
underneath the top portion of the base. As one skilled in the art
will appreciate, the casters 120 enable the mobile creel to roll
along flooring surfaces within a carpet manufacturing plant and the
plurality of substantially upright support members 130, coupled
with the plurality of casters 120, allows for easy steering of the
mobile creel during transfers from one process to another.
[0026] In a further aspect, and referring to FIG. 1, the creel
mounts 150 can be evenly spaced along the outer support members to
create a plurality of spaced levels 170 for securing yarn packages
20. In one aspect, it is contemplated that each level 170 would be
substantially horizontal, i.e., transverse to the longitudinal axis
of the respective outer support members. For example, eight spaced
creel mounts 150 can be positioned on the two outer support members
such that there are four levels for securing yarn packages 20, with
each level 170 having two spaced creel mounts.
[0027] In another aspect, the support frame 100 can comprises a
plurality of substantially horizontal creel package separators 160
mounted on the support members 130. It is contemplated that the
creel package separators 160 can be configured to divide the levels
170 for securing yarn packages 20. As one will appreciate, the
creel package separators 160 help prevent entanglement of yarn
packages 20 located on different levels 170 of the mobile
creel.
[0028] As illustrated in FIG. 2, in one aspect, the lower portion
of the upright creel docking post 200 comprises a guide plate 210
configured to receive the base 110 of each support frame 100. In
this aspect, the guide plate can have a plurality of slots defined
therein that are configured to receive the front portion of each
base 110. In another aspect, the lower portion of the docking post
200 can comprise at least one magnet. It is contemplated that the
at least one magnet can be configured to maintain the engagement of
the front portion of each base 110 with the lower portion of the
docking post 200. In an additional aspect, the front portion of
each base can also comprise at least one magnet that is configured
to attract either a portion of a slot in the guide plate or to be
attracted to a magnet positioned on the lower portion of the
docking post. It is contemplated that the additional magnets of the
docking post can reinforce the engagement of the front portion of
each base 110 with the docking post. Optionally, the guide plate
210 or the front portion of the base can comprises a rubber bumper
for dampening the impact of the engagement of the support frame 100
by the docking post 200.
[0029] In another aspect, and referring to FIG. 2, the upper
portion of the upright creel docking post 200 can comprise means
for directing at least one path of yarn 30 from the at least one
support frame 100 to a selected process, including, for example and
without limitation, a carpet tufting machine, a heat setting device
and the like. In one aspect, the means for directing at least one
path of yarn comprises a series of spaced pre-guide rings 230 that
can be positioned along the longitudinal length of the upper
portion of the docking post 200. It is contemplated that the
pre-guide rings 230 can be configured to receive at least one path
of yarn 30 from the at least one support frame 100. As one will
appreciate, the pre-guide rings 230 can maintain even tension in
the path of yarn 30 so that off-winding yarn harmonics are
reduced.
[0030] In an additional aspect, the means for directing at least
one path of yarn can further comprises a series of spaced ball
tension controllers 250 positioned along the longitudinal length of
the upper portion of the docking post 200. In one exemplary aspect,
the series of spaced pre-guide rings 230 and the series of spaced
ball tension controllers 250 can be positioned in an interdigitated
relationship. As one will appreciate, the spaced ball tension
controllers 250 can be configured to create even tension in the
yarn 30 used during carpet manufacturing processes. Known ball
tension devices, such as, for example and without limitation, Otto
Zollinger (OZ.RTM.) ball tension devices, can be used for this
purpose. In a further aspect, the means for directing at least one
path of yarn comprises a plurality of yarn guides 270 mounted to
the upper portion of the docking post 200. In this aspect, the yarn
guides 270 can be configured to guide at least one path of yarn
into a predetermined yarn formation. Optionally, the yarn guides
270 can be locking yarn guides, such as, for example and without
limitation, Yuasa locking yarn guides.
[0031] In still another aspect, and referring to FIGS. 3, 4, and 5,
the front portion of the base 110 of each support frame 100 can be
engaged with the lower portion of the upright creel docking post
200. For example, and without limitation, the mobile creel can have
one, two, three, or four support frames in engagement with the
docking post 200. As illustrated in FIGS. 4 and 5, it is
contemplated that, following the engagement of a support frame 100
with the creel docking post 200, the off-winding yarn end of one
yarn package 20 can be tied to the tail of an adjacent yarn package
on the same level of the support frame to allow for "magazine
creeling," which creates a continuous path of yarn using multiple
yarn packages. It is further contemplated that "magazine creeling"
can be expanded by linking yarn packages 20 from adjacent support
frames 100 that share a common pre-guide ring 230.
[0032] In another embodiment, and referring to FIGS. 3 and 4, the
invention relates to a support frame 100 for engagement with an
upright docking post 200 of a mobile creel 10 organizing yarn
packages 20 and directing yarn to a carpet manufacturing process.
In one aspect, the support frame 100 comprises a substantially
triangular base 110 having a front portion and a rear portion. In
one aspect, the front portion comprises a vertex of the
substantially triangular base 110. In this aspect, the front
portion of the base 110 can be configured for engagement with the
docking post 200. Additionally, in another aspect, the support
frame 100 comprises a plurality of substantially upright support
members 130 extending upwardly from the rear portion of the base
110. In still another aspect, the support frame 100 comprises a
plurality of spaced creel mounts 150 positioned on at least one
support member 130 of the plurality of support members. In this
aspect, each creel mount 150 can be configured to selectively hold
a yarn package 20. Further, each creel mount 150 can be operably
positioned to extend along a mount axis. As illustrated in FIG. 4,
it is contemplated that the mount axis A of each respective creel
mount 150 can substantially bisect the vertex of the front portion
of the substantially triangular base 110.
[0033] In use, and referring to FIGS. 3, 4, and 5, the mobile creel
10 can be provided to organize yarn packages 20 and direct yarn to
a carpet manufacturing process. A yarn package 20 can be secured on
at least one spaced creel mount 150 of the plurality of spaced
creel mounts. The front portion of the base 110 of at least one
selected support frame 100 can be positioned so as to engage the
lower portion of the upright creel docking post 200. Further, the
yarn of at least one yarn package 20 secured on the at least one
selected support frame 100 can be positioned in communication with
the means for directing at least one path of yarn from the at least
one support frame 100 to a selected process.
[0034] Optionally, and referring to FIGS. 3, 4, and 5, the
plurality of spaced creel mounts 150 can be evenly spaced along at
least two support members 130 of the plurality of substantially
upright support members to create a plurality of levels 170 for
securing yarn packages 20. In one aspect, the step of securing a
yarn package 20 on at least one creel mount 150 further comprises
securing at least two yarn packages on respective creel mounts
within a selected level for securing yarn packages. In a further
aspect, the step of positioning the yarn of at least one yarn
package 20 further comprises tying yarn from a first yarn package
secured to a first spaced creel mount within the selected level to
yarn from a second yarn package secured to a second spaced creel
mount within the selected level.
[0035] Although several embodiments of the invention have been
disclosed in the foregoing specification, it is understood by those
skilled in the art that many modifications and other embodiments of
the invention will come to mind to which the invention pertains,
having the benefit of the teaching presented in the foregoing
description and associated drawings. It is thus understood that the
invention is not limited to the specific embodiments disclosed
hereinabove, and that many modifications and other embodiments are
intended to be included within the scope of the appended claims.
Moreover, although specific terms are employed herein, as well as
in the claims which follow, they are used only in a generic and
descriptive sense, and not for the purposes of limiting the
described invention, nor the claims which follow.
* * * * *