SPINNING DEVICE FOR MAKING SLUB YARNS

Technical Field

This invention is about a spinning unit of a spinning machine used in reverse side core yarn production.

Previous Technique

Fancy yarn production in ring spinning is very important in terms of providing new market opportunities and the creation of new varieties of products. Core yarn, called as "Slub Yarn" in the market, is produced by including extremely expensive computer-controlled electromechanical systems on ring machines. With the help of these included systems, the mid-sub grooved cylinder cycles and grooved front output cylinders of the ring machine are controlled and the fancy yarn production (so called slub yarn) is carried out by changing in a controlled manner the cylinder cycles at desired times. In this system, the ring machine which is producing computer-controlled yarn by means of a flyer at a constant "Ne", by replacing the spinning between the mid-sub grooved cylinder and front cylinder through increasing or decreasing the mid-sub grooved cylinder cycle, the "Ne" of the output yarn is changed. The "Ne" alteration in the featured yarn is reflected on the yarn as a thin or thick point. If the cycle of the mid-cylinder is decreased, the yarn becomes thinner as the spinning between the front and mid grooved cylinders will increase. In the event that the cycle of the mid-cylinder is increased, the yarn becomes thicker as the spinning will decrease. Although that the number of fibre entering the spinning system does not change depending upon the flyer "Ne", the "Ne" of the featured yarn can be controlled as desired, by changing the cycle of the exit cylinder in a controlled manner. The cycles of the cylinders used in this system are controlled by means of a computer program according to being programmed. This system can only be used on machines on which it can be installed and requires a very expensive investment. In addition, it causes decrease on machine operation cycles, increase in electricity consumption even a little, decrease in production and increase in yarn production cost during the operation of the system. As the cylinder cycles in this system can be controlled by lowering they are preferred to add thick points to the normal yarn body. This is called "Positive Slub". This indicates the thick points in the yarn. If thin points are desired, the entire body of the yarn is set thinner, giving an appearance to the yarn as if there are thin points by providing the machine making continuously thick points. This causes the machine to operate constantly under excessive load with high electricity consumption which means lower cycles and less production. In addition, very short thin point formation is enabled in such systems on condition that the cycle of the front-grooved output cylinder is stopped in short intervals. These systems can only be used on the machine it is applied and are very high cost systems.

Within the international patent document No. WO2008068294, the method and device related to fancy yarn production are discussed. Ring machines are used for the production of fancy yarns and the machine contains at least two twisted yarns and fiber yarns received from the tensile device. The device holding the carrier yarn provides at least one support yarn package. The carrier yarn guide feeds minimum two support yarn one of which is farther than the other.

Within the United States patent document No. US6263654, the adjustment of the ring machine for concentrated fiber is mentioned. The ring spinning machine adjusted for concentrated spinning but not twisted fiber contains a cylinder that carried the fiber yarn wire. The cylinder is provided by opening a hole on the outer sleeve. The outer sleeve of the cylinder is supported by a framework and the holes provide frequent loops. Within the United States patent document No. US2007137165, the method and device for fancy yarn production is mentioned. The aim of the invention is to create a method that enables reproduction from the fancy yarn that was already produced. The model fancy yarn passes through a sensor for measuring purposes and the diameter of the model fancy yarn is constantly measured. The information related to the measured diameter is evaluated and the formation of the effect on model fancy yarn is determined. Twisting settings are set according to the formation of the effect and is used in the production of fancy yarn.

Brief Explanation of the Invention

The aim of this invention is to enable a spinning unit on a spinning machine that produces reverse slub yarn.

Detailed Explanation of the Invention

The "Spinning machine spinning unit" which was effectuated to achieve the aim of this invention is indicated in the enclosed figure. Regarding this figure;

Figure 1- Top schematic view of the spinning machine spinning unit subject to invention

Figure 2- Side schematic view of the spinning machine spinning unit subject to invention

Figure 3- The schematic view of the spinning system where the reverse slub yarn is produced.

Figure 4- Perspective view of the sleeve

Figure 5- Side view of the channel-opened sleeve

Figure 6- Side view of the sleeve surface area

Figure 7- Top view of the sleeve surface area

The parts in the figure are numbered one by one and the references of those numbers are given below. 1. Spinning Unit

• 2. Back spinning cylinder 3. Mid spinning cylinder

4. Front spinning cylinder

5. Back sleeve

6. Upper-mid sleeve

7. Upper apron

8. Lower apron

9. Front sleeve

91. Channel

10. Flyer Guide

F: Flyer

Ϊ: Yarn

K: Thick point on the yarn (face slub)

L: Thin point after the thick point on the yarn (reverse slub)

J: Yarn in normal thickness after the sleeve

The spinning machine spinning unit (1) invention includes the following;

At least a single-grooved back spinning cylinder (2) into which a flyer (F) produced of any or of a raw material enters to be twisted, where movement transmission is enabled with the help of gears driven by a motor,

At least a single-grooved mid spinning cylinder (3) on which an apron (8) is placed, where movement transmission is enabled with the help of gears driven by a motor,

At least a single-grooved front spinning cylinder (4) from which the flyer (F), the movement transmission of which is enabled with the help of gears driven by a motor, exits as yarn (Ϊ)

At least one back sleeve (5) located on a roller spindle in a state to provide free rotary movement, which is driven from the back spinning cylinder (2) by means of surface pressure and which will enable the spinning of the first fibers in a controlled manner that entered the spinning system in a form of flyer. - At least one upper-mid sleeve (6) located on a roller spindle in a state to provide free rotary movement, which is serving as a bearing for an apron (7) located over it by means of a connected roller cage and which will enable the rotation of the apron (7) in a controlled manner.

- At least one upper apron (7), which can freely rotate over the upper mid sleeve (6) by means of a roller cage, which is located over the grooved mid spinning cylinder (3), and which is providing the control of the fiber by virtue of the movement received from the pressure and friction forces of the mid spinning cylinder (3) and upper mid sleeve (6)

At least one lower apron (8) which is in tensile state by means of a tie rod located over the grooved mid spinning cylinder (3), which rotates through the drive of the mid spinning cylinder (3) and which enables fiber control between itself and the upper apron.

At least one exit front sleeve (9) located over a roller spindle in a state of free rotary movement which is holding the fibers selected to be yarn by pressing them by virtue of the pressure applied on the grooved front spinning (4) cylinder and on itself, and which proceeds them uninterruptedly enabling in this way the spinning of the yarn.

At least one flyer guide with a hole in the middle, located before the back spinning cylinder (2) , which is guiding the flyer, which sends the flyer to the grooved back spinning cylinder (2) and between the back sleeve (5).

The front sleeve (9) surface, which can be in different thicknesses but which is in the same thickness throughout the sleeve (9) width, is covered preferably with rubber-based material. The rubber material can be located over an aluminum ring with a hole in the middle as well as it can be a part with a hole in the middle made of the material which is forming the sleeve. The thickness of the rubber covered part of the sleeve (9) or the outer diameter of the sleeve (9) can be at a requested diameter. The diameter limit, is the own limit of the machine to produce yarn. The front sleeve (9) determines the quality and properness of the yarn (I) by means of the number of fibers it is delivering.

The fibers pressed between the front spinning cylinder (4) and front sleeve (4) are twisted by being continuously pulled through a spinner that rotates at a certain cycle. The yarn (I) exiting from the front spinning cylinder (4) passes through the yarn guide is spun between the hook ring and spinner and is winded onto the bobbin over the spinner. The raw material of the upper apron (7) and the lower apron is a rubber weighted part.

At the spinning unit of the spinning machine the fineness, thickness and smoothness of the yarn is determined by means of the fiber control of the front sleeve (9). At the spinning unit (1), the front sleeve (9) and front spinning cylinder (4) provides that the fiber which they are controlling by moving it forwards is included to the yarn (I). Whatever the thickness of the fiber delivered through the mid spinning cylinder (3) and sleeves (7,8), only the fiber compressed between the front sleeve (9) and front spinning cylinder (9) is moved forwards. The non- compressed fiber moves according to the orientation of the apron (9).

The front apron (9) at the spinning unit (1) of the spinning machine has been reshaped in order to enable fiber control in a desired manner. Over the front sleeve (9), a channel (91 ) at a certain width and depth is opened. In order to provide that fiber at a requested quantity is controlled and delivered, the channel is opened over the sleeve (9) in parallel to the spinning cylinder (4), in a state providing an angle of 90° to the flow direction of the fiber and yarn in the spinning system or over the fiber route, throughout the length of the sleeve. The said channel (91) can be at a desired length, width and depth. The channel (91) opened on the front sleeve (9) comes vertical to the fiber flow direction or is located on the fiber flow route. The channel (91) over the sleeve (91) can be opened throughout the sleeve width as well the along the fiber quantity passing over the sleeve (9). As the fiber not compressed and hold by the grooved front spinning cylinder (4) and by the front sleeve (9) will remain within the channel (91) it cannot be controlled. While the sleeve (4) delivers the fiber which it compressed throughout its surface between the grooved spinning cylinder and itself for spinning, the fibers, which were not hold along the channel at the time the channel coincides over the grooved front spinning cylinder (4), are pulled and taken by the spun yarn (I) and are included to the spun yarn. In this way, the channel enables that the fibers which should not be on the yarn are included to the yarn (Ϊ). Therefore, the fibers which are included to the yarn in excess form a thick point over the yarn. The thick point being formed originates a slub with a certain length and thickness called as the positive slub. As all fibers taken into the channel in an uncontrolled manner will be hindered whether being the fibers that should be on the continuing part of the spun yarn (I), the thick point being formed, in other words the positive slub provides that a thin (negative slub) is formed after the positive slub. In this way, by virtue of the channel located on the front sleeve (9), a negative slub that follows a positive slub is produced enabling the production of a reverse slub yarn (Ϊ).

The channel to be opened on the front sleeve (9) should be such narrow to avoid that the fiber will loss all control leading to the break of the yarn. It also must be wide enough to allow the yarn being spun to draw an amount of fibre. As no fiber will be hold between the grooved front spinning cylinder and front sleeve in case that the channel is opened wide, the spinning of the yarn is not effectuated. In a case when the opened channel is to narrow, adequate fiber escape to form a slub effect is not enabled. The width of the channel (91) to be opened on the sleeve (9) depends on the "Ne" of the spun yarn (Ϊ), on the "Ne" of the used flyer, fiber flyer raw material being used, spinning applied in the spinning unit, the slub effect desired to be effectuated, output speed of the ring machine, twisting given to the yarn and on the fiber holding feature of the sleeve. As the diameter of the sleeve can show variability, it does not affect the width of the channel (91).

For flyer "Ne" of thick flyers and average fiber lengths the channel needs to opened wide and deep, for flyer "Ne" of thin flyers and with short average fiber the channel needs to be opened narrower and less deep. However, regarding flyer "Ne" with long average fiber length but which are thin the channel is also needs to be opened in wide and deep position for the formation of reverse slub.

In order to increase the flam effect in a preferred application of the invention, more than one channel can be opened around the sleeve (9). As the sleeve diameter will determine the sleeve surrounding, a slub is formed two times around the sleeve regarding a sleeve with two opened channels.

In another application of the invention, if the sleeve diameter is large and therefore its periphery is long, three channels can be opened to the sleeve periphery if requested and if there is a spinning possibility.

The outer diameter of the sleeve (9), the desired effect and the spinning capability of the machine determined the number of channels to be opened. Sleeves can be installed at any desired time on spinning machines enabling slub production with any machine.

Regarding another application of the invention, the shape of the channel be opened on the sleeve surface are geometric or non-geometric shapes such as rectangular, square, circle, triangle, parallel edge etc. The slub frequency is determined by the sleeve (9) outer diameter and by the number of channels open to the periphery of the sleeve. The length of the slub is determined dependant on the width of the channel in relation to the yarn (I) "Ne" and flyer (F) "Ne".

In proportion with the channel (91) width, the drawing of fiber into the yarn is allowed and the yarn effectuates the thin point formation after the thick point. These thick and thin points are called as the positive and negative* slub. Deep channel creates more slab effect as a wide channel creates a longer slub effect.

Deep and wide channels lead that more fibers are remained as uncontrolled. Narrow and relatively shallow channels provide that more fibers are transferred by being controlled. In this case, the slub effect is significant or less significant or short or longer. While the width of the channel (91) to be opened on the sleeve (9) should be minimum 1 mm, the maximum width is the yarn (I) spinning limit in the spinning system. The channel (91) depth must be minimum 0.3 mm. In the event that the channel (91) depth is less deep, flam appearance is not forming as fiber non-controlling would not be provided.

Sleeve (9) diameters are in different diameters according to the characteristics of the spinning unit. (1).

The periphery of the sleeve is calculated by multiplying with the π number (pi) which is 3.14. In an application the periphery of the sleeve, the diameter of which is 32 mm, is calculated as 104 mm. In a case where the sleeve width is accepted as 30 mm and the rubber thickness is considered as 6 mm, it is observed that the sleeve will have a surface of 30 mm width and 104 mm length with a rubber material in a thickness of 6 mm. When two channels on the sleeve surface are opened in a width of 4 mm, depth of 4 mm and in a distance of 8 cm, a reverse face slub can be formed with this channel in two different periods. The first period is the distance shown in figures 6 and 7 indicated as a, which is 8 cm in this sample. In the second period it is calculated by means of the formula "c-2b-a" Regarding a, b and c points seen in figures 6 and 7 the following inferences are valid. The channels on the sleeve surface should be placed on the fiber flow path. Placing the horizontal channels in a state of enabling a 90 degree angel to the material flow and placing the different shape channels on the fiber flow path would be adequate.

"a" is the first distance and the first slub period between both channels which is calculated through "c-2b-d". "b" is the channel width which is calculated as "(c-a-d)/2" in case that both channels are at the same width.

"c" is the total periphery and total report length of the sleeve which is calculated by "2.7t.sleeve semi-diameter.

"d" is the second distance and the second slub period between both channels and is calculated by "c-2b-a".

The slub periods are calculated by determining the starting points of the slubs through the "a" and "d" values located on the sleeve surface of the spinning unit. Channels can be opened in any desired number on the sleeve surface provided that there is at least one channel. The issues that must be considered while opening channels are the slub effect, spinning unit characteristics and the flyer, yarn "Ne"' The following steps should be followed on the spinning unit (1): the entering (100) of the flyer into the spinning unit (1)

- The flyer that entered the spinning unit passes through the guide (10) the flyer is moved forward trough the sleeve and grooved cylinder by means of the pressure formed on the back sleeve and with the drive of the back spinning cylinder

the flyer is pushed (130) between the lower apron (8) and upper apron (7) the flyer (F) is compressed between the lower apron (8) and upper apron (7) surfaces and is delivered forward (140) in a controlled manner

The flyer is pushed between the grooved front spinning cylinder (4) and front sleeve (9) in a controlled manner through the lower apron (8) and upper apron (7)

Delivering the fibers outwards (160) which are hold by being compressed between the grooved front spinning cylinder (4) and front sleeve (9).

When the grooved front spinning cylinder and the channel (making a 90° vertical angel to the fiber flow direction) coincide, the uncompressed fibers between the sleeve (9) and cylinder (4) are pulled in an uncontrolled manner by the yarn being spun.

Upon that the fibers, which actually should not be normally on the yarn with spinning, pass through the yarn surface, a "Face Slub (Positive Slub)" is formed on the yarn surface.

As a result of taking the fibers by pulling, which could not be compressed between the grooved front spinning cylinder (4) and front sleeve (9) due to the channel (91 ) and as a result of diminishing number of the fiber, "Reverse Slub (Negative Slub)" is formed on the yarn surface after the thick point.

Delivering fibers at a certain amount (being constantly pulled in a controlled manner between the non-channel surface of the front sleeve and the grooved-front spinning cylinder) to be spun as normal yarn.

After that the Flyer (F) enters the spinning unit (1 ), the flyer (F) passes through the flyer guide and arrives between the back lower groove cylinder (2) and back upper sleeve (5). By means of the pressure created on the back sleeve (5) and by the drive of the back lower grooved-spinning cylinder (2), the flyer is pushed forwards through the apron (5) and the grooved-cylinder (2). By means of the lower apron (8) located over the grooved mid spinning cylinder (3) and over the tie-rod, the flyer is pushed between the upper sleeve (7), which is in tensile state by virtue of a roller cage located over the upper mid sleeve (6) on a rotary spindle and which is rotating with the pressure applied on it. The flyer is compressed between the lower apron (8) and upper apron (7) surfaces and is delivered forward in a controlled manner (140) and is transmitted to the front apron (9) by the grooved front spinning cylinder. The fibers hold between the grooved front spinning cylinder (4) and front sleeve (9) by being compressed, are delivered outwards the front spinning cylinder to be spun as yarn. When the grooved front spinning cylinder and the channel (making a 90° vertical angel to the fiber flow direction) coincide, the uncompressed fibers between the sleeve (9) and cylinder (4) are pulled in an uncontrolled manner by the yarn being spun. Upon that the fibers, which actually should not be normally on the yarn with spinning, pass through the yarn surface, a "Face Slub (Positive Slub)" is formed on the yarn surface. As a result of taking the fibers by pulling, which could not be compressed between the grooved front spinning cylinder (4) and front sleeve (9) due to the channel (91) and as a result of diminishing number of the fiber, "Reverse Slub (Negative Slub)" is formed on the yarn surface after the thick point.

Delivering fibers at a certain amount (being constantly pulled in a controlled manner between the non-channel surface of the front sleeve and the grooved-front spinning cylinder) to be spun as normal yarn. Reverse face slub yarn is produced by repeating this process (Figure 3).

By means of the sleeve (9) used on the spinning unit, the production of the slub fancy yarn which normally requires very high investment costs and which is a very expensive production, the production is enabled without a cost that requires almost no investment which can be produced on any requested machine. Based on this main concept, it is possible to develop various applications of the spinning unit subject to invention as the invention cannot be limited with the samples explained herein which is actually in the form indicated in the requests.