Abstract:
A beam rack utilizes a plurality of mini-beams located in substantially planar layer arrangements wherein the yarn ends are fed in substantially the same direction to directors which direct the yarn to a header. The mini-beams are stacked both horizontally and vertically in the beam rack. The beam rack preferably includes a bearing arm for supporting a plurality of mini-beams along bushings of the mini-beams. 
     The mini-beam is loaded with a warper wherein a plurality of yarn ends are preferably loaded on a single mini-beam. The yam ends can vary anywhere from one yarn to sixteen or more yarns per mini-beam depending on the number of mini-beams required to correspond with yarn feeds for a particular pattern. The yarn ends proceed from the mini-beams to the director, a header and on to a tufting machine.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to devices which are utilized to supply yarn to tufting machines, and more specifically to a device and a method of using a plurality of mini-beams to supply a tufting machine with yarn. 
     DESCRIPTION OF RELATED ART 
     The traditional method of supplying a tufting machine with yarn has been to utilize a creel such as the creel disclosed in U.S. Pat. No. 5,613,643. Creels are generally frames which support a plurality of stationary yarn cones. A bolt of yarn, or yarn cone, is placed on a cone holder. An end of the yarn may then be directed through a guide and then to a yarn tube. From the tube, the yarn is typically directed to a header located at the top of the creel most adjacent to a textile machine being served. Yarn strands then exit the header and proceed to a particular needle for tufting through a fabric to create a pile product, such as a carpet. When a particular bolt of yarn is almost exhausted, another bolt of yarn may be placed on the cone holder in the creel and the ends of the yarn spliced together. The yarn cones utilized are typically provided by yarn companies in predetermined amounts of yarn. 
     A disadvantage of the use of yarn creels is that for a broad beam tufting machine, which may often have as many as 1,000 needles or more, in each of two rows, a separate yarn cone is necessary for each needle. The space required to accommodate 2,000 yarn cones is substantial which has led to many attempts to better utilize space, including placing yam creels on the second floor and feeding yarns down to a ground floor tufting machine. 
     One method developed to conserve space by eliminating the use of yam creels is the use of a warper and beam. In this system, one yam creel is used to hold all the yams that would be fed to approximately 100 to 150 needles. A large roll or “beam” is mounted in a drive known as a warper and is wound with a predetermined amount of yarn from each of the yam cones in the creel, so over one hundred separate ends of yarn are on the beam. The beam may then be placed adjacent to a tufting machine and the yams from the beam threaded to needles across the tufting machine. In this fashion approximately six beams take the place of a much larger yam creel assembly. Unfortunately, the use of a beam of this type is limited because all of the yams must feed at the same rate. As a result, these regular size beams are not generally suitable for use with tufting machines utilizing pattern attachments. 
     B &amp; J Machinery Co., Inc., of Dalton, Ga., has previously marketed a mini-beam rack with yam tubes, illustrated in FIG. 3, which employed the use of mini-beams. Mini-beams could be wound on a warper and placed in the specially designed beam rack. The beam rack of this design utilized a plurality of tubes disposed to receive yarn from a given mini-beam. The tubes directed the yarn from the mini-beams to a header for delivery to a specific tufting machine. 
     The use of a plurality of mini-beams allowed each mini-beam to be wound on a warper with only about a dozen yarns. The yarns from one mini-beam could be directed to a single set of yarn feed rolls on a scroll-type pattern attachment, typified by that in U.S. Pat. No. 5,983,815. In this fashion between about 60 and 144 mini-beams could supply yarns to a pattern attachment as each mini-beam would more independently depend upon the yarn requirements for its corresponding pattern attachment yam feeder rolls. 
     The prior art rack design was similar to a creel in that it incorporated tubes which directed yarn to a header and then on to a tufting machine. This design was loaded with mini-beams from within the rack. On any given plane of mini-beams, the yams were directed towards the tufting machine from one set of mini-beams and away from the tufting machine by the other set of mini-beams. The tubes then directed the yarns towards a header for use by the tufting machine. By having multiple sets of mini-beams directing a plurality of yams away from the tufting machine, a relatively large quantity of tubing was required to redirect yam back towards the tufting machine. Additionally, the prior art beam rack design took up a considerable amount of space, similar to a creel. 
     When yarn tubes are present, an operator must direct a yarn through the tubing, usually from the header to the point nearest the yarn supply. This process may be accomplished utilizing compressed air to blow a guide yarn down each yarn tube. Once the yarn is blown through the tube, it connected to the yarn supply and yarns from the yarn supply can be pulled back through the tubing and the header. The yarn from the yam supply is then connected to the needle in the tufting machine. The process must then be repeated for every tube connected to the header. This process would be greatly simplified by removing, or reducing, the number of tubes. Accordingly, a need exists for a beam rack which does not require the use of yarn tubes. 
     The mini-beams of the prior art design have also been improved upon by the mini-beam illustrated in FIG.  2 . The prior art mini-beams had a similar overall appearance, however, the prior art mini-beams rested in the rack of FIG. 3 on smaller diameter extension members instead of on a larger diameter bushing. Accordingly, when a tufting machine would slow down there was very little friction between the mini-beam and the beam rack. There was a tendency for the inertia of the mini-beam, especially when heavily loaded with yarn, to maintain mini-beam&#39;s rotational speed when the tufting machine slowed. This resulted in yarn unwinding off the mini-beam without being taken up by the tufting machine. This yarn could sag external to the tubes and become tangled. Accordingly, a need exists to reduce the risk of possible entanglement of yarn. 
     Furthermore, each prior art beam rack was designed to be utilized with a particular tufting machine pattern attachment. The tubes provided a specific yarn to a specific header location to feed a particular yam feed module of the yarn feed pattern attachment of the tufting machine. If a different pattern attachment were desired to be used, another beam rack having the correct tube and header configuration would be necessary. This made each prior art mini-beam rack useful only with pattern attachments of a single manufacturer and mini-beam racks could not be freely interchanged between machines. 
     Accordingly, a need exists to provide a beam rack which may supply a textile machine with a plurality of yarns from mini-beams wherein the beam rack is flexibly adaptable for a variety of textile machines and/or patterns. 
     Numerous alternations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. 
     SUMMARY OF THE INVENTION 
     The beam rack of the preferred embodiment utilizes a plurality of mini-beams. The mini-beams are preferably located in substantially planar layer arrangements wherein all the yam ends are fed in a forward direction to director which guides or orients the yarn toward a header. The mini-beams are stacked both horizontally and vertically in the beam rack. The beam rack preferably includes a bearing arm for supporting a plurality of mini-beams along bushings of the mini-beams. 
     Each mini-beam is loaded with a warper wherein a plurality of yarn ends are usually loaded on a single mini-beam. The number of yarn ends can vary anywhere from a single yarn to sixteen or more yarns per mini-beam depending on the pattern to be tufted on a particular tufting machine. In the usual case, there is at least one yarn end for each repeat of the pattern, and a typical broad loom tufting machine may have as many as sixteen pattern repeats. The yarn ends will usually proceed from the mini-beams to a pattern attachment feeding into a tube bank and then to the needles of the tufting machine. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a beam rack supporting two mini-beams according to the present invention with two mini-beams in position; 
     FIG. 2 is a perspective view of two mini-beams relative to a pair of arms according to the present invention; and 
     FIG. 3 is a perspective view of a prior art mini-beam rack. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Accordingly, FIG. 1 is a perspective view of the beam rack  10  of the preferred embodiment. The beam rack  10  has a frame  11  comprised of a support section  12  and a base  13 . The base  13  may include a base member  14  and rearwardly extending legs  16 . The support section  12  may include supports  20  and directors  32 . The support section  12  is mounted upon base  13 . The directors  32  may assist in providing lateral stability to the support  20  of support section  12 . 
     The legs  16  of the base  13  preferably include feet  18 . The feet  18  may include roller mechanisms and wheel locks to allow for the easy movement of the beam rack  10 . 
     The legs  16  preferably connect to the base member  14  as illustrated in FIG.  1 . Braces  22  may also be utilized to connect the legs  16  to the base member  14 . 
     The supports  20  of the support section  12  are illustrated as being connected to base  13 . Preferably, the supports  20  are connected to the base member  14 . 
     Connected to the supports  20  are outwardly extending arms  24  and, preferably, arm supports  34 . The arms  24  preferably extend from a rear side of the supports  20  to provide mounts for the rear and front mini-beams  36 ,  37 . The legs  16  of the base  13  extend from the rear side of the support section  12 , as do the arms  24  in order to prevent the beam rack  10  from tipping about the base  13 . Alternatively arms could extend both forwardly and rearward of the support section  12 . This alternative arrangement could facilitate placing mini-beams in the beam rack  10 , but would slightly complicate feeding of yarns. 
     As may best be seen in FIG. 2, the inner surfaces of arms  24  are preferably provided with bearing arms  26 . At least a portion of the bearing arms  26  are preferably constructed of a material such as ultra high molecular weight polyethylene (UHMW) or any other bearing-type material. Alternatively, the bearing arms  26  may support bearings which cooperate with or are mounted upon the mini-beams  36 ,  37 . Connectors  30  may be utilized to connect the bearing arms  26  to the arms  24 . Connectors  30  may be any acceptable fastener such as screws and the like. Alternatively bearing arms  26  could be adhered or otherwise connected to arms  24 . 
     The bearing arms  26  preferably contain mini-beam positioning locators such as beam supports  28 . The beam supports  28  of the preferred embodiment are hemispheric cutouts in the bearing arms  26 . Since bearing arms  26  are preferably constructed of a bearing type material, the cutouts provide a surface which retains the mini-beams  36 ,  37  in a desired location while allowing rotational movement of the mini-beams  36 ,  37 . As can be seen in both FIGS. 1 and 2, a plurality of beam supports  28  may be located on a single bearing arm  26 . 
     The mini-beams  36 ,  37  are illustrated in detail in FIG.  2 . The mini-beams  36 ,  37  are preferably comprised of a pair of spaced apart discs  38  connected by an axis such as cylinder  40 . A rod  48  may extend through the cylinder  40  and discs  38  to retain the relationship of the discs  38  to the cylinder  40  as well as to one another. Fastening bushings  42  may be utilized to secure to the discs  38  and the cylinder  40 . The rod  48  may extend a distance beyond the bushings  42  to form extensions  46 . Similar extensions were utilized in the prior art mini-beams to provide an interface with the mini-beam supports of the prior art design illustrated in FIG. 3 to allow the mini-beams to rotate relative to the supports. Fastening bushings were not utilized in the prior art design. Instead fasteners, which were nuts having planar sides, secured the discs  38  to the cylinder  40 . Additionally, the rod  48  and the cylinder  40  may be integral to one another. 
     Referring back to FIG. 2, the bushings  42  of the preferred embodiment are round and of a larger diameter than the extensions  46 . The increased diameter of the bushings  42  increases the surface area which interfaces with the beam supports  28  of bearing arms  26  to provide sufficient friction to reduce the effects of inertia on rotating mini-beams  36 ,  37 . Prior art mini-beams rotating only on relatively small diameter extensions tended to rotate too freely relative to the inertia of the mini-beam and would sometimes unwind excess yarns. 
     Referring back to FIG. 1, rear and front mini-beams  36 ,  37  are illustrated supported by a pair of bearing arms  26 . Each of these mini-beams  36 ,  37  direct at least one, and preferably a plurality of yarn ends  50 , in a general forward direction. Although only three yarn ends  50  are illustrated extending from each mini-beam  36 ,  37  in FIG. 1, it is anticipated that as many as sixteen or more yarn ends may be utilized with each mini-beam  36 ,  37 . The yarn ends  5 O preferably proceed from the cylinder  40  to the director  32  or  33  where they are further directed towards a tufting machine pattern attachment header. The directors  32 ,  33  of the preferred embodiment are cylindrical rods. The directors  32 ,  33  preferably contact the yarn  50  and change, or angle, the direction of the yarn as it is fed off of the mini-beams  36 ,  37  thereby redirecting the yarn  50  towards the header. An outer surface of the directors  32 ,  33  may have a smooth surface portion for cooperating with the yarn  50  to change the direction of the yarn  50  without unduly wearing the yarn  50 . Alternatively, the directors  32 ,  33  may rotate, such as on bearings, to reduce wear to the yarn  50 . Rotating directors  32 ,  33  may have textured surfaces. 
     The arrangement of the mini-beams  36 ,  37  in the arrayed, or vertical and horizontal stacking fashion illustrated in FIG. 1, allows for an operator to relatively quickly direct yarn ends  50  from the mini-beams  36 ,  37  to a particular location on a header, if utilized, which may be located between the beam rack  10  and a tufting machine pattern attachment. 
     Pairs of vertically stacked mini-beams were utilized in the prior art in the beam rack design illustrated in FIG.  3 . Tubes were utilized to direct the yarn upwards to a header. However, the rearward mini-beams in the prior art beam rack fed yarns in tubes rearward and then over the beam rack while the forward mini-beams fed yarns in the tubes forward and up to the header. This resulted in different tube lengths and different yarn drag for forward and rearward facing mini-beams. In FIG. 1, rear mini-beam  36  is illustrated in a first vertical plane farther away from directors  32 ,  33  than a second vertical plane including forward mini-beam  37 . Mini-beams  36 ,  37  may also be located along a horizontal plane as mini-beams  36 ,  37  are illustrated in FIG.  1 . Both rear and forward mini-beams  36 ,  37  feed yarns  50  in the forward direction. The mini-beams  36 ,  37  may rotate in a clockwise direction to unidirectionally feed yarns  50 . The unidirectional feeding of yarns  50  have generally been found to eliminate the need to use tubing to direct yarn to a header. If tubing were desired to be used, with the unidirectional yarn feeding, the tubing lengths could be more equal and prevent the substantial variance in drag imposed on the yarns. 
     In the preferred embodiment the yarn is directed from the mini-beams  36 ,  37 , past the corresponding directors  32 ,  33 , to an appropriate location such as a header directing bar, or other guide, located either on the beam rack  10  or on a yarn feed pattern attachment. This design eliminates the steps of blowing air in the tubes to direct yarn through the tubes. As yarn is delivered from the mini-beams  36 ,  37  to a yarn feed pattern attachment, the mini-beam  36 ,  37  rotates relative to the arms  24 . In the preferred embodiment illustrated in Figures  1  and  2 , the mini-beams  36 ,  37  rotate in the cutouts, or beam supports  28 , of the bearing arms  26 . 
     Additionally, when the tubes are not a part of the beam rack  10 , the beam rack  10  has the flexibility to be easily utilized with a variety of pattern attachments. 
     Arms  24  of the beam Tack  10  are preferably spaced apart in a vertical direction a distance sufficient to allow for mini-beams  36 ,  37  to be positioned on the beam supports  38  and allowing for the yarn ends  50  to be directed away from the beam rack  10  unobstructed by the beam rack towards the directors  32 ,  33 , a tube, a header, or other structure prior to being delivered to a yarn feed attachment. Preferably the yarn ends  50  contact the directors  32 ,  33  and proceed to a header. 
     Beam racks  10  of the preferred embodiment locate mini-beams  36 ,  37  in arrays. Preferably arrays of mini-beams include at least two mini-beams in depth, namely a rear mini-beam  36  and a fore mini-beam  37 . Additionally arrays of mini-beams include a plurality of mini-beams  36 ,  37  in a vertical arrangement, approximately corresponding to a height, as well as a plurality of mini-beams across, approximately corresponding to a width. The array formation has been found helpful in providing a plurality of mini-beams in a relatively small space. Additionally, an array need not include a mini-beam on every location of the array (i.e., one example could be two mini-beams  36 ,  37  across, two mini-beams high, and some of the mini-beams  36  omitted). 
     The beam rack  10  of the preferred embodiment is ideally suited for short production run situations where the pattern being produced at a particular time will only be run for a single shift. The beam rack  10  may be loaded expeditiously compared to loading a creel. Furthermore, the beam rack  10  may be extremely useful with sample machines, and small yarn lots, and scroll-type patterns. For textiles made to order, the beam rack  10  allows for rapid placement of yarns in a desired location for use with a textile machine, providing a time saving alternative to the yarn supply choices of the prior art. Additionally, a beam rack  10  could be utilized in combination with a creel, so that each device is configured to supply certain needles with yarn. This is particularly attractive for certain related carpet designs which are produced identically except for changing colors or accent yarns. In this case, the beam rack  10  may be utilized solely for the accents so that the colors could be easily changed. Of course, it is contemplated that in most situations the beam rack  10  will totally replace creels. 
     The beam rack  10  allows a user to reduce the quantity of yarn maintained by the textile producing company. Specifically, when using creels, the textile machine operator must maintain at least one cone of every color utilized for a particular textile product. This could easily exceed 1,000 yarn cones of a particular color yarn. Furthermore, a cone must be present for each needle in the tufting machine. When utilizing the beam rack  10 , mini-beams  36 ,  37  are loaded from a source of colored yarn with a warper. The number of yarn cones required is only the number of yarns of a single color being wound on a single mini-beam in the preferred embodiment, thus eliminating the need to have an excess quantity of yarn cones on hand. 
     Utilizing a warper, a mini-beam  36 ,  37  may be loaded in approximately four to sixteen minutes depending on the number of yarn ends which will be utilized from the mini-beam. Furthermore, multiple warpers may be utilized to rapidly load mini-beams  36 ,  37  for use with the beam rack  10 . Additionally, warpers may be loading one set of mini-beams  36 ,  37  while another set of mini-beams  36 ,  37  is in use on a beam rack  10 . 
     A warper may load the mini-beams of the preferred embodiment with five yarn ends with about 4000 yards of yarn each. About twelve yarn ends may be loaded onto a single mini-beam  36 ,  37  with about 2200 yards of yarn each. When the mini-beams  36 ,  37  are utilized with a tufting machine, a ratio of about 5:1 has been achieved for the ratio of yarn loaded versus yards of carpet produced. Factors such as the gauge of machine, the width of repeat, the backing feed rate, the number of yarn ends utilized on a particular machine, and the number of mini-beams  36 ,  37  will effect the yardage of textile produced from a loaded beam rack, however, one or two typical loaded beam racks  10  will support the operating of a tufting machine for about an eight hour shift. 
     The preferred warper assemblies will comprise between about three to about eight individual warpers so that about three to eight mini-beams may be loaded simultaneously. A broad loom tufting machine will typically require between about 48 and 144 mini-beams, as a separate mini-beam is required for each set of yarn feed rolls being utilized in the yarn feed pattern attachment. 
     Numerous alternations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.