Textile core having transfer tail engagement

A textile core for winding a package of yarn. The textile core includes a tubular body having opposed ends and a bodywall formed of a paperboard material. To prevent slippage of a transfer bunch or tail formed on the core during winding processes, a plurality of spaced, discreet perforations are provided on the exterior periphery of the tubular body adjacent at least one end thereof. The perforations extend substantially around the circumferential periphery of the tubular body, and extend radially into the bodywall for only a portion of the thickness thereof. A projection adjacent each perforation is also provided, extending radially outwardly from the bodywall and formed of paperboard material removed from the adjacent perforation. The projections are capable of frictionally engaging at least one yarn winding formed on the top thereof and thus prevent slippage of the transfer tail.

FIELD OF THE INVENTION 
The present invention is directed to an improved textile core for winding a 
package of yarn. More particularly, the present invention is directed to a 
textile core having improved yarn engagement means on the exterior 
peripheral surface thereof for frictionally engaging and securing a 
transfer tail of the yarn package during winding and after winding of the 
yarn onto the core. 
BACKGROUND OF THE INVENTION 
Textile yarn cores, i.e., yarn carriers or bobbins, are widely used in the 
textile industry for winding and supporting yarn packages. In the package 
forming process, a moving yarn line is strung up on a rapidly rotating 
empty core. Typically, one or more of the initial strands of yarn are 
introduced into a starting groove cut into the surface of one end of the 
core so that the yarns are thereby secured onto the tube and subsequently 
wound onto the core in a uniform pattern. 
In building a yarn package onto a rapidly rotating core, typically a small 
number of initial yarn windings are provided at one end of the core spaced 
from the main yarn package. This initial yarn grouping is referred to in 
the art as a "transfer bunch" or "transfer tail." The transfer tail is 
segregated from the primary body of the yarn package so that an end of the 
yarn wound onto the core can be readily found at a later point in time. 
For example, the transfer tail can be subsequently tied to the yarn end of 
another yarn package to allow a series of yarn packages to be connected so 
that when the thread of the first package runs out during a manufacturing 
process, unwinding of the thread on the second package immediately begins. 
One problem encountered during and after winding of the yarn onto the core, 
particularly when the yarn core is covered with a smooth exterior paper 
covering, is the slippage of the transfer bunch or tail off of, or along 
the core. Several prior techniques of securing the transfer tail to the 
core have been proposed. In one such technique, a narrow continuous groove 
or ring is formed circumferentially about one end of the exterior 
peripheral surface of the yarn core. The yarn is held in contact with the 
groove of a rotating yarn core until several yarn windings are retained 
therein to secure the transfer bunch. 
In another technique, the circumferential exterior peripheral surface of 
the core is roughened by abrading or grinding the paper surface. This 
results in the surface filaments or fibers being raised from the body of 
the core and thus providing a continuous roughened area which will provide 
friction or retention of the yarn. 
U.S. Pat. No. 2,569,094 to Dunlap discloses another textile core for 
supporting yarn packages against slippage on the core. The core is 
disclosed as having knob-like raised configurations or bosses spaced 
circumferentially at either end of the core. The spaced bosses provide a 
configured pattern at the ends of the core adapted to anchor the end loops 
against slippage. The spaced bosses may be formed on the core either by 
forming them in a semi-circular paper blank and applying the blank to the 
core after it is formed or by embossing the raised portions in the core 
body after it is formed. This structure has not, however, achieved 
widespread commercial acceptance. 
These and other core configurations can provide some amount of anti-slip 
properties to the exterior of a core to prevent slippage of a transfer 
tail during and after winding processes. However, there can be problems 
associated with these configurations. For example, typically cores having 
a circumferential groove around one end thereof exhibit decreased core 
structural integrity. This is especially noticeable in the sidewalls of 
the core, which can exhibit reduced strength. 
Similarly, processes used to form cores having a roughened or abraded 
surfaces can also result in a weakened sidewall structure. For example, 
the core must be maintained at a specific angle while in contact with the 
abrading surface. If the angle position is moved even slightly outside of 
the beginning plane, then the abrading device can cut into the surface of 
the cone, resulting in an uneven, weakened sidewall. In addition, it is 
often desirable to provide visible indicia on the surface of the core, 
designating, for example, the source or type of yarn. Printing such 
indicia is typically difficult to achieve on a roughened surface. 
The past decade has evidenced continually increasing speeds for winding of 
yarns onto textile cores. As the winding speeds have increased, the need 
to form transfer tails at increasing winding speeds has resulted in 
increasing slippage of transfer tails either off of, or along the core, 
resulting in increasing numbers of defective yarn packages. However the 
increasing yarn winding speeds have also increased the need for yarn cores 
of high wall strength. 
SUMMARY OF THE INVENTION 
The present invention provides an improved textile core for winding a 
package of yarn. The textile core of the invention includes yarn 
engagement means for frictionally engaging a transfer tail of a yarn 
package, the formation of which does not decrease the strength of the 
core, and in particular the sidewalls thereof. Further, printed indicia 
may be easily applied to the surface of the textile core of the invention 
to provide readily accessible information regarding the product carried 
thereon. The yarn engagement means can be simply formed and provides an 
efficient and effective means for preventing slipping of the transfer 
bunch during and after winding. 
In the present invention, the improved textile core for winding a package 
of yarn includes a tubular body having opposed ends and a bodywall formed 
of a paperboard material. The tubular body may be frustroconically or 
cylindrically shaped, and is formed of any of the known types of 
paperboard material using known techniques. 
To prevent slipping of the transfer bunch during and after winding of the 
yarn to form the yarn package on the core, a yarn engagement means is 
provided to frictionally engage a transfer tail of the yarn package. The 
yarn engagement means of the invention is provided on the exterior 
periphery of the tubular body adjacent at least one end of the textile 
core and includes a plurality of spaced, discreet perforations, which 
extend substantially around the circumferential periphery of the tubular 
body, and which preferably are formed as a circumferentially aligned row 
of perforations. The core may have one row of perforations, or may include 
a plurality of circumferential arrays of perforations extending along 
substantially the entire longitudinal peripheral surface of the tubular 
body. 
Each of the perforations extend radially into the bodywall of the textile 
core. The perforations, defined by an open top and a closed bottom, are 
shallow, extending into the bodywall for only a portion of the thickness 
thereof. Thus the presence of the perforations in the sidewall does not 
adversely effect or decrease the strength of the sidewalls. 
Adjacent each of the perforations is a discreet projection extending 
radially outwardly of the bodywall of the core. The projections are 
fibrous in nature, being formed of paperboard material removed from the 
adjacent perforation. The projections are formed during the step of 
forming perforations in the bodywall of the core and thus a plurality of 
roughened contact points are provided along the exterior surface of the 
core without the need for adding extra material to the core body. The 
individual projections defined by the plurality of individual roughened 
areas provide a plurality of rough, raised surface projections for 
contacting and mechanically entangling yarn windings placed beside of, or 
onto the top of the projections. Yet because the roughened area is formed 
of a plurality of discrete projections, as opposed to a continuous 
circumferential groove or a continuous abraded area, the strength of the 
core sidewall is not adversely effected. 
In one embodiment of the invention, the textile cores of the invention are 
formed using a simple and efficient process, and do not require expensive 
and specialized equipment. In this embodiment of the invention, the yarn 
engaging means is formed by bringing a portion of the exterior peripheral 
surface of a paperboard core into pressure contact with a toothed blade. 
The toothed blade is rotated at a low speed relative to the surface speed 
of the textile core so that no groove or continuous cut is formed in the 
surface of the core. Thus the speed of the blade is just sufficient to 
provide discrete perforations in and around the circumferential periphery 
of the core. As each tooth of the blade enters into and exits the surface 
of the core, it forms a discrete projection adjacent the just-formed 
perforation by pulling a segment of paperboard upwardly and out of the 
core. Preferably, the toothed blade is a circular blade having beveled 
teeth. 
Improved textile cores according to the invention readily entangle with 
windings provided thereon and thus effectively prevent a transfer tail 
from slipping off of the core. Yet the yarn engagement means of the 
improved textile core provide mechanical frictional engagement of the yarn 
windings without a corresponding loss in the strength of the core 
sidewalls. Therefore, the textile cores of the invention can be 
effectively used in high speed processes during and after winding 
processes. The number of defective yarn packages resulting from transfer 
tail slippage is thus reduced, resulting in increased productivity and 
savings for both the manufacturer and user of the yarn package. 
In addition, the textile cores of the invention are easily manufactured and 
do not require expensive and difficult core forming techniques. Thus, 
textile cores according to the invention can have improved transfer tail 
entanglement as compared to prior art cores yet can be more efficiently 
and easily prepared as compared to prior art core manufacturing processes.

DETAILED DESCRIPTION OF THE INVENTION 
In the following, preferred embodiments of the invention are described in 
detail. It will be recognized that specific terms used in describing the 
invention are used in the descriptive sense only and not for purposes of 
limitation. Moreover, it will be apparent that the invention is 
susceptible to numerous alterations, variations and modifications within 
its scope. 
FIG. 1 illustrates a perspective view of a textile core of the invention 
having a package of yarn thereon. The textile core includes a tubular body 
designated generally at 10 having opposed ends 12 and 14. The tubular body 
comprises a body wall 16 formed of a paperboard material. Although 
illustrated as having a frustroconical, i.e. conical shape, it will be 
apparent that the tubular body could also have a cylindrical shape, 
spool-like shape or other shape. 
As illustrated in FIG. 1, body wall 16 is formed by a conventional 
convolute wrapping process known in the art. However, the body wall can 
also be formed by a spiral wrapping process. In preferred embodiments, 
body wall 16 will include multiple paperboard layers. Both the convolute 
wrapping process and the spiral wrapping process are well known to those 
skilled in the art. In general, such processes include the wrapping of one 
or more adhesive coated plies around a mandrel to provide a tubular body. 
The thickness of the body wall and the density of the paperboard ply used 
in the wrapping process are chosen to provide the desired strength in the 
resultant body wall. For example, where the core is intended for a 
light-duty or light-weight uses, the paperboard ply can have a light 
density and/or light weight and the body wall thickness can be relatively 
low, for example, in the range of from about 0.065 inches to about 0.090 
inches. For heavy-duty uses, a thicker body wall, for example, in the 
range of between about 0.090 inches and about 0.150 inches is needed and 
typically a heavy and/or thick paperboard ply material is used. 
FIG. 1 also illustrates a transfer bunch or transfer tail of the yarn 
package, designated generally at 18. As shown in FIG. 1, transfer tail 18 
of the yarn package is circumferentially positioned around the exterior 
periphery of tubular body 10 adjacent one end 14 thereof. 
In addition, FIG. 1 illustrates yarn engagement means of the invention, 
designated generally at 20, also circumferentially provided around the 
exterior periphery of tubular body 10 adjacent end 14. As seen in FIG. 1, 
yarn engaging means has the appearance of a plurality of circular-shaped 
areas linearly aligned in two spaced-apart rows and circumferentially 
extending around the exterior periphery of tubular body 10. 
Yarn engagement means 20 is provided to mechanically entangle and hold the 
transfer tail yarn windings at a location spaced from the main yarn 
package which is built onto the yarn core. As known in the art, the 
transfer tail can be tied or otherwise joined to the yarn end from another 
yarn package as previously described. 
FIG. 2 is an enlarged fragmentary perspective view of one end of the 
textile core of FIG. 1 illustrating an enlarged view of yarn engagement 
means 20 of the invention. Yarn engagement means 20 for engaging yarn 
windings includes a plurality of spaced, discrete perforations 22. 
Perforations 22 extend substantially around the circumferential periphery 
of tubular body 10. As used herein, the term "substantially around the 
circumferential periphery" refers to the presence of a plurality of 
spaced, discrete perforations extending around greater than at least half 
of the circumferential periphery of tubular body 10. Preferably the 
perforations extend around more than about 60 percent, more preferably 
around more than about 75 percent, and most preferably extend around more 
than about 90 percent of the circumferential periphery of the tubular 
body. 
As illustrated in FIG. 1 and FIG. 2, the plurality of discrete spaced-apart 
perforations are linearly aligned and extend circumferentially in two 
spaced-apart rows around the exterior periphery of the tubular body 10. As 
explained in more detail below, yarn engagement means 20 can include other 
arrangements of perforations 22, such as a spiral arrangement thereof, 
although preferably the perforations are in a substantially linear 
alignment. The yarn engaging means can include one such linear array, two 
arrays as illustrated, or more, and can be formed as plurality of 
circumferential arrays of perforations extending substantially across the 
entire longitudinal peripheral surface of tubular body 10. A core having a 
plurality of circumferential arrays is illustrated in FIG. 8. 
FIG. 3 is a greatly enlarged cross-sectional view of the textile core of 
FIG. 2 taken along line 3--3, illustrating perforations 22 of yarn 
engaging means 20 of the invention. As best seen in FIG. 3, each of 
spaced, discrete perforations 22 extend radially into bodywall 16. 
Perforations 22 extend radially into bodywall 16 for only a portion of the 
thickness thereof, preferably to a depth of from about 0.028 to about 
0.030. This is advantageous in that the structural integrity, and thus the 
sidewall strength, of the tubular body is not diminished. Thus, the 
textile core of the invention can better withstand the stresses involved 
in winding and subsequent processes than prior textile core 
configurations. Each of spaced, discrete perforations 22 are further 
defined by an open top 24 and a closed bottom 26. 
Each spaced, discrete perforation 22 is adjacent a projection 30 which 
extends radially outwardly from the peripheral surface of bodywall 16. 
Projections 30 are fibrous in nature, comprising paperboard material which 
is removed from each adjacent perforation 22 during formation thereof. 
Outwardly extending projections 30 act to roughen the surface of body wall 
10 along a plurality of discrete locations so that a transfer tail, 
instead of being placed against a relatively smooth outer covering over 
which it can slide, will be frictionally engaged and held. Because the 
transfer tail is frictionally engaged by projections 30, the depression of 
each of perforations 22 can be shallow; there is no need for the transfer 
tail to be engaged within a continuous groove or engaged within the 
perforations. 
Perforations 22 and projections 30 are provided in number sufficient to 
engage yarn windings and prevent slippage thereof. Preferably, bodywall 16 
comprises about 10 to 30 perforations per inch, and more preferably about 
15 to 25 perforations per inch, around the circumferential periphery of 
tubular body 10. 
FIG. 4 is a cross-sectional view of yarn engagement means 20 of FIG. 3 
taken along line 4--4 and illustrating a plurality of yarn windings 32 
formed on the top thereof. As will be seen the projections frictionally 
engage one or more of the windings to thereby anchor the winding or 
windings on the surface of the core. Windings formed on top of the 
`anchored` winding or windings are frictionally engaged with the 
underlying winding(s) and are thereby also anchored in place. FIG. 4 
further illustrates that each of perforations 22 extend radially into body 
wall 10 for only a portion of the thickness thereof. Although perforations 
22 appear in FIG. 4 as having a substantially square shape, it will be 
appreciated by the skilled artisan that perforations 22 may have other 
configurations, for example, have at least one angled sidewall. 
FIG. 5 is a perspective view of one preferred process for forming a textile 
core in accordance with the present invention and illustrates a textile 
core in contact with a rotating toothed blade 40. To form the textile core 
of the present invention, toothed blade 40 is provided and brought into 
pressure contact with a portion of the exterior peripheral surface of a 
tubular body 10 of a paperboard core. Toothed blade 40 is rotating at a 
low speed which is insufficient to form a continuous cut in the surface of 
the core but which is sufficient to provide a plurality of spaced, 
discrete perforations 22 as described above extending substantially around 
the circumferential periphery of the core, each of the perforations 
extending radially into the body wall for only a portion of the thickness 
thereof. As toothed blade 40 comes into pressure contact with a portion of 
the peripheral surface of the core, paperboard material which is removed 
by the toothed blade to form perforations 22 is lifted so that paperboard 
projections 30 extends radially outwardly of the core body wall adjacent 
each perforation. 
FIG. 5 illustrates one preferred construction of toothed blade 40. Toothed 
blade 40 includes a substantially planar blade body 42 having two opposed 
sides and including a peripheral toothed cutting edge 44. Advantageously, 
toothed blade 40 has a predetermined body width between opposing sides of 
about 0.120 to 0.125 inches. As illustrated, cutting edge 44 is beveled on 
side of the blade body 42. The angle of the bevel is preferably an acute 
angles as defined by the angle formed between the plane 46 of the blade 
body and the plane defined by the cutting edge 44 of the blade as 
generally indicated by arrows 48. Advantageously, this acute angle is from 
about 25.degree. to 30.degree. to plane 46 of blade body 42. Preferably 
the blade has between about 17 and about 18 teeth per inch, each having a 
radial height of between about 0.025 and about 0.035 inch. 
In a preferred embodiment, at least two toothed blades are provided to form 
two spaced-apart linearly arranged rows of perforations. It will be 
apparent, however, to the skilled artisan that one toothed blade up to a 
number of toothed blades sufficient to provide the desired arrangement of 
arrays of perforations extending longitudinally substantially across the 
entire exterior peripheral surface of the core may be used. 
Blade 40 is used to form the plurality of spaced, discrete perforations 22 
in tubular body 10 using a conventional apparatus as generally illustrated 
in FIG. 5. As illustrated in FIG. 5, two toothed blades are attached to a 
rotating means 50 of a conventional type and brought into pressure contact 
with tubular body 10 which is also rotated by means 52. Toothed blades 40 
are pressed into tubular body 10 during rotation of both the blades and 
the tubular body to thereby form a plurality of spaced, discrete 
perforations 22. 
Toothed blade 40 is rotated at a speed sufficient to provide a plurality of 
spaced, discrete perforations as described above. As will also be 
appreciated by the skilled artisan, the speed of rotation of toothed blade 
40 will vary depending upon the construction of the textile core of the 
invention, and the desired degree of perforation in the tubular body and 
the rotational speed of the core. In a preferred embodiment, toothed blade 
40 is rotated at a speed about the same as the speed of the core. 
FIG. 6 is a fragmentary enlarged cross-sectional view of a portion of FIG. 
5, illustrating the direction or rotation of one of toothed blades 40 and 
tubular body 10. FIG. 6 also illustrates the contact between the toothed 
blade and the exterior peripheral surface of the core during formation of 
yarn engagement means 20 of the present invention. Although FIG. 6 
illustrates rotation of tubular body 10 in a counter-clockwise direction 
and rotation of blade 40 in a clockwise direction, it will be apparent 
that these directions can be reversed. It will also be apparent that 
although toothed blade 40 is illustrated as a circular cutting blade, 
blades having a straight surface and blades having an arcuate cutting 
surface which extends less than a full 360.degree. can also be provided. 
FIG. 7 is a fragmentary greatly enlarged view of one of toothed blades 40 
and the exterior peripheral surface of tubular body 10 of FIG. 6. FIG. 7 
illustrates in greater detail the formation of the plurality of 
perforations 22 of yarn engagement means 20 of the present invention. FIG. 
7 illustrates that as blade 40 and tubular body 10 are rotated, teeth edge 
44 of blade 40 punctures the exterior peripheral surface of tubular body 
10 to form perforations 22 and raises fibers of the paperboard material to 
provide a projection 30 extending radially outwardly from the exterior 
surface of the tubular body 10. As described above, these upwardly 
extending projections 30 in the transfer tail area catch yarn or thread 
being wound onto the core and hold it in place. 
In use, the textile core of the invention is placed on an appropriate 
winder and rotated. Following initiation of the windup process, a transfer 
tail is formed either manually by an operator or by means of an 
automatically acting apparatus which maintains the threadline over the 
yarn engagement means for a suitable number of turns, e.g., 10-20 turns. 
Textile cores in accordance with the present invention can have significant 
advantages and benefits. Because the yarn engagement means is formed of a 
plurality of discrete spaced perforations, good anti-slip properties are 
provided on the peripheral surface of the core body without a concomitant 
adverse affect on the structural integrity, and thus the strength, of the 
core. Thus textiles cores formed according to the present invention can be 
effectively used both during winding processes and in subsequent 
applications at high speeds without slippage of the transfer tail 
occurring. In addition, the textiles cores of the invention are simply 
made, and do not require complicated surface treatment techniques. 
The invention has been described in considerable detail with reference to 
its preferred embodiments. It will be apparent, however, that numerous 
variations and modifications can be made without departure from the spirit 
and scope of the invention as described in the foregoing detailed 
specification and defined in the appended claims.