Yarn carrier for pressure kier

An improved yarn package carrier for supporting packages of yarn in a pressure kier. The improved yarn package carrier comprises a circular base for being positioned within the kier adjacent its bottom and having an upper surface. The spindles are mounted on the upper surface of the yarn carrier base and have progressively greater pre-determined lengths so as to extend upwardly in tiers to a point above the top opening of the kier and into the area defined by and enclosed within the dome-shaped cover into close proximity thereto from its edge to its apex. As a result, the capacity of the kier is greatly increased by enabling as many yarn packages to be carried by the spindles as can be mounted on each spindle intermediate the upper surface of the carrier base and the inner wall of the dome-shaped cover.

BACKGROUND OF THE INVENTION 
This invention relates to an improved yarn package carrier of the type used 
to support numerous packages of yarn in vertically-spaced relation on a 
plurality of upright spindles within a pressure kier. Pressure kiers 
typically have cylindrical side walls and a dome-shaped cover to seal 
closed the top opening. The kier must be able to withstand high internal 
pressures. As a result, the kier cover is dome-shaped to disperse the 
pressure within the kier more evenly and to more easily withstand the 
stress on its structural parts. 
Pressure kiers are very commonly used to package dye yarns manufactured of 
various synthetic as well as natural fibers, and are almost indispensible 
in the dyeing of large, tightly wound packages of nylon and orlon, among 
others. 
While dyeing with a combination of high pressure and heat is still the best 
means of applying a high quality dye to these types of yarns and fibers, 
the greatly increasing cost of energy and hydrocarbon-derived dyestuffs 
necessitates a more effective and efficient means of carrying out these 
processes. Even though the various dyeing equipment manufacturers can be 
expected eventually to develop new and much more efficient dyeing 
machinery, there exists a vast quantity and variety of older and 
relatively inefficient equipment in place which still has many years of 
useful life left but is becoming increasingly expensive to operate because 
of the greatly increasing cost of energy and dyestuffs. 
It has been observed that all dome-covered pressure kiers, even those with 
very high pitched domes, are provided with yarn carriers, the spindles of 
which are all the same length and carry the same number of yarn packages. 
Invariably, these spindles extend to below or just even with the top 
opening of the kier. As a result, the area enclosed within the dome-shaped 
cover constitutes a large amount of essentially wasted space, since, while 
it must be filled with extremely hot water or air, it is not contributing 
to the productivity and efficiency of the kier. Furthermore, while it has 
not been heretofore recognized, it appears that the unoccupied space 
enclosed within the dome-shaped cover of a pressure kier contributes to 
poor quality dyeing by permitting foam to accumulate in the top of the 
kier, resulting in light or faded spots in the yarn packages carried near 
the top of the yarn carrier spindles. 
SUMMARY OF THE INVENTION 
Accordingly, it is an object of this invention to provide an improved yarn 
package carrier of the type used to support numerous packages of yarn in 
vertically-spaced relation on a plurality of upright spindles within a top 
opening, pressure dyeing apparatus such as a pressure kier. 
It is a further object of this invention to provide an improved yarn 
package carrier with a greatly increased yarn package capacity, thereby 
enabling greatly increased efficiency in the consumption of energy and 
dyeing chemcials. 
It is yet another object of this invention to provide an improved yarn 
package carrier which reduces the incidence of second-quality yarn by 
preventing the development and accumulation of foam in the dome-shaped 
cover of the pressure kier, thus avoiding light and faded spots on the 
upper yarn packages. 
These and other objects and advantages of the present invention are 
achieved in the preferred embodiment set forth below by providing an 
improved yarn package carrier of the type used to support numerous 
packages of yarn in vertically-spaced relation on a plurality of upright 
spindles within a top opening, pressure dyeing apparatus having 
cylindrical side walls and a dome-shaped cover cooperating therewith to 
sealingly close the opening. The improved yarn package carrier comprises a 
circular base which is positioned within the dyeing apparatus adjacent its 
bottom. The carrier has an upper surface with a plurality of spindles 
mounted thereon perpendicular thereto. The spindles have progressively 
greater, pre-determined lengths so as to extend upwardly in tiers to a 
point above the top opening of the dyeing apparatus and into the area 
defined by and enclosed within the dome-shaped cover into close proximity 
thereto from its edge to its apex. As a result, the capacity of the dyeing 
apparatus is increased by enabling as many yarn packages to be carried by 
the spindles as can be mounted on each spindle intermediate the upper 
surface of the carrier base and the inner wall of the dome-shaped cover. 
According to a preferred embodiment of the invention, a standard yarn 
carrier having 54 spindles, each spindle being 30.25 inches (76.8 cm.) in 
length and accommodating 8 packages, is modified by replacing these 
spindles with eighteen, 32-inch (81.2 cm.) and eighteen, 34-inch (86.4 
cm.) spindles, each holding 9 yarn packages; twelve, 36-inch (91.4 cm.) 
spindles, each holding 10 yarn packages; and six, 37.5-inch (95 cm.) 
spindles, each holding 11 yarn packages. Therefore, a 54-spindle yarn 
carrier which previously held 432 yarn packages can now accommodate 510 
packages within the same pressure kier. The improved yarn carrier, when 
loaded with yarn packages, gives a "wedding cake" effect. It is apparent 
when viewing the improved yarn carrier that the yarn packages extend 
upwardly towards the center of the yarn carrier and well into the area 
enclosed by the dome-shaped cover when in its closed position.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now specifically to the drawings, a pressure kier of a 
conventional type used in accordance with the present invention is 
illustrated in a simplified, representational form by broad reference 
numeral 10 in FIG. 3. The body of the kier is defined by cylindrical side 
walls 11, a bottom 12, and a circular top opening defined by the terminus 
of the cylindrical side walls 11. 
A platform 13 is positioned concentrically in the bottom of the kier 10 as 
a support for the yarn carrier. 
Still referring to FIG. 3, a dome-shaped cover 14 is shown in partial 
cross-section in close sealing engagement with the top opening of the kier 
10. The cover 14 is hingedly secured to the kier 10 by hinge 15 and brace 
16. A counterweight 17 is provided in order to provide a mechanical 
advantage in opening and closing the cover 14. An enlarged, downwardly 
facing U-shaped lip 19 is provided around the outer edge of the cover 14 
for sealingly engaging the top opening of the kier 10 during the pressure 
dyeing cycle. 
Positioned within the kier 10 is an improved yarn package carrier indicated 
at broad reference numeral 20. The carrier 20 is comprised of a circular 
base 21 having an upper, substantially planar surface 21a. The base 
includes a circular, concentric pedestal 22 on the bottom, downwardly 
facing surface of the base 21, as is shown in FIG. 3. The pedestal 22 
provides a secure platform on which the base 21 can rest, and spaces the 
body of the base 21 a sufficiently great distance from the bottom 12 of 
the kier 10 so that free circulation of the dye liquor is facilitated. 
The yarn carrier 20, especially when fully loaded with yarn packages, is 
extremely heavy. To facilitate movement of the yarn carrier 20 into and 
out of the kier 10, an elongate, upwardly extending handle 24 is securely 
fastened to the center of the yarn carrier base 21, as is shown in FIG. 2. 
Handle 24 is provided with a through slot 24a in the upwardly extending 
free end of the handle, through which a hook can be passed. Typically, the 
yarn carrier 10 is moved by means of an overhead electric hoist. 
One of the problems encountered in the reduction to practice of the 
improved yarn package carrier 20 has been the wide variety of shapes and 
sizes of kiers presently being used. Even among kiers of the same general 
size, internal dimensions dimensions and proportions vary as does the 
degree of curvature of the dome-shaped cover. The specific preferred 
embodiment of the invention which is described herein involves the 
modification of a conventional yarn carrier having an outside diameter of 
65 inches (165 cm.), and intended to fit within a Gaston County Dyeing 
Machine Company kier having an inside diameter of 67.25 inches (170.8 
cm.), a pot depth of 32.5 inches (82.5 cm.) and a dome apex of 19 inches 
(48.3 cm.) from the cover lip. 
While one specific preferred embodiment is disclosed herein, the invention 
is susceptible of application in any size or proportion of kier. 
Adaptation to other size kiers involves primarily a determination of the 
extent to which the spindles of the yarn carrier can be lengthened and/or 
repositioned to accommodate a greater number of yarn packages, while still 
permitting the cover of the kier to be closed and properly locked. As 
experimentation has shown, the modification described herein is most 
efficient when dyeing yarn packages called "muffs" or other packages 
having a relatively short height, since these packages provide smaller 
incremental increases in the distance required on each spindle to 
accommodate a given number of yarn packages. As FIG. 3 illustrates, a 
greater percentage of the space enclosed within the dome-shaped cover 14 
of the kier 10 can be filled when dyeing packages having a relatively 
short height. 
Referring to FIG. 1, a top plan view of the spindle layout on the improved 
yarn carrier is shown. In its conventional form with 54 spindles, each 
having a length of 30.25 inches (76.8 cm.) the carrier will accommodate 
eight one-pound "muffs" per spindle for a total of 432 "muffs" per 
carrier. On the 65-inch (165 cm.) carrier base described, the spindles 
have a lateral spacing of no less than seven inches (17.8 cm.). 
In accordance with the present invention, each of the 54 spindles have been 
replaced with lengthened spindles as follows: 
18 spindles, each 32 inches (81.2 cm.) in length (reference numeral 26) 
18 spindles, each 34 inches (86.4 cm.) in length (reference numeral 27) 
12 spindles, each 36 inches (91.4 cm.) in length (reference numeral 28) 
6 spindles, each 37.5 inches (95 cm.) in length (reference numeral 29) 
As is shown in FIG. 1, the eighteen outer spindles 26 are positioned in 
groups of three around the outer peripheral edge of the upper surface 21a 
of yarn carrier base 21. Spindles 27 are positioned around the upper 
surface 21a of the yarn carrier base 21 just inboard of the spindles 26. A 
space of approximately 2 inches (5.08 cm.) is allowed between the cover 14 
and the top of the longest spindles 29. 
Spindles 28 are likewise positioned in uniformly spaced-apart relation on 
the upper surface of yarn carrier base 21a just inboard of spindles 27. 
Finally, the six spindles 29 are positioned in uniform spaced relation 
immediately around the carrier handle 24. 
As shown in FIG. 1, each of the four tiers of spindles (26, 27, 28, and 29) 
are arranged on the upper surface 21a of the yarn carrier 20 in the form 
of hexagons, as in many conventional kiers. Thus, only the length of the 
spindles, and not the spacing between spindles, has been modified in this 
embodiment of the invention. 
The spindles in accordance with the above-described embodiment of this 
invention accommodate conventional one-pound yarn muffs as follows: 
Spindles 26 and 27 (36 spindles total) each accommodate 9 yarn packages; 
Spindles 28 (12 spindles total) each accommodate 10 spindles; and, 
Spindles 29 (6 spindles total) each accommodate 11 yarn packages. 
The number of different lengths selected for the various groups of spindles 
will vary greatly depending on kier size, the shape and curvature of the 
dome-shpaed cover, and many other variables. As noted above, the spindles 
in the preferred embodiment of the invention are four different lengths, 
notwithstanding the fact that only three different numbers of yarn 
packages (9 packages, 10 packages, and 11 packages) are placed on the 
spindles. However, with different size packages the difference in length 
can be important. Moreover, in accordance with the present invention the 
spindles should be extended to within approximately two inches of the 
cover 14, regardless of the particular size of the package which might be 
accommodated thereon. In individual instances where an additional package 
could be placed on each spindle with only a very slight increase in 
length, the spindles may be extended closer than two inches to the cover 
14. 
Thus, the yarn carrier 20, as modified, will now accommodate 510, one-pound 
yarn packages, whereas prior to the modification, it would accommodate 
only 432. 
The stairstep, or tiered, configuration of the modified spindles is shown 
representationally in FIG. 2. A more complete view of the modified yarn 
carrier is shown in FIG. 3. 
By increasing the yarn carrier capacity from 432 to 510 yarn packages, 
capacity of the kier is increased approximately 20% without the necessity 
of purchasing new equipment or carrying out any substantial and expensive 
modifications to the kier itself. 
However, it has been learned that additional increases in capacity can be 
obtained by increasing the space between each spindle in order to 
accommodate larger packages. Of course, this means reducing the number of 
spindles on the yarn carrier. By increasing the length of the spindles in 
accordance with the present invention, increases in kier capacity of 
approximately 35% are possible. For example, the spacing between spindles 
on a conventional yarn carrier can be increased from 7 inches (17.8 cm.) 
to 8.5 inches (21.6 cm.). The number of spindles is thereby reduced from 
54 to 41. With a spacing of 8.5 inches (21.6 cm.) between spindles, 
larger, 1.5 pound (0.68 Kg.) packages can be accommodated on the yarn 
carrier. The spindles, when arranged according to this modification, are 
spaced with 20 spindles around the periphery of the yarn carrier, 14 
spindles immediately inboard of the 20 outer spindles and 7 spindles in 
closely circling relation to the handle of the yarn carrier. As in the 
preferred embodiment illustrated in the drawings, the outer 20 spindles 
each carry 9 yarn packages. The innermost 7 packages are lengthened to 
accommodate 11 yarn packages. The 14 intermediate spindles each carry 10 
yarn packages, therefore, the 41 spindles, lengthened in accordance with 
this invention, will now accommodate 397 packages, each package weighing 
1.5 pounds (0.68 Kg.). Therefore, the number of packages accommodated by 
the yarn carrier is increased from 328 to 397 by extending the spindles 
upwardly into the area enclosed by the dome-shaped cover of the kier. 
The modifications described and/or illustrated above are sufficient to 
demonstrate the fundamental concept of this invention--that yarn capacity 
can be increased and dyeing quality improved without extensive 
modification by increasing the length of spindles within the kier to 
extend upwardly into the area enclosed by the dome-shaped cover and to 
therefore accommodate more yarn packages. Given the extremely wide variety 
of kier shapes and capacities, the exact length by which the spindles can 
be lengthened is a matter of measurement and calculation in each separate 
instance. As described above, the only modification usually required is to 
the length of the spindles on the yarn carrier 20. However, there may be 
instances in individual cases where a slight lowering of the platform on 
which the yarn carrier rests within the kier will enable some or all of 
the extended spindles to accommodate one additional yarn package each. 
The greatest cost savings have been realized in the dyeing of stretch 
nylon, which requires expensive dye types and long dyeing cycles. For 
example, dyeing stretch nylon in a kier using a conventional yarn carrier 
costs approximately 0.696 dollars per pound (1.53 dollars per Kg.), 
whereas dyeing costs using a modified yarn carrier have extended spindles 
in accordance with the present invention, a cost per pound of 0.586 
dollars (1.28 dollars per Kg.) was achieved for a savings of 11 cents per 
pound (0.24 dollars per Kg.). This saving is a result of a combination of 
factors. First, there is a direct saving in the quantity of dye used per 
pound of yarn. This results because the same amount of water and dye are 
used in both cases. Since the yarn carrier according to this invention 
carries more yarn, the cost of dye per pound of yarn dyed is reduced. 
Since the same amount of dye liquor is used to dye more yarn, a direct 
saving also results in that the amount of energy required to raise the 
quantity of dye liquor necessary to dye one package of yarn is reduced. As 
the cost of primary energy and petroleum-derived dyestuff increases, the 
savings realized for the above reasons can be expected to increase 
accordingly. By modifying yarn carriers in accordance with this invention, 
dyers will find it possible to attain substantial savings in dyeing costs 
without an offsetting expenditure for new equipment. Yarn carriers have 
been modified according to this invention at a cost of approximately $5.00 
per spindle or approximately $270 per 54-spindle carrier. If spindles are 
also respaced from 7 to 8.5 inches in order to accommodate larger yarn 
packages, the cost of the modification per spindle is somewhat greater. In 
either case, the cost of these modifications, in view of the savings 
attained, is a very small fraction of the cost required to replace older, 
less efficient kiers with newer and more energy-efficient ones. 
A completely unexpected result of the practice of this invention has been a 
substantial increase in yarn quality. Yarn spotting is and has been a 
chronic problem in pressure dyeing. Since the presence of light spots on 
yarn generally exhibits itself in packages positioned near the top of 
spindles on conventional yarn carriers, it was long ago understood that 
spotting was caused primarily by incomplete dyeing resulting from the 
accumulation of foam in the area of the kier enclosed by the cover, and 
hence having its greatest effect on yarn packages positioned uppermost in 
the kier. 
Numerous solutions have been proposed for this problem. Wetting agents, 
anti-foaming agents, lengthened dyeing times, elevated dyeing 
temperatures, and "rest" periods during the dyeing cycle to enable the 
foam to dissipate have all been only partially successful, and in each 
case more expensive. 
Dyeing yarn packages in accordance with the present invention has resulted 
in an almost complete elimination of yarn spotting. It is believed that 
this improvement in yarn quality results from extending the yarn carrier 
spindles upwardly into the area enclosed by the cover so that yarn 
packages accommodate this area during the dyeing cycle. With the 
elimination of the large open area within the kier cover, foam is no 
longer permitted to accumulate since its rapid circulation over the yarn 
packages within this area causes the foam to dissipate as quickly as it is 
generated. As a result of this phenomonen, dyeing cycles and temperatures 
can be reduced somewhat and anti-foaming agents can be eliminated. 
Described above is a preferred embodiment of a modified yarn carrier which 
greatly reduces the cost of dyeing yarn packages, and, at the same time, 
greatly increases the quality of the yarn. Various details of the 
invention as described may be changed without departing from the scope of 
the invention. Furthermore, the foregoing description if for the purpose 
of illustration only and not for the purpose of limitation--the invention 
being defined by the claims.