Dye tube spacer for package dyeing

A dye tube spacer for package dyeing. The spacer prevents distortion of the ends of the yarn package when the package is compressed prior to dyeing. The spacer includes a continuous vertical inner wall having an upper edge and a lower edge, the inner diameter of the wall being substantially equal to the outer diameter of the tube. A vertical outer wall is spaced from the inner wall and has an upper edge and a lower edge. A top annular wall is inclined upwardly from the upper edge of the inner to the upper edge of the outer wall, the wall having a diameter substantially equal to the diameter of the end of the yarn winding. A bottom annular wall extends from the lower edge of the inner wall to the lower edge of the outer wall. A support shelf extends inwardly from the inner wall and is positioned to engage the end of the tube. The inclined top and bottom annular walls contact the ends of the yarn packages and prevent undesirable distortion of the yarn during compression prior to dyeing.

BACKGROUND OF THE INVENTION 
(1) Field of the Invention 
The present invention relates generally to package dyeing systems and, more 
particularly, to a dye tube spacer for preventing undesirable distortion 
of a compressed yarn package during dyeing. 
(2) Description of the Prior Art 
In conventional package dyeing, a plurality of yarn packages, each 
including a yarn winding around a tube, are placed on a spindle having a 
diameter substantially equal to the inner diameter of the tube. The yarn 
packages are then compressed by exerting pressure on the ends of the 
spindles. The yarn packages are compressed to compensate for variations in 
package density and to allow more packages to be loaded into the dyeing 
vessel. However, because the ends of adjacent packages engage one another, 
the ends of the yarn packages can be distorted. This problem is usually 
correctable during backwinding when the yarn is inspected, lubricated and 
rewound on new tubes prior to shipment to the end use customer. 
However, recently there has been research directed at producing a dyed yarn 
package which can be directly shipped to the customer without inspecting, 
lubricating and rewinding. Numerous technical obstacles must be overcome 
before such a dyed yarn package becomes practical. These problems include 
better dyeing control, combined dyeing and lubricating in a single 
operation and high speed compressible dye tubes. In addition, it would no 
longer be possible to correct the distortion of the ends of the yarn 
packages during backwinding when the yarn is inspected, lubricated and 
rewound on new tubes prior to shipment to the end use customer since this 
step would be eliminated. 
Thus, there remains a need for a new and improved dye tube spacer which 
allows the yarn packages to be compressed prior to dyeing while, at the 
same time, prevents distortion of the ends of the yarn packages during 
compression thereby allowing the package to be shipped directly to the end 
user without rewinding. 
SUMMARY OF THE INVENTION 
The present invention is directed to a dye tube spacer for package dyeing 
which prevents distortion of the ends of the yarn package when the package 
is compressed prior to dyeing. The spacer includes a continuous vertical 
inner wall having an upper edge and a lower edge, the inner diameter of 
the wall being substantially equal to the outer diameter of the tube. A 
vertical outer wall is spaced from the inner wall and has an upper edge 
and a lower edge. A top annular wall is inclined upwardly from the upper 
edge of the inner to the upper edge of the outer wall, the wall having a 
diameter substantially equal to the diameter of the end of the yarn 
winding. A bottom annular wall extends from the lower edge of the inner 
wall to the lower edge of the outer wall. A support shelf extends inwardly 
from the inner wall and is positioned to engage the end of the tube. The 
inclined top and bottom annular walls contact the ends of the yarn 
packages and prevent undesirable distortion of the yarn during compression 
prior to dyeing. 
Accordingly, one aspect of the present invention is to provide a dye tube 
spacer. The spacer includes: (a) a cylindrical inner wall having an upper 
edge and a lower edge; (b) an outer wall spaced from the inner wall and 
having an upper edge and a lower edge; (c) an top annular wall is inclined 
upwardly from the upper edge of the inner to the upper edge of the outer 
wall; and (d) a bottom annular wall extending from the lower edge of the 
inner wall to the lower edge of the outer wall. 
Another aspect of the present invention is to provide a dye tube spacer. 
The spacer includes: (a) a continuous vertical inner wall having an upper 
edge and a lower edge; (b) a vertical outer wall spaced from the inner 
wall and having an upper edge and a lower edge; (c) a top annular wall 
inclined upwardly from the upper edge of the inner to the upper edge of 
the outer wall; (d) a lower annular wall inclined downwardly from the 
lower edge of the inner wall to the lower edge of the outer wall; and (e) 
a horizontal, annular support shelf extending inwardly from the inner 
wall. 
Still another aspect of the present invention is to provide a spacer for 
supporting a yarn package formed of a tube with upper and lower ends and a 
winding of yarn with inwardly inclined ends thereon. The spacer includes: 
(a) a continuous vertical inner wall having an upper edge and a lower 
edge, the inner diameter of the wall being substantially equal to the 
outer diameter of the tube; (b) a vertical outer wall spaced from the 
inner wall and having an upper edge and a lower edge; (c) a top annular 
wall inclined upwardly from the upper edge of the inner to the upper edge 
of the outer wall, the wall having a diameter substantially equal to the 
diameter of the end of the yarn winding; (d) a bottom annular wall 
extending from the lower edge of the inner wall to the lower edge of the 
outer wall; and (e) a support shelf extending inwardly from the inner wall 
and positioned to engage the end of the yarn tube. 
These and other aspects of the present invention will become apparent to 
those skilled in the art after a reading of the following description of 
the preferred embodiment when considered with the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
In the following description, like reference characters designate like or 
corresponding parts throughout the several views. Also in the following 
description, it is to be understood that such terms as "forward", 
"rearward", "left", "right", "upwardly", "downwardly", and the like are 
words of convenience and are not to be construed as limiting terms. 
Referring now to the drawings in general and FIG. 1 in particular, it will 
be understood that the illustrations are for the purpose of describing a 
preferred embodiment of the invention and are not intended to limit the 
invention thereto. As best seen in FIG. 1, a dye tube spacer, generally 
10, includes a continuous, circular, vertical inner wall 12 or open-ended 
cylinder, a circular vertical outer wall or open-ended cylinder 14. 
Vertical walls 12 and 14 are joined at their upper edges by a top wall 16 
and at their lower edges by a bottom wall 18. A ledge 20 extends inwardly 
from wall 12, equidistant its upper and lower edges. Walls 12 and 14 are 
axially aligned around the vertical axis of spacer 10. 
The height of inner wall 12 is preferably equal to approximately twice the 
length of the dye tube extending beyond the yarn packages to be dyed, plus 
the width of ledge 20 when the yarn packages are in a compressed state. 
Normally, the height will be from about 35 to about 50 mm. The internal 
diameter of inner wall 12 is substantially equal, or slightly less than 
the outer diameter of the dye tubes, or normally from about 75 to about 80 
mm. Thus, the dye tube ends slip into the inner opening of the spacer with 
the ends against the sides of ledge 20 when the packages are compressed. 
Annular outer wall 14 is concentric with inner wall 12 and spaced therefrom 
to form an annular space between walls 12 and 14. Outer wall 14 is formed 
of identical arcuate segments which are equally spaced from each other. 
Wall segment includes triangular shaped drainage openings 22 which have 
their bases adjacent walls 16 and 18, respectively. Since the purpose of 
openings 22, as well as the spaces between the arcuate sections, are for 
drainage and weight savings, other outer wall configurations to address 
these considerations will be obvious to the skilled artisan. For example, 
the outer wall may be continuous with equally spaced circular or 
rectangular openings. 
The central cross-section of outer wall 14 lies in a horizontal plane with 
the central cross-section of wall 12. Thus, walls 12 and 14 each having 
equal segments above and below this horizontal plane. The length of wall 
14 is greater than the length of wall 12, however, so that the segments of 
wall 14 project further above or below the horizontal plane than the 
corresponding segments of wall 12. The diameter of wall 14, and its 
length, will be determined by the diameter of the yarn package and the 
angle of the yarn winding at the end of the package. The horizontal plane 
is perpendicular to the vertical axis of spacer 10. 
Annular top wall 16 extends from an inner edge integral and coextensive 
with the upper edge of inner wall 12 to an outer edge integral and 
coextensive with the upper edge of outer wall 14. Since outer wall 14 
projects further above the horizontal plane of the spacer than inner wall 
12, top wall 16 is inclined upwardly and away from the horizontal plane in 
the direction of outer wall 14. This angle should be equal to the 
corresponding angle of the end of the yarn package, which will normally be 
from about 5.degree. to about 25.degree., preferably about 10.degree., 
from the horizontal plane. Since the horizontal plane is perpendicular to 
the vertical axis of the dye tube spacer, this angle corresponds to an 
angle of from about 65.degree. to about 85.degree., preferably about 
80.degree., from the vertical axis of the dye tube spacer. 
Similarly, annular bottom wall 18 extends from an inner edge integral and 
coextensive with the lower edge of inner wall 12 to an outer edge integral 
and coextensive with the lower edge of outer wall 14. Since outer wall 14 
also projects further below the horizontal plane of the spacer than inner 
wall 12, bottom wall 18 is inclined downwardly and away from the central 
plane in the direction of outer wall 14. This angle will be equal to the 
corresponding angle of top wall 16, i.e. from about 5.degree. to about 
25.degree., preferably about 10.degree., from the central plane, or from 
about 65.degree. to about 85.degree., preferably about 80.degree., from 
the vertical axis of the dye tube spacer. 
Horizontal, annular ledge 20 projects inwardly from inner wall 12 and is 
positioned equidistant between the upper and lower edges of wall 12 along 
the horizontal plane. The width of ledge 20 preferably approximates the 
thickness of the dye tube, providing maximum support, without unduly 
projecting into the center of inner wall 12, and thus interfering with 
insertion of the spindle. Thus the width of ledge 20 will normally be from 
about 8 to about 10 mm. 
From the foregoing description, and the illustration of the intermediate 
dye tube spacer, it will be apparent that the upper half of the 
intermediate spacer is a mirror image of the bottom half of the 
intermediate spacer. Therefore, the spacer can be used with either wall 14 
or wall 16 as the top wall. 
The dye spacer used at the ends of the group of yarn packages is only about 
one-half the width of the intermediate dye tube spacer, and has the 
configuration of one-half of the intermediate spacer, with a planer wall 
covering the opposite side. As best seen in the Figures, the end dye tube 
spacer, or cap, generally 24, includes a continuous, circular, vertical 
inner wall 26 or open-ended cylinder, and a circular vertical outer wall, 
generally 28. Vertical walls 26 and 28 are joined at their upper edges by 
a top wall 30 and at their lower edges by a bottom wall 32. A ledge 34 
extends inwardly from wall 26, adjacent wall 32. Vertical walls 26 and 28 
are axially aligned around the central vertical axis of spacer 24. 
The height of inner wall 26 is preferably equal to approximately one-half 
the length of wall 12, or a length equal to the length of one dye tube 
extending beyond a yarn package to be dyed when the yarn packages are in a 
compressed state, plus the thickness of ledge 34, which is approximately 
the thickness of ledge 20. Normally, the height of inner wall 26 will be 
from about 17 to about 25 mm. The internal diameter of inner wall 26 is 
substantially equal to the inner diameter of wall 12. 
Annular outer wall 28 is concentric with inner wall 26 and spaced therefrom 
to form an annular space between walls 26 and 28. Outer wall 28 is formed 
of identical arcuate segments which are equally spaced from each other. 
Each wall segment includes triangular-shaped drainage openings 36. As in 
intermediate dye tube spacer 10, the purpose of openings 36, as well as 
the spaces between the arcuate sections, is for drainage and weight 
savings, and other outer wall configurations may be used to address these 
considerations. 
The bottom ends or openings of inner walls 26 and 28 lie within a 
horizontal plane which is perpendicular to the vertical axis of spacer 24. 
Wall 28 is of a greater length than wall 26, however, so that the upper 
end of wall 28 is higher than the upper end of wall 26. The inner and 
outer diameters of wall 26, will be the same at the inner and outer 
diameters of wall 14. 
Annular top wall 30 extends from an inner edge which is integral and 
coextensive with the upper edge of inner wall 26 to an outer edge which is 
integral and coextensive with the upper edge of outer wall 28. Since outer 
wall 28 projects further above the central plane of the spacer than inner 
wall 26, top wall 30 is inclined upwardly and away from the central plane 
in the direction of outer wall 28. This angle will be equal to the angle 
of top wall 14, or from about 5.degree. to about 25.degree., preferably 
about 10.degree., from the central plane, or from about 65.degree. to 
about 85.degree., preferably about 80.degree., from the vertical axis of 
spacer 24. 
Unlike bottom wall 18 of intermediate dye tube spacer 10, annular bottom 
wall 32 of spacer or cap 24 is planer and lies in the horizontal plane 
with the lower ends of walls 26 and 28, and extends from an inner edge 
integral and coextensive with the lower edge of inner wall 26 to an outer 
edge integral and coextensive with the lower edge of outer wall 28. 
Horizontal, annular ledge 34 is only required to abut the end on one yarn 
tube, i.e., the outer end of the last yarn tube on the spindle on the end 
when spacer 24 is inserted over the spindle. Therefore, ledge 34 projects 
inwardly from inner wall 26 in the same way that inner wall 12 projects 
inwardly from ledge 20, but is positioned in the horizontal plane with 
bottom wall 32. The width of ledge 34 preferably approximates the 
thickness of ledge 20. 
In operation, a plurality of yarn packages, each including a yarn winding 
around a tube, are placed on a spindle having a diameter substantially 
equal to the inner diameter of inner walls 12 and 26, with adjacent 
packages separated by intermediate dye tube spacers 10. End spacers 24 are 
inserted over the spindle at each end, with the top spacer being inverted 
from the aspect illustrated herein, so that top wall 30 faces downward to 
engage the side of the yarn winding on the top yarn package. The yarn 
packages are then compressed by exerting pressure on the end spacers. This 
pressure may be exerted before or after the yarn packages are inserted 
onto a dyeing rack or into a dyeing kettle. As a result of the present 
invention, there is no significant distortion of the yarn packages from 
this pressure. Therefore, the packages can be used in subsequent 
operations without the need for rewinding. 
Certain modifications and improvements will occur to those skilled in the 
art upon a reading of the foregoing description. By way of example, two 
ledges can be used instead of one ledge in the intermediate dye tube 
spacer. Also, the top and bottom wall can extend beyond the outer wall. In 
addition, while the spacer is preferrably formed from hollow walled 
stainless steel, other non-corrossive materials could be substituted. It 
should be understood that all such modifications and improvements have 
been deleted herein for the sake of conciseness and readability but are 
properly within the scope of the following claims.