FILAMENT STOCK BOX

Abstract: A filament stock box having choke means (8, 105, 202, 202′, 302, 303) mounted therein for controlling the flow of cut-to-length monofilament (9, 104, 201, 301) during the picking process, the choke means providing a less dense downstream mass of filaments to insure a smooth entry of pickers into the filament to form tufts without bending or crimping the filaments to be picked.

Description: This invention relates to a filament stock box and particularly, but not exclusively, a filament stock box for filaments used for tufting brushes. The need for improving filament stock boxes or magazines can be best illustrated by comparing and describing conventional filament stock boxes with the new and improved filament stock box of this invention. The conventional staple-set brush picking operation (forming a filament tuft) employs a picker which can remove only one filament tuft at a time from a stock box by first entering the stock box approximately at its midsection (lateral to the parallel filament) and picking a given amount of filament at the filament's midsection. Such filament stock boxes are disclosed in, for example, U.S. Patent Numbers 2,433,191 and 3,059,972. The picker then proceeds to transport the predetermined volume of parallel filament to a suitable means for doubling the filament at its midsection, just prior to stapling, thus resulting in a tuft having a U-shape wherein both ends of the individual filament are located at the working end of the resultant tuft. A staple or anchor is then inserted through the U-shape loop and the tuft forced into a predrilled or moulded hole in a brush-block. Each tuft is formed in this manner, one after another, until the necessary number of filament tufts have been picked and stapled. The conventional filament stock box holds filaments having a length double that of the finished tuft. Also, the conventional stock box merely holds parallel filament and depends upon the picking wheel for removing a given amount of filament therefrom. The conventional filament stock box then does not particiate in forming: (1) tuft trim (2) tuft cross-section (3) tuft diameter, and can only contribute to the formation of one tuft at a time. The filament stock box of the present invention functions on an entirely different principle, and allows for exact control of filament flow through the box during the picking operation. Said boxes are capable of dispensing two, three or any number of predetermined filament tufts simultaneously, so that a brush or broom construction containing all its filament tufts can be fabricated instantly. First, the filament employed for forming the tufts is half the length required for forming tufts in the conventional stapling manner. In our U.S. Patent Nos. 3,471,202, Re: 27,455 and 3,563,609, the disclosures of which are hereby incorporated by reference, we describe tuft picking devices and tuft-forming means wherein brush and broom constructions containing tuft filament are simultaneously picked and fabricated (see also DE-A-2937241). The tuft picking devices described in the above mentioned inventions work in conjunction with the improved stock box of this invention. The picker or picking unit enters the filament stock box longitudinally of the filament's end and engages the filament from one end; at this instant, the filament tuft is formed and trimmed. Secondly, in order to effect this operation it is necessary to provide means within the filament stock box for filament alignment and retention during picking. Thirdly, it is necessary to provide means for retaining the unpicked filament during tuft removal from the stock box. Fourthly, means must be provided for allowing the reserve supply of filament contained in the filament stock box to be moved into position for subsequent picking. Unlike conventional stock boxes, the new and improved filament stock box of this invention plays an integral part during tufted brush construction and formation, namely that of co-operating with the picking unit. In instances where the picking devices are comprised of many metal tubular means, the primary problem is indexing said metal means into an already filled stock box. This requires the picker to occupy the same space as the filament; in other words, the picker must push or move filament out of the way in order to allow the filament in the stock box to either (1) enter the tubular opening, or (2) move outside of the opening and lie parallel to the tube length, without bending, crimping-over or distorting the filament. For this to take place, the necessary amount of filament must be present in the box opposite the openings in said box. During the energizing mode of indexing however, when the picker moves forward into the box, there must be control means or choking means present which will allow only the correct amount of filament flow into the picking zone. According to the present invention there is provided a filament stock box for dispensing cut-to-length filaments in predetermined tufts comprising:- a box having front, back and side walls and a base, the lower portion of said front wall having at least one aperture therethrough having a predetermined configuration; and vibratable means coupled to said back wall for causing at least the lower portion thereof to vibrate towards and away from said front wall whereby, when filaments are contained within said box and are oriented parallel to the planes containing said side walls, said back wall vibrates against the adjacent ends thereof while a tuft thereof is withdrawn through the aperture(s); characterized in that choke means are disposed within said box above the aperture(s) and define a filament picking zone therebelow and a filament reservoir thereabove for regulating the flow of filaments from the reservoir into the picking zone whereby the density of filaments in the picking zone is less than the density in the reservoir. Some embodiments of the invention will now be described, by way of examples, with reference to the accompanying drawings, in which:- Figure 1 is a rear view of an embodiment of the filament stock box of this invention with the rear wall and filament in the picking zone removed, Figure 1 a is a side/cross sectional view of the filament stock box of Figure 1, Figure 2 is a rear view of another embodiment of this invention with the rear wall and a portion of the filament removed, Figure 2 a is a side/cross sectional view of the filament stock box of Figure 2 with the cross section being taken along line A-A of Figure 2, Figure 3 shows the filament stock box of Figure 2 a prior to indexing, Figure 4 is similar to Figure 3 and shows the picking element during energizing, Figure 5 is a fragmentary cross sectional view of the stock box of Figure 4 as taken along line B-B of Figure 4, Figure 6 is similar to Figures 3 and 4 and shows the picking element after energizing but prior to withdrawal from the stock box, Figure 7 is a fragmentary cross sectional view of the stock box of Figure 6 as taken along line C-C of Figure 6, Figure 8 is a rear view of another embodiment of the filament stock box of this invention with the rear wall and a portion of the filament removed, Figure 9 is a side/cross sectional view of the filament stock box of Figure 8 with the cross section being taken along line D-D of Figure 8, Figure 10 is a rear view of another embodiment of the filament stock box of this invention with the rear wall and a portion of the filament removed, illustrating an adjustable choke system comprising two sets of choke means, and Figure 11 is a side/cross sectional view of the filament stock box of Figure 10 with the cross section being taken along line E-E of Figure 10. The term "synthetic" filament as used hereinafter includes synthetic monofilaments which are formed from linear thermoplastic polymers from the group consisting of polystyrene and polystyrene copolymers, polyvinyl chloride and polyvinyl chloride-acetate copolymers, polyethylene, polypropylene, polyethylene-polypropylene copolymers, polyamides, polyesters and polyurethane. Both oriented and unoriented monofilaments may be employed. Also, various cross-sectional shapes may be imparted to the monofilament, such as circular, lobular, trifoil, X, Y, triangular, polygonal and star cross sections. Mixtures of synthetic monofilaments may be employed in cases where the compositions of the monofilaments are compatible during any fusing operations, i.e. heat sealing. Such filaments may have suitable crimp imparted to their length or a portion thereof. The term "picking" as used in the specification refers to the formation of filament tufts wherein two or more tufts are formed simultaneously by longitudinally engaging more than one cut-to-length filament at their ends and then removing them from a parallel disposed bundle of filaments. The picking devices employed are those types which are disclosed in the aforementioned U.S. Patent No. 3,471,202. The term "apertures" as used in the specification refers to an opening in the face of the stock box, said opening allowing entrance of the picker into the filament contained therein. Each aperture corresponds in cross section to the cross section of a picker. The term "choke means" as used in the specification refers to means actually located within the filament stock box. The choke means controls the flow of filament from the large filling reservoir to the picking zone where the apertures are located. The choke means may be fixed or adjustable, depending upon the versatility and use of the stock box for more than one kind of filament. The term "filament void" refers to an area directly under the choke means wherein the filament level fluctuates during the picking operation. It is contemplated that filament which passes through the choke means will rise to occupy the void during the energizing (vibration) phase of the picking operation. The term "energizing" (or vibration) refers to the process of imparting energy to the non-working end of the filament during the indexing of the picker means into the filament stock box in order to fill the picker means with filament. The filament stock box illustrated in Figures 1 and 1 a comprises a frame 1 having two sides 2, a bottom 4 and a back 6. The front 3 is attached above an apertured plate 5. There are a predetermined number of apertures 7 located in said apertured plate 5 corresponding to a tuft design. Choke means 8 is located within the frame 1 between the two sides 2 and above the apertures 7 in order to retain parallel filaments 9 in the same attitude as the sides of the frame 1 and thus release or meter said filaments 9 downwards into the picking zone 10 for subsequent picking. The filament stock box illustrated in Figure 2 comprises a frame with sides 100, bottom 101 and front sections 102 and 103 in which the filaments 104 are retained therein between the sides 100 and inside retaining means 100′. The front section 103 is comprised of a plate with apertures 106 for the picking element to enter and choke means 105 is provided to allow the filaments 104 to flow therethrough. In order to fully illustrate the embodiment of this instant invention it is necessary to describe the different stages of operation, namely the picking operation relating to tuft formation. Referring now to Figures 2-7, the stock box which is made up of pieces, 100, 100′, 101, 102 and 103 is supported on a support means. Cut-to-length filaments 104 are contained therein and, in general, fill the entire inside portion of the stock box. However, the filaments supported above the choke means 105 are more dense since they are compacted by the weight of the filaments. The choke means 105 has openings 109 of a given width, and this width controls the flow of filaments 104 therethrough. As the filaments 104 flow through the openings 109 they are separated from one another and fall loosely downwards to the section of the stock box where the picking apertures 106 are located. As seen in Figure 2 a , the filaments 104 above the choke means 105 are very dense, while there is actually some open space 108 directly below the choke means 105 where there is a filament void, and the filaments 104′ below the choke means 105 are less dense. The sequence of picking is best described by reference to Figure 3. The picking element 110 containing picker tubes 110′ is indexed forward in the direction indicated by arrow H,simultaneously as energy is imparted in directionI by a flapper plate 111, held on the frame by screw 112 directly under the back portion of the frame 113. As the flapper plate 111 is indexed back and forth in directions F and G, the filaments 104, held in place by the choke 105, start to move through and downwards towards the apertures 106 in the front face plate 103, filling up the area under the choke 105. Simultaneously, as shown in Figure 4, the picker tubes 110′ on picker element 110 enter the apertures 106 and pass therethrough during the energizing mode. The picker tubes 110′ engage the filaments 104′. When the picker tubes 110′ enter the same space as the filaments 104′ there is room for both picker tubes 110' and filaments 104′ because the filaments 104′ are only lightly packed into the area behind the apertures 106. Figures 6 and 7 further illustrate indexing of the picker tubes 110' into the stock box. Energizing or vibration then ceases for a moment. The picker element 110 with each individual picker tube 110′ is now filled with filaments 104′. Excess filaments 104′ have filled void 108 and the filaments 104′ located outside of and around the picker tubes 110′ are tightly packed. As the picking element 110 is withdrawn from the stock box, the filaments remaining therein seek the attitude illustrated in Figure 2. There is a slight void 108 created under each choke member 105, and a very light density opening 108′ at each position where a picker tube 110′ had previously been located, thus leaving approximately the amount of filament 104′ under the chokes 105 equal to the difference between the volume that can actually be allowed into the area 107 less the amount of filament removed during picking. This volume of filament 104′ remains constant so that, during picking, the choke system 105 of this invention permits a smooth and controlled entry of the picking tubes into the filament 104′. The choke system of this invention then ensures there will be enough filament 104′ to fill the picker tubes 110′ and that there will not be too much filament 104′. In the latter situation picking would produce a pushing backwards of some of filaments 104′, and individual filaments 104′ would become bent over between the picker tubes 110′ and the flapper place 111. This would create a snarled or entangled attitude whereby the entangled filaments would interfere with the flow of filaments 104 through chokes 105. The aforementioned illustration is only one of the preferred embodiments of this invention, and many other types of choking means may be employed. In Figures 8 and 9, there is illustrated a choke system comprising a double row of choke means 202 thus creating more resistance to flow of filaments 201 through the stock box. The frame 200 contains tightly packed filaments 201 located above choke means 202. The filaments 201′ under the choke means 202 are less dense in the area of the apertures 203 and thus the volume of filaments 201′ is controlled during the energizing mode and only a controlled amount is allowed to pass through openings 204 between chokes 202. By having the double row of chokes 202, the filaments flowing through opening 204 are impeded in their flow downwards as they come into contact with a second choke 202′ which continues to slow down the rate of fall as well as the amount allowed to fall. Spacing the choke members closer to each other will have the effect of closing the opening therebetween and slowing down the rate of fall. The volume of filaments in the area of the apertures 203 then can be metered by this choke system. Chokes of this type would be preferred for level monofilament which would tend to flow very rapidly through a single choke system as described in Figures 1-7. Further means for controlling the amount of filament to be present in the aperture area of a filament stock box can comprise non-stationary choke means. Figures 10 and 11 illustrate a further embodiment for measuring filament. The filaments 301 contained in stock box 300 are allowed to first flow through an opening 306 which is controlled by choke means 303 which in turn can be adjusted by screws 304. As the filaments flow through opening 306 onto the choke means 302, they are kept less dense and in turn, during the energizing mode, the filaments 301 are further slowed by choke 302 and continue to flow through choke 302 into the picking zone adjacent to the apertures 305. The filaments 301′ are much less dense in a choke controlled stock box 300, and the choke means can be opened or closed at any time during picking. The filaments employed for brush and broom construction are in the order of 0,127mm (0.005″) diameter up to and including 6,35mm (0.250″) diameter. Lengths of filaments may vary from about 1,27cm (0.5″) up to about 25,4cm 10.0″ and may be level or crimped along their length. With these variables, this invention may vary from a single choke means whereby the flow passes through the space between the stock box side walls and a single choke up to a combination of multiple stationary and adjustable chokes. The minimum opening in the choke means is about 0,32cm (0.125″), and the maximum distance is about 3,81cm (1.5"). The length of the opening must never be more than the length of the filament metered therethrough. The choke means may be mounted directly on the aperture plate or on its own plate attached to the front of the frame directly above the aperture plate. Adjustable choke means may be attached to the side frames and/or partitions located within said frame. It should be understood that by providing apertures having different configurations, circular, square, triangular, etc., different tuft cross sections may be obtained. Likewise, by arranging the apertures within the aperture face, it is also possible to pick tuft configurations having unlimited geometric arrangements. From the foregoing it will be apparent to those skilled in the art that the present invention provides a very simple and effective filament stock box.

Claims: A filament stock box for dispensing cut-to-length filaments in predetermined tufts comprising:- a box having front (3), back (6) and side walls (2) and a base (4), the lower portion of said front wall (3) having at least one aperture (7, 106, 203, 305) therethrough having a predetermined configuration; and vibratable means (111) coupled to said back wall (6, 113) for causing at least the lower portion thereof to vibrate towards and away from said front wall (3, 102) whereby, when filaments (9, 104) are contained within said box and are oriented parallel to the planes containing said side walls (2), said back wall (6, 113) vibrates against the adjacent ends thereof while a tuft thereof is withdrawn through the aperture(s) (7, 106, 203, 305); characterized in that choke means (8, 105, 202, 202', 303, 302) are disposed within said box above the aperture(s) (7, 106, 203, 305) and define a filament picking zone therebelow and a filament reservoir thereabove for regulating the flow of filaments from the reservoir into the picking zone whereby the density of filaments in the picking zone is less than the density in the reservoir. A filament stock box as claimed in claim 1, in which said choke means (8, 105, 202, 202', 302) is stationary. A filament stock box as claimed in claim 1 or claim 2, in which said choke means (8, 105, 202, 202', 303, 302) defines an opening (109, 204, 306) extending from said front wall and towards said back wall. A filament stock box as claimed in claim 3, in which said choke means (303) further includes adjustment means (304) for adjusting the width of said opening (306). A filament stock box as claimed in claim 3 or 4, in which the length of said opening (109, 204, 306) is less than the length of filaments passing therethrough. A filament stock box as claimed in any preceding claim, in which said choke means (105, 202, 202', 302) includes at least one rod-like bar (105, 202, 202', 302) extending from said front wall and towards said back wall. A filament stock box as claimed in claim 6, in which a plurality of said rod-like bars (105, 202, 202', 302) are mutually spaced apart and disposed in parallel planes extending from said front wall and towards said back wall of said box above said aperture(s). A filament stock box as claimed in claim 7, in which said rod-like bars (202, 202', 302) are disposed in two rows, with the longitudinal axis of each bar contained in a different parallel vertical plane. A filament stock box as claimed in claim 7, in which said bars are disposed in an upper row and a lower row with the longitudinal axis of each lower bar being contained in a vertical plane common to the plane containing the longitudinal axis of an upper bar. A filament stock box as claimed in claim 7, in which said bars are disposed in three rows.

Inventors: LEWIS, JOHN C. JR.
Applicants: TUCEL INDUSTRIES, INC.
Application year: 1987
Main classification: A46D1
IPC codes: A46D1